Design for Manufacture and Assembly

Design for additive manufacturing is adopted to help solve problems inherent to attaching active personal sampler systems to workers for monitoring their breathing zone. A novel and parametric 3D printable clip system was designed with an open source Computer-aided design (CAD) system and was additively manufactured. The concept was first tested with a simple clip design, and when it was found to be functional, the ability of the innovative and open source design to be extended to other applications was demonstrated by designing another tooling system. The clip system was tested for mechanical stress test to establish a minimum lifetime of 5000 openings, a cleaning test, and a supply chain test. The designs were also tested three times in field conditions. The design cost and functionalities of the clip system were compared to commercial systems. This study presents an innovative custom-designed clip system that can aid in attaching different tools for personal exposure measurement ...

The goal of this paper is providing a methodology properly supporting façade optimization in a DfMA (Design for Manufacturing and Assembly) perspective. DfMA has proven to facilitate offsite manufacturing, lowering costs and improving speed and quality of construction, especially combined with BIM strategies. A BIM-based methodology can help in setting parameters for the proper optimization of the façade, balancing production related needs and design requirements. The proposed method allows the exploration of alternatives (known as Design Optioneering) to optimize the choice of façade elements. This method is based on a mathematical algorithm and script including parameters related to geometry, production waste management and designer's needs. The proposed methodology has been tested on a newly built school in Northern Italy.

Satisfactory weatherproofing of buildings is vital to maximise their design life and performance which requires the careful design of external sealing technologies. Systems commonly available have served well in conventional construction however with many prefabricated systems emerging in the building industry new and novel means of weatherproofing between panels and modules need to be developed purpose specific to this application. This paper presents a holistic and fundamental methodological approach to Design and Development of waterproof seals and has been applied specific for prefabricated panelised and modular systems. Two purpose specific weatherproof seals are finally presented. Flow charts of the overview of the suggested methodological approach and the processes within which include DfMA that have been incorporated into understanding and developing seals for this practical application. These strategies have enabled a resourceful and holistic set of processes that can be adapted and used for similar forms of product research in new and developing areas of construction such as prefabrication. The design and development process is thoroughly investigated and has resulted in an exploration of the technical challenges and potential solutions which take into consideration factors from installation limitations to building tolerances. Keywords: panelised and modular prefabricated construction; weatherproofing and waterproofing; sealing joints of façade components and walls; Design for Manufacturing and Assembly (DfMA), design and development

One of the most obvious environmental problem confronting Nigeria, like most other developing countries is solid waste generation and management. The major substances composing municipal solid waste include plastic which is not biodegradable. The problem of municipal solid waste disposal is now a global one that must be addressed in order to solve the world’s environmental and energy problems. In this research work, the design and fabrication of a furnace for plastic wastes recycling was undertaken. The furnace consists mainly of thermometer for measuring temperature, mild steel, glass fiber, heating coil, outer and inner layer. Before using the furnace for first time it was season. To season the furnace, the furnace opening was closed without loading it and heated to 1350 0C which was the highest design temperature range. Various weights of plastic wastes which comprises of 3kg, 5 kg, 8 kg, 10 kg, 14 kg and 15 kg were used to evaluate the fabricated furnace. The time of melting and the temperature of melting were recorded. The results obtained shown that as the weight of plastic wastes melted increases the time and temperature of melting also increases. Besides, the fabricated furnace was cost effective and can be afforded by average Nigerian.

The objective of this project is to analyze a disco light with the approach of remanufacturing in mind. Product remanufacturing consists of the following: incorporating the concepts of design for assembly (DFA) and design for disassembly (DFD) [1]. In other words, the process of handling, accessibility, orienting, feeding, assembling, and disassembling are carefully considered in the initial stages of product design. Design for assembly is a crucial step in reducing assembly costs and increasing productivity (assembly time). Typically, DFA involves reducing the total number of components, increasing symmetry and more. Along the same lines, design for disassembly is essential for remanufacturing and contributes to increased cost savings. The goal of DFD is to retrieve the core of the product in the most efficient way [1]. This project will explore the concepts of DFA and DFD in-depth. We will redesign a disco light to facilitate the ease of assembly and disassembly, and most importantly, reduce associated costs.

Featured Application: The customizable clip system opens new possibilities for occupational health professionals since the basic design can be altered to hold different kinds of samplers and tools. The solution is shared using an open source methodology to allow for distributed manufacturing of the free designs.

Abstract: Design for additive manufacturing is adopted to help solve problems inherent to attaching active personal sampler systems to workers for monitoring their breathing zone. A novel and parametric 3D printable clip system was designed with an open source Computer-aided design (CAD) system and was additively manufactured. The concept was first tested with a simple clip design, and when it was found to be functional, the ability of the innovative and open source design to be extended to other applications was demonstrated by designing another tooling system. The clip system was tested for mechanical stress test to establish a minimum lifetime of 5000 openings, a cleaning test, and a supply chain test. The designs were also tested three times in field conditions. The design cost and functionalities of the clip system were compared to commercial systems. This study presents an innovative custom-designed clip system that can aid in attaching different tools for personal exposure measurement to a worker's harness without hindering the operation of the worker. The customizable clip system opens new possibilities for occupational health professionals since the basic design can be altered to hold different kinds of samplers and tools. The solution is shared using an open source methodology.

Perkembangan teknologi yang semakin pesat di sentra Industri mendorong perlunya Sumber
Daya Manusia (SDM) yang terampil dan ahli. Kerja Praktek merupakan salah satu mata kuliah di
Perguruan Tinggi yang dapat menunjang terbentuknya SDM tersebut. Mahasiswa dilatih untuk
belajar di Industri dengan cara menerapkan teori yang diperoleh dari bangku perkuliahan. Salah
satu Industri yang menyelenggarakan Kerja Praktek yaitu PT. Petrokimia Gresik. PT. Petrokimia
Gresik merupakan Badan Usaha Milik Negara (BUMN) dan salah satu anak perusahaan dari PT.
Pupuk Indonesia. Selain itu, PT. Petrokimia Gresik bergerak di bidang industri kimia, engineering,
dan jasa konsultan. Salah satu bentuk kerja praktek di PT. Petrokimia yaitu melalui Departemen
Fabrikasi. Departemen Fabrikasi membantu mahasiswa untuk belajar mengenai kegiatan fabrikasi
dan permesinan untuk mendukung kelancaran operasional pabrik dan unit pendukungnya, proyek
proyek pengembangan pabrik serta penjualan jasa ke pihak luar. Laporan Kerja Praktek ini
membahas kondisi pabrik PT. Petrokimia Gresik khususnya pada Departemen Fabrikasi dan
proses fabrikasi dari Sulphur Melter Heating Coil (30 E-1002A/B) yang dilakukan oleh
Departemen Fabrikasi PT Petrokimia Gresik. Sulphur Melter Heating Coil (30 E-1002A/B) adalah
salah satu jenis dari heat exchanger yang berfungsi untuk memanaskan. Proses fabrikasi Sulphur
Melter Heating Coil dibagi menajadi beberapa tahap, yaitu: Drawing untuk memperoleh gambar
teknik; Pemilihan material yang dibutuhkan; Proses manufaktur part coil, part cover, dan part
slave nozzle; proses assembly menggunakan sambungan baut dan las; inspeksi dengan
pemeriksaan dimensional, penetran test, dan full annealing.

This paper presents the application of the Design for Manufacture and Assembly method (DFMA) during the conception of a space product. This approach enables to capture manufacture and assembly requirements in early phases of development. DFMA guides the manufacture processes and materials that rule the Fins Module interface to the Microsatellite Launch Vehicle (VLM-1) main structure. The results of this process are the requirements captured in the beginning of the project development, allowing avoiding problems that generally occur in the manufacture stage and in assembly, integration and test (AIT) phase. Rework, material loss, wasting time to assembly and integration, over engineering and unnecessary engineering are problems that the method intends to reduce in the physical implementation phase.

In this paper, different types of polyurethane foams (PUR) having various chemical compositions have been produced with a specific density to monitor the microstructure as much as possible. The foam may have a preferential orientation in the cell structure. The cellular polyurethane tends to have stubborn, typical cellular systems with strong overlap reversibility. Free expansion under atmospheric pressure enables formulas to grow until they are refined. Moreover, the physicochemical characterization of the developed foams was carried out. They later are described by apparent density, Shore hardness, Raman spectroscopy analysis, X-ray diffraction analysis, FTIR, TGA, DSC, and compression tests. The detailed structural characterization was used by scanning electron microscope (SEM) and an optical microscope (MO) to visualize the alveolar polymer’s semi-opened cells, highlighting the opened-cell morphology and chemical irregularities. Polyurethane foams with different structural varia...

Manufacturing defects are the major concern of all manufacturing industries. These defects occur due to poor material quality or lack of skilled labour. This paper focuses upon one such operation that was dependent on the skills of the operator which was deskilled by one of the successful devices in lean production which is used to eliminate waste caused by errors i.e 'mistake-proofing' or 'Poka-yoke'. The use of Poka Yoke in the Ultra SD Cartridge assembly operation eliminated the requirement of skilled operator. This was effectively done by introducing a new locating fixture on the assembly line.

Propoes a methodology that enables a dynamic and interactive 3‐Dvisualization model of the assembly process to be developed from the CAD files of each part in the assembly. Makes three main contributions to the research in this area. First, a taxonomy of features for assembly is presented. Second, a process model for generating interactive 3D models of the assembly process is developed and, third, a new algorithm for creating a dynamic assembly model is derived. This algorithm, called the 3D assembly visualization (3AV) algorithm, involves instantiating the motion attributes that specify the motion of each part in the assembly. This dynamic assembly model is then converted to a 3‐D renderable format for visualization. An example is presented that uses virtual reality modeling language (VRML) as the 3‐D representation language. The result is a dynamic and interactive visual representation of the assembly operation. Such visualization can be of considerable use in DFA.

The general objective of AM-NPP is to increase the knowledge of finnish stakeholders on the use of Addtive Manufacturing (AM), in particular Laser Powder Bed Fusion (L-PBF), therefore ensuring the safe use of additively manufactured metallic components in the nuclear sector. It is a technology which is showing a lot of applicability potential, e.g. in dealing with obsolescence in Nuclear Power Plants, but for which there is still little exposure to for both licensees and regulator. AM-NPP aims at closing this gap. The work developed during the different work packages aims at: Expanding standard procedures and deepen understanding of materialprocess-property relationships; contributing with scientific based facts to the introduction of AM in nuclear design codes; and, identifying safe ways of replacing obsolete components and realize new designs using AM. During the first two years of the project the focus has been on creating a roadmap of the use of AM in Finnish nuclear sector. Also, applicability of AM components and methods of quality control have been studied.

Prefabricated forms of construction have led to the rapid onsite assembly of buildings however there are still on-site tasks and processes which can be reevaluated and redone specifically in keeping with the principles of prefabrication instead being adapted to fit its purpose. One such process is that of waterproofing between prefabricated panels and modules which come from the factory fully complete façade and all. Conventional means of waterproofing can be used however it results in more work done on site, potential delays and generally requires access from the external face of the building. This paper presents the Modelling, Implementation and Evaluation of purpose developed weatherproof seals specific for Prefabricated Construction. An overview is provided of the entire development process and specific focus is given to the modeling using finite element analysis (FEA) computer simulations, manufacturing and testing which then resulted in the implementation in a prefabricated pa...

Before examining requirements to extend previously created integrated environmen engineering, it is worth considering what is meant by this term. From concurrent engineering research in other domains we have the following definitions: 路 In Winner et al. (1988) concurrent engineering is defined as "a systematic approach to the integrated, concurrent design of products and their related processes, including manufacturing and

Prefabricated forms of construction have led to the rapid onsite assembly of buildings however there are still on-site tasks and processes which can be reevaluated and redone specifically in keeping with the principles of prefabrication instead being adapted to fit its purpose. One such process is that of waterproofing between prefabricated panels and modules which come from the factory fully complete façade and all. Conventional means of waterproofing can be used however it results in more work done on site, potential delays and generally requires access from the external face of the building. This paper presents the Modelling, Implementation and Evaluation of purpose developed weatherproof seals specific for Prefabricated Construction. An overview is provided of the entire development process and specific focus is given to the modeling using finite element analysis (FEA) computer simulations, manufacturing and testing which then resulted in the implementation in a prefabricated panelised building which is used as a case study and the means of further evaluation. These strategies have enabled an efficient and robust prefabricated waterproofing solution specific for this form of construction to be understood and implemented. The resulting case study has successfully verified the time and cost savings when compared to conventional techniques whilst still providing a durable and effective weatherproof seal for prefabricated panelised and modular systems.

The development of a test system to complete existing equipment in a research laboratory is a real design-activity, with even high complexity levels and many constraints, in terms of resistance to mechanical stresses and geometric connectivity to existing mechanical interfaces as well. Such a project must also be focussed, if possible, on cost saving and realisation speed, to make the best possible use of research funds, having often a limited time-availability. Concurrent Engineering (CE), born in the early 90s, is as a well-defined system approach to optimize the design and engineering cycles, with emphasis on tasks parallelization. In particular, CE revolves around the concept of considering all elements of a product lifecycle in the early design phases. By doing so, the resulting project is virtually free from design errors, which are expensive to be corrected in existing components and critical for the success of that project. The "Theory of Inventive Problem Solving" or TRIZ includes a practical methodology, some tools, a knowledge-base and a model-based technology for generating innovative solutions for problem solving. CE and TRIZ together can be particularly-effective also in the design of unique components, e.g. those composing the equipment of a research laboratory. This work illustrates the approach followed in defining a component of a system to measure the agricultural machinery performance. This rig will connect the rear wheels of a tractor to an existing PTO-dyno through two multiplication stages. In particular, the cited methodologies have been applied in the development of a hub-adapter, i.e. the element that interfaces with the machine in test. The research for technical documentation and standards, the direct measurement of existing parts, the computer-aided design with 3D-modelling and finite element calculation of the components, have allowed to obtain iteratively a project verified in all aspects, ready to be realized.

In this paper, different types of polyurethane foams (PUR) having various chemical compositions have been produced with a specific density to monitor the microstructure as much as possible. The foam may have a preferential orientation in the cell structure. The cellular polyurethane tends to have stubborn, typical cellular systems with strong overlap reversibility. Free expansion under atmospheric pressure enables formulas to grow until they are refined. Moreover, the physicochemical characterization of the developed foams was carried out. They later are described by apparent density, Shore hardness, Raman spectroscopy analysis, X-ray diffraction analysis, FTIR, TGA, DSC, and compression tests. The detailed structural characterization was used by scanning electron microscope (SEM) and an optical microscope (MO) to visualize the alveolar polymer’s semi-opened cells, highlighting the opened-cell morphology and chemical irregularities. Polyurethane foams with different structural varia...

In this paper, different types of polyurethane foams (PUR) having various chemical compositions have been produced with a specific density to monitor the microstructure as much as possible. The foam may have a preferential orientation in the cell structure. The cellular polyurethane tends to have stubborn, typical cellular systems with strong overlap reversibility. Free expansion under atmospheric pressure enables formulas to grow until they are refined. Moreover, the physicochemical characterization of the developed foams was carried out. They later are described by apparent density, Shore hardness, Raman spectroscopy analysis, X-ray diffraction analysis, FTIR, TGA, DSC, and compression tests. The detailed structural characterization was used by scanning electron microscope (SEM) and an optical microscope (MO) to visualize the alveolar polymer’s semi-opened cells, highlighting the opened-cell morphology and chemical irregularities. Polyurethane foams with different structural varia...

Prefabricated forms of construction have led to the rapid onsite assembly of buildings however there are still on-site tasks and processes which can be reevaluated and redone specifically in keeping with the principles of prefabrication instead being adapted to fit its purpose. One such process is that of waterproofing between prefabricated panels and modules which come from the factory fully complete façade and all. Conventional means of waterproofing can be used however it results in more work done on site, potential delays and generally requires access from the external face of the building. This paper presents the Modelling, Implementation and Evaluation of purpose developed weatherproof seals specific for Prefabricated Construction. An overview is provided of the entire development process and specific focus is given to the modeling using finite element analysis (FEA) computer simulations, manufacturing and testing which then resulted in the implementation in a prefabricated pa...

There are several well-known quantitative evaluation methods in design for assembly. The best known design for assembly methods are Boothroyd-Dewhurst method, the Hitachi method, the Lucas method and IPA Stuttgart method. A case study of implement design for assembly principles on elevator car doors has been conducted. Based on a concurrent engineering type of design project plan, design objectives and constraints for elevator cars were evaluated and performance criteria for economical installation and maintenance were listed. Analytically criticizing commonly used designs, an innovative design were developed on a CAD package. The advantages and limitations of the new design have been comparing with two conventional designs in a systematic benchmark scheme. In this study conventional and proposed car door mechanisms are compared according to their parts number, cost and processes.

Motion time study has been popularly used in time measurement of product Design For Assembly (DFA). However, it takes a lot effort to develop the estimated time of manual handling and insertion. In this paper, we propose a new methodology called neural networks to predict the estimated time. Back-Propagation Networks (BPN) is employed to model the problem. The proposed neural