Product design for manufacture and assembly solution manual

The procedure: STEP 1. Take assembly apart or imagine doing so -- assigning identification to each part as it is removed. Consider sub-assemblies as parts, and analyse them separately recursively. STEP 3. Begin re-assembly of the product. Start with the part with the highest identification number, going all the way up to the part 1. Fill up the assembly worksheet as you go along.

In reality, assembly workers use both hands and often assemble two parts in a step. However, a change in the assembly procedure will correspondingly change the assembly time for the ideal product -- thereby keeping the efficiency constant. Figure 4. A piston-assembly design [source Boothroyd 91] The computation is done by systematically completing the data in the following table.

The data requires several estimates for assembly efficiency of different components based on their characteristics. This data is compiled empirically — by a large number of time- motion studies conducted over may years. We will use the charts from Boothroyd handouts given in class. Table for computation of Design efficiency Source: Boothroyd One of the key features of the Boothroyd-Dewhurst method is estimation of the ideal product -- which translates to the method of filling up column 9 in the chart.

They give the following guidelines: Rule 1. During operation of the product, does the part move relative to all other parts already assembled? Rule 2. Must the part be of a different material than the parts already assembled?

If the answer to any of these questions is YES, a 1 is entered in column 9 except if there are multiple parts in column 2, in which case the minimum number of separate parts required is entered in column 9. If yes, there is an opportunity for reduction in number of parts.

STEP 2. Examine columns 4 and 6. These figures indicate potential for assembly time reduction. Based on these ideas, a redesign of the piston assembly is presented below. Eliminate separate fasteners when possible. Design multi-functional parts by maximum use of the capabilities of individual manufacturing processes.

For example, use near-net shape moulding and casting when possible to reduce part count. Eliminate product features that are of no value to the customer. Do not over-use piece part producibility guidelines in early stages of design -- they lead to simplified production of individual parts, but much higher part count. Example: In figure 6, the single component design has potentially higher waste since an irregular shape must be cut out of the stock sheet; but the assembly cost for the second design is much higher.

Single component Figure 6b. Two-component sub-assembly 2. Try to Eliminate Adjustments Why? Adjustments require decision making during assembly so…? May lead to malfunctions after some usage by customer. Communication is a key part of the DFM process. If a designer asks you a question about a production process, give your full attention. The way products are designed and built is changing rapidly.

We can provide you with the right tools and workflows for each step of the product design and development process. Avoid warranty issues and boost the performance of your products while broadening your capacity for innovation. We can help 3 Product Design for Manual Assembly 3. Additive manufacturing. A Deloitte series on additive manufacturing Design and Manufacture H-E Parts understand the importance of accurate and reliable cooling and heat transfer solutions to suit the harsh and unique environments your equipment operates under, so we offer custom design and built equipment.

The goal is to design a product that is easily and economically manufactured. By simplifying the design of a product it is possible to manufacture and assemble it more efficiently, in the minimum time and at a lower cost.

Design for Manufacturing Definition: DFM is the method of design for ease of manufacturing of the collection of parts that will form the product after assembly. Fig 1. By closing this message or continuing to use our site, you agree to the use of cookies.

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Features Discusses fundamentals of techniques widely used in industry for product simplification and cost structured designed processes reduction Covers methods for analyzing products that lead to simpler and more cost-effective designs Provides the basic equations and data that demonstrate how to make manufacturing and assembly cost estimates Presents the basic tools for cost analysis within the context of DFMA Includes updated case studies that allow realistic student assignments Supplies cost information on materials, labor, and machine operations Summary Hailed as a groundbreaking and important textbook upon its initial publication, the latest iteration of Product Design for Manufacture and Assembly does not rest on those laurels.

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