Product Process Development

Design For X (Assembly,

Dissassembly, Poka Yoke,
Maintenance)
 Design for Manufacturing Assembly
• Design for Manufacturing (DFM) refers to design (activity
that is based on minimizing the cost of production and/or
time to market for a product, while maintaining an
appropriate level of quality.

• Design for Assembly (DFA) involves making (directions and

methods for attaching and joining the parts of a product
simpler.
Bill of Materials
Examples of ways to reduce the overall number of components: (a) a component with many pieces; (b) part
redesigned and manufactured by a multimold manufacturing process to substantially reduce the number
of individual pieces and to provide some of the elements with elasticity.
 Assembly Principles
1.Simplify and reduce the number of parts because for each part there is an
opportunity for a defective part and an assembly error. Fewer parts mean
less of everything that is needed to manufacture a product: engineering
time, drawings and part numbers; and inventory; number of purchase
orders and vendors; number of, containers, amount of material-handling
equipment.
2.Standardize and use common parts and materials to facilitate design
activities, to min­imize the amount of inventory in the system, and to
standardize handling and assembly operations. The use of common parts
will result in lower inventories, reduced costs, and simplified operator
learning.
3.Mistake-proof product design and assembly so that the assembly process
is unambigu­ous. Components should be designed so that they can only be
assembled in one way: they cannot be reversed. Notches, asymmetrical
holes, and stops can be used to mistakes-proof the assembly process.
4.Design for parts orientation and handling to minimize the effort and
ambiguity in ori­enting and merging parts. Parts should be designed to
orient themselves when fed into a process. Product design must avoid
parts that can become tangled, wedged, or disoriented.
5.Minimize flexible parts and interconnections by avoiding flexible and
flimsy parts such as belts, gaskets, tubing, cables, and wire harnesses.
Their flexibility makes material han­dling and assembly more difficult, and
these parts are more susceptible to damage. Use plug-in boards and back
planes to minimize wire harnesses.
6.Design for ease of assembly by utilizing simple patterns of movement and
minimiz­ing the number of axes of assembly. Complex orientation and
assembly movements in various directions should be avoided.
7.Design for efficient joining and fastening. Threaded fasteners (screws,
bolts, nuts, and washers) are time-consuming to use in assembly and
difficult to automate. Where they must be used, standardize to minimize
variety, and use fasteners such as self-threading screws and captured
washers. Consider the use of adhesives and connectors that snap
together.
8.Design modular products to facilitate assembly. A modular design should
minimize the number of part and assembly variations and manufacturing
processes, while allowing for greater product variation during final
assembly.
 DFM and DFA Design Guidelines
• Minimize part countMinimize countby incorporating
multiple functions into by single parts.
• Several parts could be fabricated by using different
manufacturing processes (sheet metal forming, injection
molding).
• Ask yourself if a part function can be performed by a
neighboring part.
• ModularizeModularizemultiple parts into
single submultiple subassemblies
• Design to allow assembly in open spacesallow
spaces, not , confined spaces. Do not bury
important components.
• Parts should easily indicate orientation for insertion parts
insertion. .
• Parts should have self parts self-locking features so that the
precise alignment during assembly is not required. Or,
• Provide marks (indentation) to make orientation easier.
• Use standardized products, and
• Standardize parts to reduce variety of
operations, choices, and inventory burden.
• Design parts so they do not tangle or stick to
each to other.
• Distinguish ‘‘apparently parts”
• Distinguish different parts that are shaped similarly, or
hard to distinguish, by nongeometric means, such as
color coding. -
• Design parts to prevent nesting.
• Nesting is when parts that are stacked on top
of one another clamp or stick to one another,
for example, cups and coffee lids
• Design parts with orienting featuresDesign
featuresto make to alignment easier.
• Provide alignment features on the on
assembly so parts are easily oriented.
• Design the mating parts for easy insertion or
attachment
• Provide allowance (tolerance) on each part to
compensate for variation in part dimensions.
• Design the first part large and wide for
stability ,
• Then assemble smaller parts on top of it,
sequentially.
• If you cannot assemble parts from the top
down you exclusively, then minimize the
number of insertion directions .
• Never require the assembly to be turned
require over.
• Joining Options: parts can be joined using fasteners
(screws, nuts and bolts, rivets), snap fits, welds or
adhesives. Design to eliminate bolts, eliminate
fasteners and to place them away from obstructions
Examples
 Design for Disassembly
• The disassembly of products—the separation by
nondestructive or semi-destructive means—appears to be
one of the more serious problems impeding the reuse of
products, since many products are not designed for easy
disassembly.
• The influence of design for disassembly (DFD) on recyclability
and easy disassembly is that it makes it possible to reuse,
remanufacture, and recycle materials in an efficient manner.
Reuse and remanufacture can save many resources by
prolonging the useful life of products.
 DFD GUİDELİNES AND THE EFFECTS ON
THE DESİGN FOR ASSEMBLY
There are two strategies in planning the dismantling of
a product.
• Remove the most valuable parts first and stop
dismantling when the marginal return on the
operation becomes unfavorable.
• Maximize the yield of each dismantling operation by
having the dismantling operation releasing many
parts at once.
When designing for disassembly one should consider the following:
• Identification: Materials and parts must be identified. For example, in the
United States polymers are classified into seven categories.
• Recycling: To recycle metals and alloys, their grade or levels of
contaminants must be known. The general principle is to reduce variety.
• Compatibility: Ensure compatibility of materials. For example, swelling of a
product component due to corrosion locks parts together and the corrosion
(or wear) of the heads of fasteners can also make dismantling more difficult.
• Overall form and structural strength: Build in weak points for dismantling
in such a way that service loads can still be carried.
• Fasteners and adhesives: Consider such means as fasteners that insert as a
rivet, but can be removed as a screw, and adhesives that are strong in shear
but are weak when peeled apart.
• How these guidelines interact with, and affect, the design for assembly are summarized
below.
• Positive Effects on Assembly
• Reduce the number of components.
• Reduce the number of separate fasteners.
• Provide open access and visibility for separation points.
• Avoid orientation changes during disassembly.
• Avoid nonrigid parts.
• Ensure that disassembly can be done with common tools and equipment.
• Design for ease of handling and cleaning of all components.
Negative Effects on Assembly
• Design two-way snap fits or break points on snap fits.
• Use joining elements that are detachable or easy to destroy.
• Design for ease of separation of components.
• Use water-soluble adhesives.
DFD Guidelines Having Relatively Little Effect on Assembly
• Design products for reuse.
• Eliminate need to separate parts.
• Reduce number of different materials.
• Enable simultaneous separation and disassembly.
• Place components in logical groups according to recycling and disassembly
sequences.
• Identify separation points and materials.
• Facilitate the sorting of noncompatible materials.
• Use molded-in material identification in multiple locations.
• Provide a technique to safely dispose of hazardous waste.
• Select an efficient disassembly sequence.
 Design for Poka-Yoke
• It was the Japanese manufacturing engineer Shigeo Shingo
who developed the idea into a tool for achieving zero defects
and eventually eliminating the need for quality control
inspections.
• Poka-yoke has three basic functions to use against defects—
shutdown, control, and warning. Recognizing that a defect is
about to occur is called prediction, and recognizing that a
defect has already occurred is called detection. To detect
defects, the poka-yoke system uses such devices and means
as guide pins of different sizes, error detection and alarms,
limit switches, counters, and checklists.
• Many defects are caused by human errors. These errors and their
safeguards are as follows.
• Forgetfulness—A required action is not performed.
Safeguards: Alerting operator in advance or checking at regular intervals.
• Misunderstanding—A prohibited action is executed.
Safeguards: Training, checking in advance, standardizing work practices.
• Identification—An error is made in selecting among alternatives.
Safeguards: Training, attentiveness, vigilance.
• Inexperience—Information essential for an action is misinterpreted.
Safeguards: Skill building, work standardization.
• Inattentiveness
Safeguards: Discipline, work standardization, work instructions.
There are various types of defects. In order of importance, these defects
can be as follows.
• Omitted processing.
• Processing errors.
• Errors in setting up work pieces.
• Missing parts.
• Wrong parts.
• Processing wrong work pieces.
• Incorrect operation.
• Adjustment error.
• Equipment not set up properly.
• Tools and jigs improperly prepared.
• Several classes of devices that have proven useful in mistake-proofing
assembly and manufacturing operations.
– The first set of devices uses mechanical objects such as guide pins of
different sizes, blocks, and slots so that a part can only be oriented in
a specific way before critical operations are performed.
– A second set of devices use electronic sensors such as limit switches,
light, and proximity gauges to determine the presence or absence of a
mistake.
– The third set of devices use special jigs and fixtures to detect
upstream mistakes and to mistake-proof machine setup operations.
Counters have been used to verify that the correct number of parts
has been used or the correct number of operations has been
employed.
 DESIGN FOR MAINTAINABILITY
(SERVICEABILITY)
• Maintainability is composed of those elements of a product's design that
assure that the product will perform satisfactorily throughout its intended
life with a minimum expenditure of money and effort.
• Experience indicates that those systems that have been designed for
producibility are most likely to be maintainable. Each maintainability
design feature is justified by its ability to support needed maintenance
functions. These functions can serve one or more of the following three
principal maintenance purposes.
– Preventive: To help keep the product in good condition.
– Corrective: To return a malfunctioning product to its usable condition.
– Overhaul: To return a product to its approximate original condition.
Maintainability features include the following: accesses; controls and displays;
connectors, cou­plings, and lines; fasteners; handles; labels; appropriate mounting and
positioning; and test and work points.
The following are some guidelines for a design for maintainability:
• Provide easy and properly-sized access with common fasteners and attachments.
• Design for few serviceable items, each requiring simple procedures with minimum
skills.
• Use modular construction.
• Place components/modules that need regular replacement or servicing in accessible
locations.
• Require common hand tools and a minimum number of them.
• Provide built-in tests and indicators for maintenance diagnosis; provide accessible test
• points.
• Mistake-proof fasteners and connectors for easy reassembly.
• Require no, or minimal, adjustment; keep adjustable items easily
accessible.
• Provide easy access to serviceable items; provide for their removal
without having to remove unrelated components.
• Provide for visual inspection and for easy identification.
• Provide for easily replaced modules and parts; make them
interchangeable and standard.
• Provide means to lift and manipulate heavy components.
• Provide safety interlocks, covers, guards, and switches.