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Transcript of 06 DFM-DFA
DESIGN FOR X
Dr. M.K. Herliansyah, ST. MT.
Program Studi Teknik IndustriJurusan Teknik Mesin dan Industri
Fakultas Teknik Universitas Gadjah Mada2010
Design for X Topics
Design for Manufacturing Design for Assembly Design for Production Design for Recycling/Disposal Design for Life Cycle Prototyping Design for Automation
Gathering DFM Information Design documents:
– Sketches, – Drawings, – Spesifikasi produk, dan – Alternatif-alternatif desain.
Pemahaman dan informasi detil mengenai proses produksi dan perakitan/assembly
Perkiraan:– manufacturing costs, – production volumes, dan – ramp-up timing.
DFM Method Memperkirakan manufacturing costs. Mengurangi biaya-biaya untuk
mempersiapkan/pembuatan components. Mengurangi biaya-biaya untuk proses
perakitan/assembly. Mengurangi biaya-biaya pendukung proses
production. Mempertimbangkan dampak/pengaruh DFM
decisions pada faktor-faktor yang lain.
DFM Method
Reduce the Cost of Supporting Production
Consider the Impact of DFM Decisions on Other Factors
Proposed Design
Estimate The Manufacturing Cost
Reduce the Cost of Components
Reduce the Cost of Assembly
Recompute the Manufacturing Costs
Good Enough?
N
Y
Acceptable Design
Estimate the Manufacturing Costs
Finished GoodsManufacturing System
Equipment Information Tooling
WasteServicesSuppliesEnergy
Raw Materials
Labor
PurchasedComponents
Manufacturing Costs Defined• Menghitung seluruh pengeluaran untuk
input system (sebagai contoh: pembelian komponen-komponen, energi, raw materials, dan lain-lain) dan pengeluaran untuk penanganan limbah yang dihasilkan oleh sistem.
Elements of the Manufacturing Cost of a Product
Manufacturing Cost
OverheadAssemblyComponents
Standard Custom LaborEquipmentand Tooling
SupportIndirect
Allocation
RawMaterial
Processing Tooling
Manufacturing Cost of a Product Component Costs (komponen-komponen dari
produk yang dibuat)– Komponen-komponen yang dibeli dari supplier– Custom parts yang dibuat didalam shop floor-nya sendiri
atau shop floor para supplier sesuai dengan spesifikasi desain dari manufacturer’s
Assembly Costs (labor, equipment, & tooling) Overhead Costs (all other costs)
– Support Costs (material handling, quality assurance, purchasing, shipping, receiving, facilities, etc.)
– Indirect Allocations (tidak berhubungan secara langsung dengan suatu particular product tetapi harus dibayar dalam proses bisnis)
Fixed Costs vs. Variable Costs
Fixed Costs – ditentukan terlebih dahulu dalam suatu jumlah tertentu tanpa memperhatikan jumlah unit yang diproduksi (i.e. setting up the factory work area or cost of an injection mold)
Variable Costs – ditentukan secara langsung dalam jumlah yang proporsional dengan jumlah unit yang diproduksi (i.e. cost of raw materials)
Reduce the Cost of Components
1. Understand the Process Constraints and Cost Drivers
2. Redesign Components to Eliminate Processing Steps
3. Choose the Appropriate Economic Scale for the Part Process
4. Standardize Components and Processes5. Adhere to “Black Box” Component
Procurement
Redesign costly parts with the same performance while avoiding high manufacturing costs.
Work closely with design engineers—raise awareness of difficult operations and high costs.
1. Understand the Process Constraints and Cost Drivers
2. Redesign Components to Eliminate Processing Steps Reduce the number of steps of the
production process– Will usually result in reduce costs
Eliminate unnecessary steps. Use substitution steps, where applicable. Analysis Tool – Process Flow Chart and
Value Stream Mapping
3. Choose the Appropriate Economic Scale for the Part Process
Economies of Scale – As production volume increases, manufacturing costs usually decrease.
Fixed costs divided among more units. Variable costs are lower since the firm can
use more efficient processes and equipment.
4. Standardize Components and Processes Economies of Scale – The unit cost of a
component decreases as the production volume increases.
Standard Components—common to more than one product
Analysis tools – group technology and mass customization
5. Adhere to “Black Box” Component Procurement Black box—only give a description of what
the component has to do, not how to achieve it
Successful black box design requires clear definitions of the functions, interfaces, and interactions of each component.
Summary What is DFM?
DFM is product design considering manufacturing requirements
DFM is the first step in which a team approach is taken to develop the product
DFM is an umbrella which covers a variety of tools and techniques to accomplish a manufacturable product
Why DFM? Lower development cost Shorter development time Faster manufacturing start of build Lower assembly and test costs Higher quality
Summary How do all the pieces fit together?
The objective of DFM is to identify product concepts that are easy to manufacture
Focus on component design for ease of manufacture and assembly
Integrate manufacturing to ensure the best match of needs and requirements.
DFM in industry is typically divided into 2 main activities:
A team which will be responsible for the product development and delivery. (cross functional team: ME, EE, MFG., CE, PE, Quality)
The tools and methods to enable DFM that ensure the design meets the objectives.
Manufacturing Today Global Competition
Trade barriers have been removed (NAFTA) Must compete with the best from all over the world
Japan, Europe, India, Mexico, etc Infrastructure's forming off shore
Quality Requirements ISO 9000 Six Sigma (Motorola Inc)
Product Cycles Every generation is faster Rate of change is increasing
Cost Costs decrease every year (customers expect costs to go down) Performance increasing every year
DFM Typical Approach
DesignTest Tool Build
Launch
finishstart
Product Development Steps
Product Development team making it happen!!- Product requirements and deliverables- DFM tools and methods
Product Development Process Conceptual DESIGN and development Product optimization, TEST TOOL BUILD (ease of assembly) LAUNCH, ramp, ship, and deliver
Product Team Product requirements and deliverables Collaborative cross functional team
(ME, EE, MFG, Test, Quality, etc.). Not “designed in a vacuum”
Uses DFM tools and methods
DFM Product Considerations Product Considerations
Environmental Ergonomics Safety Pollution Recycling Shock/vibration Temperature
Customer Depth of product line Customization Test requirements
Process and Tooling Cycle time Quality Ease of Assembly Ease of Testing Rework Shipping and Handling Tooling Costs
Suppliers Partnerships Supplier tolerance capability Merging mechanical sub-assemblies Costs
DFM Tools and Methodology Tools and Methodologies
Design For Assembly (DFA), (IBM experience) Failure Mode and Effect Analysis (FMEA), (Sun
example) Taguchi Method, (Hitachi experience) Value Analysis--”Value Engineering” (HP example) Quality Function Deployment (QFD), Going to the
Gemba (Hitachi) Group Technology, (IBM example) Cost management and optimization, SPC, Six-Sigma
(Motorola), TQC, etc
DFA Systems
Boothroyd Dewhurst DFM & A Munro & Assoc. (Design Prophet/Profit) Others
Product Design Today Development Cycle
Endless engineering changes Non standard parts have long lead times
Quality “Designed and thrown over the wall” Lower due to more parts, manual processes, and
untested parts Customer configuration management
Cost Higher due to unique designs and specialized parts
Equipment and Tooling Reliability and quality problems
DFM/A System In Global Manufacturing
Commercial Airplanes - Military Aircraft & Missiles - Space & Communications - Air Traffic Management - Boeing Capital Corporation - Shared Services Group - Phantom Works
747 Final Assembly at Everett, Washington
747 Freighter
747 Freighter
DFM Tools: DFA Guidelines
- Standard parts (one screw type)
- Parts are self-guiding
-Die cast with minimal amount of holes (debris chip)-Standard cutters -Guide features- Common datum’s for all fixtures
-One common plane for assembly- Tabs for robotic lift
- One assembly direction “tops down”-No adjustments required-No hidden features
- bottom rails for conveyor
- Test direction access from top
- Easy to fabricate parts
- Sub-assemblies reduce handling of small hard to grip parts
- Symmetry in two axis
- Holes large enough (straightness issues if too deep)
- Avoid tangle with use of fixtures
DFM Tools: DFA Guidelines Summary of DFA Guidelines
1. Minimize the number of parts2. Standardize and use as many common parts as possible3. Design parts for ease of fabrication (use castings without machining
and stampings without bend)4. Minimize the number of assembly planes (Z-axis)5. Use standard cutters, drills, tools6. Avoid small holes (chips, straightness, debris)7. Use common datum’s for tooling fixtures8. Minimize assembly directions9. Maximize compliance; design for assembly10. Minimize handling 11. Eliminate adjustments12. Use repeatable, well understood processes13. Design parts for efficient testing14. Avoid hidden features 15. Use Guide features16. Incorporate symmetry in both axis17. Avoid designs that will tangle.18. Design parts that orient themselves
DFM Tools and Methodology FMEA (Failure Mode and Effects Analysis)
Method for analyzing the causes and effects of failures. Highlights designs and assemblies most likely to cause failures. Helps identify and prioritize corrective action Indicates where the most improvement in terms of severity,
frequency, and detectability can be made. Widely used manufacturing technique (Mil standards, SAE, ANSI
Specs)
Reduce the Costs of Assembly
1. Design for Assembly (DFA) index
2. Integrated Parts (Advantages and Disadvantages)
3. Maximize Ease of Assembly
4. Consider Customer Assembly
1. Design for Assembly Index
Determining the Theoretical Minimum Number of Parts Does the part need to move relative to the
rest of the assembly? Must the part be made of a different
material from the rest of the assembly for fundamental physical reasons?
Does the part have to be separated from the assembly for assembly access, replacement, or repair?
2. Advantages of Integrated Parts
Do not have to be assembled Often less expensive to fabricate rather than
the sum of each individual part Allows critical geometric features to be
controlled by the part fabrication process versus a similar assembly process
2. Disadvantages of Integrated Parts
Conflict with other sound approaches to minimize costs
Not always a wise strategy
3. Maximize Ease of Assembly
Part is inserted from the top of the assembly Part is self-aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately upon insertion
4. Consider Customer Assembly
Customers will tolerate some assembly Design product so that customers can easily
and assemble correctly Customers will likely ignore directions
Reduce the Costs of Supporting Production Minimize Systemic Complexity (inputs, outputs,
and transforming processes)– Use smart design decisions
Error Proofing (Poka Yoke)– Anticipate possible failure modes– Take appropriate corrective actions in the early
stages– Use color coding to easily identify similar
looking, but different parts
Consider the Impact of DFM Decisions on Other Factors Development Time Development Cost Product Quality External Factors
– Component reuse– Life cycle costs
DFM&A Road Map Membentuk sebuah multifunctional team Menetapkan sasaran produk melalui competitive
benchmarking Melakukan DFA analysis Melakukan segmentasi produk hingga mencapai
manageable subassemblies atau levels of assembly Sebagai sebuah team, menggunakan prinsip-prinsip DFA Menggunakan teknik-teknik kreatif untuk meningkatkan
desain yang dihasilkan Sebagai sebuah team, melakukan evaluasi dan memilih ide
rancangan yang terbaik Memastikan bahwa setiap bagian komponen diproduksi
pada level yang ekonomis Menentukan target cost untuk setiap komponen dalam
desain produk yang baru
DESIGN FOR PRODUCTION
Design for Production
1. Design Organization
2. Timing of Production
3. Material Identification
4. Specific Design Details (outputs)
Production Input
At various design stages– Concept
• Production Input
– Functional• None
– Transition• Tactics
– Work Instruction• Production Preparation
New Idea: Provide Production Inputs
1. In proper level of detail at proper stage
2. In proper form
3. Just-in-time
Problems with Old Approach
Work is carried out from beginning to end at each stage
Too slow Needs continuous recycling
Design for Production General Principles
1. Use Common Sense
2. Plan and Define
3. Consider Available Facilities
4. Consider Available Tools
5. Consider Available Worker Skills
6. Employ Simplicity
7. Standardize
Design for Production Guidelines
1. Minimize Total Number of Parts
2. Develop a Modular Design
3. Minimize Part Variations
4. Design Parts to be Multifunctional
5. Design Parts for Multiuse
6. Design Parts for Ease of Fabrication
7. Avoid Separate Fasteners
Design for Production Guidelines
8. Minimize Assembly Direction (Top Down Direction Preferred)
9. Maximize Compliance in Assembly10. Minimize Handling in Assembly11. Minimize complexity of Design12. Maximize common Jigs and Fixtures13. Optimize Work Position14. Ease Access
PROTOTYPES
Types of Prototypes
Two dimensions– Physical vs. Analytical– Comprehensive vs. Focused
Physical vs. Analytical
Physical– Tangible artifacts created to approximate the
product– Used for testing and experimentation
Analytical– Represents the product in a nontangible, usually
mathematical manner– Product is analyzed, not built
Comprehensive vs. Focused
Comprehensive– Implement all (or most) of the attributes of the product
– Full-scale
– Fully operational version of the product
Focused– Implement a few of the attributes of the product
– Use two or more focused prototypes together to investigate the overall performance of a product
Prototype Uses Learning
– Will it work?– How well does it meet the customer needs?
Communication– Within the company– With customers, vendors, and suppliers
Integration– Subsystems and components work together
Milestones– Product achieved a desired level of functionality
Principles of Prototyping Analytical Prototypes are generally more flexible
than Physical Prototypes Physical Prototypes are required to detect
unanticipated phenomena A Prototype may reduce the risk of costly
iterations A Prototype may expedite (make it faster) other
development steps A Prototype may restructure task dependencies
Use of comprehensive prototypesT
ech
nic
al o
r M
arke
t R
isk
Hig
hLo
w
Cost of Comprehensive Prototype (Time or Money)
Low High
One prototype may be builtfor verification.
Examples: printed goods
Few or no comprehensiveprototypes built.
Examples: commericalbuildings, ships
Many comprehensiveprototypes built.
Examples: software,consumer products
Analytical prototypes usedextensively.
Carefully plannedcomprehensive prototypes.
Sometimes the first unitbuilt is actually sold.
Examples: airplanes,satellites, automobiles
Prototyping Technologies
3D Computer Modeling– Easily visualize the 3D form of the design– Automatically compute physical properties– Other more focused descriptions can be created
based on one design– Detect geometric interference among parts
Prototype Technologies
Free-Form Fabrication (or Rapid Prototyping)– 3D printers that create physical objects directly
from 3D computer models– Less expensive– Reduce product development time, improve
resulting product
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
3D Printing
Planning for Prototypes
1. Tentukan kegunaan dari prototype yang akan dibuat.
2. Menetapkan level kedekatan/kemiripan prototype yang akan dibuat.
3. Tentukan garis besar/outline rencana experiment menggunakan prototype tersebut
4. Membuat schedule untuk procurement, construction, dan pengujian prototype
Define the Purpose
List specific learning and communication goals
List any integration needs Determine if the prototype is intended to be
one of the major milestones of the overall product development project
Establish the Level of Approximation
Determine physical or analytical prototype Choose the simplest prototype that will
serve the purpose established in step 1. Consider existing prototypes or a another
prototype being built that can be borrowed
Outline an Experimental Plan
Menggunakan prototype untuk pengujian/ experiment
Menggali maximum value dari aktivitas prototyping.
Mengidentifikasi variable-variable yang digunakan dalam experiment, test protocol, rencana proses analisa terhadap data-data yang dihasilkan.
Create a Schedule for Procurement, Construction, and Test
Menentukan kapan komponen-komponen yang akan digunakan siap untuk dirakit/diassembly
Menentukan waktu kapan prototype akan diuji pertama kalinya
Menentukan harapan-harapan untuk completed testing and final results (termasuk dalam hal ini performance yang diharapkan dari produk tersebut)
Milestone Prototypes Alpha Prototypes – memperkirakan
apakah produk yang dirancang dapat berfungsi/bekerja sesuai dengan yang direncanakan/dirancang
Beta Prototypes – memperkirakan keandalan/reliability dan mengidentifikasi kemungkinan adanya kesalahan-kesalahan/bugs dalam produk yang dirancang
Preproduction Prototypes – produk pertama yang dibuat/dihasilkan dengan keseluruhan proses produksi
Reference
Ulrich, K. & Eppinger, S. (2000). Product Design and Development. Boston,
MA: Irwin McGraw-Hill.
TERIMA KASIHATAS PERHATIAN DAN KERJASAMANYA
Dr. Muhammad K. Herliansyah, ST. MT.
http://herliansyah.staff.ugm.ac.id
Tugas Mandiri:
Define each of the following parameters and what they mean in a design for manufacturing system: – • Rate – • Quality – • Cost – • Flexibility
You are the decision-maker at an automobile manufacturer. Describe one change for each of the terms above that you might make to improve that parameter. What trade offs would be associated with each of those changes?