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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:sharuzi@ump.edu.mymailto:sharuzi@ump.edu.my

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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)