PERANCANGAN UNTUK KETERBUATAN

(DFMA : “ DESIGN FOR

MANUFACTURING AND ASSEMBLING” )Dr.-Ing. Indra Djodikusumo1

ENGINEERING DESIGN BOOKS

2

Perancangan Konsep ���� “ Conceptual Design”

Perancangan Wujud(Perwujudan) ���� “ Embodiment Design”

Design Requirements/Design Specifications &Objectives

Concept / Principle Solution

(Perwujudan) ���� “ Embodiment Design”

Perancangan Detail(Penyiapan Dokumen Produksi dan Operasi)

���� “ Detail Design”

Definitive Layout

Production Documents andOperation Documents

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PERANCANGAN KONSEP

Metode pengembangan konsep:

1) Metode dasar

a) Galang gagas (brain storming)

b) Penulisan gagasan (metode 6-

Design

Requirements/

Design

Specifications and

Objectives

Principle

Solution/

Concept

4

b) Penulisan gagasan (metode 6-

3-5)

c) Analogi

d) Ekstrim/kebalikan

e) Pakar/buku referensi/jurnal

2) Metode morfologi

3) Metode logika (TRIZ dan

Perancangan Aksiomatik)

PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

5

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi

STEPS IN EMBODIMENT DESIGN

1) Identify embodiment-determining requirements2) Produce scale drawing of spatial constraints3) Identify embodiment-determining main function carriers4) Develop preliminary layouts and form design for the embodiment-determining main

function carriers5) Select suitable preliminary layout6) Develop preliminary layouts and form-design for the embodiment for the remaining

function carriers7) Search for solution to auxiliary functions

Concept

6

7) Search for solution to auxiliary functions8) Develop detailed layouts and form designs for the main function carriers ensuring

compatibility with the auxiliary function carriers9) Develop detailed layouts and form designs for the auxiliary function carriers and

complete the overall layouts10)Evaluate against technical and economical criteria

1) Optimize and complete form design2) Check for errors and disturbing factors3) Prepare preliminary partts list and production documents

Preliminary Layout

Definitive Layout

PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

7

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi

CHECKLIST IN EMBODIMENT DESIGN

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CHECKLIST IN EMBODIMENT DESIGN (CONT’D)

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CHECKLIST IN EMBODIMENT DESIGN (CONT’D)

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PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

11

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi

RULES IN EMBODIMENT DESIGN

1) Clarity that is, clarity of function or

lack of ambiguity of a design—

• facilitates reliable prediction of the

performance of the final product and in

many cases saves time and costly analyses.many cases saves time and costly analyses.

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RULES IN EMBODIMENT DESIGN (CONT’D)

2) Simplicity generally guarantees economic

feasibility.

� A smaller number of components and

simple shapes are produced more simple shapes are produced more

quickly and easily.

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RULES IN EMBODIMENT DESIGN

3) Safety imposes a consistent approach to

the problems of strength, reliability,

accident prevention and protection of

the environment.

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PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

15

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi

PRINCIPLES IN EMBODIMENT DESIGN

1) Principles of Force Transmission

� Flowlines of Force and the Principle of Uniform Strength

� Principle of Direct and Short Force � Principle of Direct and Short Force Transmission Path

� Principle of Matched Deformations

� Principle of Balanced Forces

� Summary of Force Transmission Principles

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PRINCIPLES IN EMBODIMENT DESIGN

(CONT’D)

2) Principle of the Division of Tasks

� Assignment of Subfunctions

� Division of Tasks for Distinct

FunctionsFunctions

� Division of Tasks for Identical

Functions

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PRINCIPLES IN EMBODIMENT DESIGN

(CONT’D)

3) Principle of Self-Help

• Concepts and Definitions

• Self-Reinforcing Solutions

• Self-Balancing Solutions• Self-Balancing Solutions

• Self-Protecting Solutions

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PRINCIPLES IN EMBODIMENT DESIGN

(CONT’D)

3) Principles of Stability and Bi-

Stability

• Principle of Stability

• Principle of Bi-Stability• Principle of Bi-Stability

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PRINCIPLES IN EMBODIMENT DESIGN

(CONT’D)

3) Principles of Fault-Free Design

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PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

21

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi

GUIDELINES IN EMBODIMENT DESIGN

1) Design for X

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

2) Design to Allow for Expansion

• Expansion

• Expansion of components

• Relative Expansion of Components

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

3) Design to Allow for Creep and Relaxation

• Behaviour of Materials Subject to

Temperature Changes

• Creep

• Relaxation• Relaxation

• Design Features

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

4) Design against Corrosion

• Causes and Effects of Corrosion

• Free Surface Corrosion

• Contact Corrosion

• Stress Corrosion• Stress Corrosion

• Selective Corrosion within a Material

• General Recommendation

• Examples of Design against Corrosion

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

5) Design to Minimise Wear

• Causes and Effects

• Design Features

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

6) Design for Ergonomics

• Fundamentals

• Human Activities and Ergonomic Constraints

• Identifying Ergonomic Requirements

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

7) Design for Aesthetics

• Aim

• Visual Information

• Guidelines for Aesthetics

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

8) Design for Production

• Relationship Between Design and Production

• Appropriate Overall Layout Design

• Appropriate Form Design of Components

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DESIGN GUIDELINES WITH EXAMPLES FOR CAST

COMPONENTS

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DESIGN GUIDELINES WITH EXAMPLES FOR CAST

COMPONENTS (CONT’D)

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DESIGN GUIDELINES WITH EXAMPLES FOR CAST COMPONENTS (CONT’D)

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DESIGN GUIDELINES WITH EXAMPLES FOR

SINTERED COMPONENTS

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DESIGN GUIDELINES WITH EXAMPLES FOR

SINTERED COMPONENTS

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DESIGN GUIDELINES WITH EXAMPLES FOR

DROP-FORGED PARTS

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DESIGN GUIDELINES WITH EXAMPLES FOR

DROP-FORGED PARTS (CONT’D)

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DESIGN GUIDELINES WITH EXAMPLES FOR

DROP-FORGED PARTS (CONT’D)

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DESIGN GUIDELINES WITH EXAMPLES FOR

COMPONENTS MACHINED BY TURNING

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DESIGN GUIDELINES WITH EXAMPLES FOR

COMPONENTS MACHINED BY TURNING (CONT’D)

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DESIGN GUIDELINES WITH EXAMPLES FOR

COMPONENTS MACHINED BY BORING

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DESIGN GUIDELINES WITH EXAMPLES FOR

COMPONENTS MACHINED BY MILLING

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DESIGN GUIDELINES WITH EXAMPLES FOR

COMPONENTS MACHINED BY GRINDING

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

8) Design for Assembly

• Types of Assembly

• General guidelines for Asssembly

• Designing Assembly Interfaces

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ARRANGE ASSEMBLY OPERATIONS

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REDUCE ASSEMBLY OPERATIONS

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STANDARDIZE ASSEMBLY OPERATIONS

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SIMPLIFY ASSEMBLY OPERATIONS

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REDUCE INTERFACES

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STANDARDIZE INTERFACES

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SIMPLIFY INTERFACES

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GUIDELINES IN EMBODIMENT DESIGN

(CONT’D)

8) Design for Maintenance

9) Design for Recycle

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CLOSING

� Karakteristik Perancangan Wujud:

� Kompleks

� Iteratif

� Multidisiplin

� Memerlukan kerjasama yang erat antara � Memerlukan kerjasama yang erat antara

berbagai ahli

� Diperlukan berbagai pengambilan keputusan

yang penting dalam perancangan

� Dapat digunakan sebagai “kendaraan” untuk

kerjasama antara berbagai KK di FTMD

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PERANCANGAN WUJUD

Principle

Solution/

Concept

Design

and

Requirements/

Design

Tata Letak

“Sistem Teknik”/

“Definitive

Layout”

Material Fungsi

1) Steps

2) Checklist

3) Rules

4) Principles

5) Guidelines

6) EvaluationEmbodiment Design

53

Design

SpecificationsLayout”

Final Assy.Sub Assy.

Component

Geometry ProsesProduksi