Post on 15-Jan-2016
Design for Manufacture &Design for Manufacture &DFXDFX
Park, Mok-Min
2004, 05, 10MAI Lab. Seminar
Design for manufacture and design for ‘X’: Design for manufacture and design for ‘X’: concepts, applications, and perspectivesconcepts, applications, and perspectives
Computers & Industrial Engineering 41 (2001) 241-260
Tsai-C. Kuo, Samuel H. Huang, Hong-C. Zhang
Dept. of IE and Mgt, Minghsin Institute of Technology, Hsinchu, Taiwan, ROC Dept. of ME, IE, and NE, Univ. of Cincinnati, USA Dept. of IE, Texas Tech Univ., USA
Historical backgroundHistorical background
Engineering design 원하는 요구를 만족시키기 위하여 시스템 , 컴포넌트나
프로세스를 개발하는 일련의 과정 Two approaches: after a design is completed
Value Engineering (VE): 제품의 기능과 가격을 고려 Producibility Engineering (PE): 가용한 기술과 툴을 이용하여
적절한 비용으로 생산 Limits of VE & PE
제품의 제조 가능성을 초과하는 최적해 VE 는 과학적인 접근보다는 회사의 정책에 연관 디자인이 결정되면 대부분의 비용이 이미 결정
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Design for Assembly (DFA)Design for Assembly (DFA)
Boothroyd & Dewhurst(1987)’s DFA method 기본적인 기준을 이용하여 각 부품이 왜 필요하고 다른 부품과
합쳐져야 하는지에 대해서 자문 특별히 구축한 DB 의 실시간 표준을 이용하여 조립 시간을 개산 Design efficiency 는 실제 조립 시간과의 비교를 통하여 구함 제조나 품질에서 문제를 일으킬 수 있는 assembly difficulty 를 파악
Two factors The total number of parts The ease of handling, insertion, and fastening of the part
Applications Hitachi: Assembly Evaluation Method (AEM) Sony: Design for Assembly Cost effectiveness (DAC) GE: manufacturing producibility handbook, workshops
DFEDFA DFM DFD DFR DFLC DFQ DFMt 2/20
Design for Manufacture (DFM)Design for Manufacture (DFM)
Processes for the manufacture of a particular part 원자재 선택 표준 컴포넌트 사용 프로세스 선택 범용 부품 설계 모듈 디자인 개발 조립 방위 최소화
Stoll(1988) cited a checklists of DFM guidelines Many DFM studies have been completed
Machining parts (Booth & Radovanovic, 1989) injection molding (Dewhurst, 1987) sheet metal stamping (Zenger & Dewhurst, 1988) die cast parts (Dewhurst & Blum, 1989)
DFM applications can be carried out with great efficiency via a CAD/CAM system
DFEDFA DFM DFD DFR DFLC DFQ DFMt 3/20
Design for disassembly (DFD)Design for disassembly (DFD)
Two basic methods of disassembly (Leonard, 1991) reverse assembly, brute force
Some obstacles (Seliger, Zussman & Kriwet, 1993) Difficult to gain all the information Parts might have been modified during repair Wear can make joined elements
Determination of disassembly sequence Dewhurst(1991) Gu and Yan(1995): a graph-based heuristic approach Etc.
DFEDFA DFM DFD DFR DFLC DFQ DFMt 4/20
Design for recyclability (DFR)Design for recyclability (DFR)
Environmental conscious increases The aim of recycling
Maximize the recycling resources Minimize the mass and pollution potential of
remaining products DFM of plastics that can be easily recycled Dismantling techniques and recycling costs
DFEDFA DFM DFD DFR DFLC DFQ DFMt 5/20
Design for environment (DFE)Design for environment (DFE)
Three main goals of DFE (Hovath, et al. , 1995) Minimize the use of non-renewable resources Effectively manage renewable resources Minimize toxic release to the environment
HP provides DFE tools (Korpalski, 1996) DFE guidelines Product assessments Product stewardship metrics
DFEDFA DFM DFD DFR DFLC DFQ DFMt 6/20
Design for life-cycle (DELC)Design for life-cycle (DELC)
Product life-cycle cost (Jovane, 1993)
DFEDFA DFM DFD DFR DFLC DFQ DFMt
Life-cyclephase
Company costs User costs Society cost
Need market recognition
Design development
Productionmaterials, energy, facilities,wages, and salaries
Waste, pollution, health damages
Distribution transportation, storage, wastetransportation, storage
Waste, pollution, packing, health damages
Use warranty serviceenergy, materials, maintenance
Waste, pollution, health damages
Disposal disposal duesWaste, pollution, disposal, health damages
Recycling recycling dues Waste, pollution, health damages
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Design for quality (DFQ)Design for quality (DFQ)
The objectives of DFQ (Crow, 1983) Meet customer requirements Robust product Continuously improve product reliability,
performance, and technology Methods of DFQ
Taguchi method(1986) Quality Function Deployment (QFD) Benchmarking
DFEDFA DFM DFD DFR DFLC DFQ DFMt 8/20
Design for maintainability (DFMt)Design for maintainability (DFMt)
Maintainability is (Kapur & Lamberson, 1977) The probability that a failed system can be repaired in a specific int
erval of downtime Objective of DFMt
The product can maintained throughout its useful life-cycle at reasonable expense without any difficulty
Maintainability design guidelines 접근성 고장의 확인 및 격리 능력 교체 부품의 비중 한계 교체 부품의 운반 가능성을 고려한 크기 한계 교체 부품의 자동 ( 원격 ) 교체 가능성
DFEDFA DFM DFD DFR DFLC DFQ DFMt 9/20
SummarySummary
여러 측면에서의 설계 목적과 제약 사항들을 사전에 고려하여 더 나은 제품을 설계
DFMA 를 통해서 낮은 비용으로 용이한 제품 생산 DFD, DFR, DFLC 를 통해서 제품의 수명 주기 후에
처리를 용이 DFE 를 통해서 환경적인 안전과 건강과 관련된
문제들을 해결하고 간접적인 비용을 절감 DFQ, DFMt 를 통해서 검사 , 재작업 , 진단에
소요되는 비용을 절감
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Future trendsFuture trends
Integration issues in DFX Systematic identification of user’s life-cycle requirements Methods to represent, store, and retrieve design
alternatives Comprehensive measure of goodness of a design
Human factors engineering in DFX Workplace design, human-equipment interface, training
program Intelligent DFX systems
필요한 경험을 쌓는 데 많은 시간이 소요 Knowledge-based system 을 이용하여 design feature 간의
관계를 이해하는 데 도움을 줄 수 있다 .
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Productivity evaluation method andProductivity evaluation method anddesign for manufacturabilitydesign for manufacturability
JSAE Review 16 (1995) 375-381
Hiroshi Onitsuka, Kaoru Eguchi, Naoaki Miura, Hiroatsu Matsumura
Powertrain Prototype Engineering Department, Nissan Motor Co., Ltd., Kanagawa, Japan
IntroductionIntroduction
Nissan 에서 미국 시장을 겨냥하여 개발한 VQ engine에 적용된 방법론
높은 품질과 낮은 비용이 목적 엔진 조립 공정의 70% 가 자동화
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Productivity evaluation methodProductivity evaluation method
The degree of progress achieved in design for manufacturability
The evaluation method provides an index of how difficult a part would be to build, or the poorness of its workability
Stabilize production quality and achieve low cost level
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Assembly productivity evaluation methodAssembly productivity evaluation method
Standard time Most fundamental work aspects of an element 부품을 줄이는 것으로 향상 가능
Difficult operation time Additional time spent when the construction of a part requires extra
work 제거 가능한 다양한 방식의 작업이 존재
어떤 부품이 생산성 증가를 위하여 개선 가능한 지를 알려줌 Std time/dif oper time 중 어느 것이 효과적인 지 알려줌 제품 개발 초기 단계에 전체 line cycle time 에 대한 추정
14/20
Maching productivity evaluation methodMaching productivity evaluation method
Cost of facilities 와 cost of the tools 로 평가 예를 들어 , 가공해야 할 hole 의 수가 많으면 ,
standard operation score 가 높다 . Hole 들이 가까이 있는 경우에는 multi-axis head 를
사용할 수 없기 때문에 difficult operation score 가 높다 .
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Design for global manufacturing and assemblyDesign for global manufacturing and assembly(DFGMA)(DFGMA)
IIE Transactions 29 (1997) 585-597
G. Don TaylorDept. of IE, Bell Engineering Center, Univ. of Arkansas, USA
IntroductionIntroduction
Dowlatshahi(1992) reports The design phase is responsible for only 5% of product
cost But, it can determined 75% of the manufacturing cost and
80% of product quality performance
General DFX strategies are difficult to manage in multi-facility, global settings
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Mathematical formulationMathematical formulation
Manufacturing cost
manufacturing= process + design + logistics + inventory
ijklmijklmijklmijklmijklm CICLCDCPCM
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General DFGMA modelGeneral DFGMA model
Objective function:
m
IjklmIjklmlkj
XCM:min
l
IjklIjklkj
YCS
k
IjkIjkj
YCT '
l
jkljklkj
ZCC
manufacturing cost
set-up cost
tooling cost
capital procurement cost
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i : product Ij : process j (1:automated, little flexible, 2: flexible)k : site k (Europe, Asia, North America)l : period l(3 quarter period)m : demand location
General DFGMA modelGeneral DFGMA model
constraints
l
lml
Ijklmkj
DX
jklm
ijklmIjklm
ijklm
I
iijkl AXCXC
)()(1
1
)]([ Ijklm
Ijklm YMX
10 jkA
)('1, jkljklljkjkl ZAAA
0jklA
int,0IjklmX
int,1,0' IjkY
int,1,0IjklY
int,1,0jklZ
)']([ Ijkl
Ijkl YMX
19/20
i : product Ij : process j (1:automated, little flexible, 2: flexible)k : site k (Europe, Asia, North America)l : period l(3 quarter period)m : demand location
simulationsimulation
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