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Design forDesign forManufacture andManufacture and
Assembly (DFMA)Assembly (DFMA)BMF 4723BMF 4723
Engr. an !"aru#i $% an$arun
s"aru#i&um'.edu.my
*77**+2
mailto:[email protected]:[email protected] -
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,ntroduction
,s a combination bet-een DFM DFA
DFM Design for ManufactureManufacture
Manufacturing of indi/idualcom'onent 'arts of a 'roduct or
assembly
DFA Design for AssemblyAssembly
Addition or %oining of 'arts toform a com'lete 'roduct
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DFM0
1"e design for ease of manufactureof t"e collection of 'arts t"at -illform t"e 'roduct after assembly.
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DFA0
1"e design of t"e 'roduct for ease ofassembly.
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"ere to a''ly0
. 1o t"e design team in sim'lifying t"e'roduct structure to reducemanufacturing and assembly costs
and to uantify t"e im'ro/ements byusing concurrent engineeringa''roac"es.
2. As a tool for benc"maring to study
com'etitor5s 'roducts.3. As a s"ould6cost tool to "el' negotiate
su''liers contracts.
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DFMA
,ntended to increase t"e a-areness ofengineering design team to t"e need forconcurrent 'roduct and 'rocess
de/elo'ment. Design 'rocess is -"ere about 8 of
'roduct5s total costs are determined.
1"e cost of maing c"anges to a 'roduct
as it 'rogresses t"roug" t"e 'roductde/elo'ment 'rocess increases byorders of magnitude at /arious stages.
,f t"e cost of maing a c"ange to a 'roduct
during its conce'tual design '"ase is 9M:
1"en t"e cost of maing t"e same c"angeafter t"e dra-ings are released and t"e initial
'rototy'e are fabricated is a''ro;imately9M:
,f t"is same c"ange is not a''lied until t"e'roduction run "as started t"e cost im'act
-ill be a''ro;imately 9M:
,f t"e need for t"e design c"ange is notrecogni#ed after t"e 'roduct "as been'urc"ased t"e total cost -ill be a''ro;.
times more t"an during conce'tual design
re/ie-.
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1"e !i; Basic
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1"e 1en
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1"e 1en
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.. !im'licity!im'licity
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$o- to ee' 'art countminimum0
:ey 'rinci'les re/ol/e around 1$9EEuestions=
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,f all ans-ers is >?
1"e 'art5s1"e 'art5s
function can befunction can becombined -it"combined -it"
anot"er e;istinganot"er e;isting'art'art
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1"e e@ects of reduced 'artcounts0
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"y do -e need fastener0
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"y fasteners s"ould beminimi#ed09?1?1E DE!,C>! MA9?1?1E DE!,C>! MA
9E,9E ADD,11,?>A9E,9E ADD,11,?>AFA!1E>E9! A>DFA!1E>E9! A>D
,>1E9FA1E9FA ?9GA9,?! DE!,C> ?9E>1 ?1,?>!E>1 ?1,?>!
9?D DE!,C>9?D DE!,C>!$?D BE !19,ED ?F!$?D BE !19,ED ?F
A> EH EHE9!FA!1E>E9!
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Minimum ?rientations
Cuiding 'rinci'le are=
1o create a design t"at can be easilyassembled -it" minimum use of s'ecial
tooling.1o al-ays use gra/ity to aid you in
assembly.
Minimi#ing number of fasteners -illob/iously "eaded for minimi#ingnumber of orientations needed.
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Multifunctional arts
,s a 'rimary met"od of reducing t"etotal 'arts count.
1"us en"ancing design sim'licity.
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Modular !ubassemblies
Cood design met"od to 'redesigned forcontinuous 'roduct im'ro/ement t"roug"bloc u'grades.
romote similar 'roduct lineen"ancements o/er time.
As ne- tec"nology mo/es into 'racticeand becomes cost e@ecti/e modularsubassemblies can be easily re'laced to
'ro/ide e;'anded ca'abilities "ig"er'rocessing s'eeds maretcom'etiti/eness or more economicalsubstitutions.
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$o-e/er
,t may increase t"e total 'art countof t"e original 'roduct.
ositi/e trade6o@ could yet beac"ie/ed by t"e added ease ands'eed of im'lementingim'ro/ements for many 'roducts or'roduct families.
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2.2. se !tandard Materialsse !tandard Materials
DA9D,JE
Design reuse I Most cost6e@ecti/e
met"od
By deKning com'any6or 'roductfamily6related standard materials
standard 'arts s'eciKc design 'rocessstandards. I 9educe cost and 11M-"ile reliability -ill be ma;imi#ed.
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1"e ey element of standardi#ationL
Establis" t"e disci'line -it"in t"eorgani#ation to ee' t"e standards
current and readily a/ailable to t"e Dteam.
Enforcing t"eir e@ecti/e and consistent
use.
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3.3. !'ecify 1olerances!'ecify 1olerances
Embodied in se/ent" commandmentI A/oid Dicult com'onent.
,t is based on 'rocess ca'ability notfrom design engineer5s anity.
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4.4. se of
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+.+.
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1"e traditional P?/er6t"e6-all5a''roac" is guaranteed to 'roduce'roduct attributes t"at contribute to
$ig"er 'roduction cost onger11M.
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1"e Final 1"ree Design
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True learning is based ondiscovery by mentoring ratherthan the transmission of
knowledge(Qo"n De-ey)