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DFMA I Design For Manufacturing & Assembly

helpful to engineer how a product can be designed for ease of manufacturing and assembly design for manufacturing and assembly Minimize part count by incorporating multiple functions into single parts. Design parts so they do not tangle or stick to each other Design parts with orienting features to make alignment easier. Design the mating parts for easy insertion.If you cannot assemble parts from the top down exclusively, then minimize the number of insertion direction. Never require the assembly to be turned over.

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Ram Chandran
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234 views22 pages

DFMA I Design For Manufacturing & Assembly

helpful to engineer how a product can be designed for ease of manufacturing and assembly design for manufacturing and assembly Minimize part count by incorporating multiple functions into single parts. Design parts so they do not tangle or stick to each other Design parts with orienting features to make alignment easier. Design the mating parts for easy insertion.If you cannot assemble parts from the top down exclusively, then minimize the number of insertion direction. Never require the assembly to be turned over.

Uploaded by

Ram Chandran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Design for Manufacturing

and Assembly I:
General Principles
by Kenneth Youssefi
Product Design and Manufacturing Minicurriculum
San Jos State University

Design for Manufacturing and Assembly


Design for manufacturing (DFM) is design based on
minimizing the cost of production and/or time to market
for a product, while maintaining an appropriate level of
quality. A primary strategy in DFM involves minimizing
the number of parts in a product.
Design For Assembly (DFA) involves making attachment
directions and methods simpler.

Ken Youssefi

SJSU: PDM II

DFMA Slide 2

DFM and DFA Benefits

It reduces part count thereby reducing cost. If a design is


easier to produce and assemble, it can be done in less
time, so it is less expensive. Design for manufacturing
and assembly should be used for that reason if no other.

It increases reliability, because if the production


process is simplified, then there is less opportunity for
errors.

It generally increases the quality of the product for the


same reason as why it increases the reliability.

Ken Youssefi

SJSU: PDM II

DFMA Slide 3

DFM and DFA

DFM and DFA starts with the formation of the design


team which tends to be multi-disciplinary, including
engineers, manufacturing managers, cost accountants, and
marketing and sales professionals.

The most basic approach to design for manufacturing and


assembly is to apply design guidelines.

You should use design guidelines with an understanding


of design goals. Make sure that the application of a
guideline improves the design concept on those goal.

Ken Youssefi

SJSU: PDM II

DFMA Slide 4

DFM and DFA Design Guidelines

Minimize part count by incorporating multiple functions into 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.

Ken Youssefi

SJSU: PDM II

DFMA Slide 5

DFM and DFA Design Guidelines


Modularize multiple parts into single sub-assemblies.

Ken Youssefi

SJSU: PDM II

DFMA Slide 6

DFM and DFA Design Guidelines


Design to allow assembly in open spaces, not confined
spaces. Do not bury important components.

Ken Youssefi

SJSU: PDM II

DFMA Slide 7

DFM and DFA Design Guidelines


Parts should easily indicate orientation for insertion.
Parts should have self-locking features so that the precise
alignment during assembly is not required. Or,
provide marks (indentation) to make orientation easier.

Ken Youssefi

SJSU: PDM II

DFMA Slide 8

DFM and DFA Design Guidelines


Standardize parts to reduce variety.

Ken Youssefi

SJSU: PDM II

DFMA Slide 9

DFM and DFA Design Guidelines


Design parts so they do not tangle or stick to each other.

Ken Youssefi

SJSU: PDM II

DFMA Slide 10

DFM and DFA Design Guidelines


Distinguish different parts that are shaped similarly, or
hard to distinguish, by non-geometric means, such as color
coding.

Ken Youssefi

SJSU: PDM II

DFMA Slide 11

DFM and DFA Design Guidelines


Design parts to prevent nesting. Nesting is when parts that
are stacked on top of one another clamp to one another, for
example, cups and coffee lids

Ken Youssefi

SJSU: PDM II

DFMA Slide 12

DFM and DFA Design Guidelines


Design parts with orienting features to make
alignment easier.

Ken Youssefi

SJSU: PDM II

DFMA Slide 13

DFM and DFA Design Guidelines


Provide alignment features on the assembly
so parts are easily oriented.

Do

Ken Youssefi

SJSU: PDM II

DFMA Slide 14

DFM and DFA Design Guidelines


Design the mating parts for easy insertion.
Provide allowance on each part to compensate for variation
in part dimensions.

Case I

Case II

Ken Youssefi

SJSU: PDM II

DFMA Slide 15

DFM and DFA Design Guidelines


Design the first part large and wide to be stable and then
assemble the smaller parts on top of it sequentially.

Case I

Case II

Ken Youssefi

SJSU: PDM II

DFMA Slide 16

DFM and DFA Design Guidelines


If you cannot assemble parts from the top down
exclusively, then minimize the number of insertion
direction. Never require the assembly to be turned over.
Case I

Case II

Ken Youssefi

SJSU: PDM II

DFMA Slide 17

DFM and DFA Design Guidelines


Joining parts can be done with fasteners (screws, nuts and
bolts, rivets), snap fits, welds or adhesives.

Ken Youssefi

SJSU: PDM II

DFMA Slide 18

DFM and DFA Design Guidelines

Ken Youssefi

SJSU: PDM II

DFMA Slide 19

Minimizing the Number of Parts


To determine whether it is possible to combine
neighboring parts, ask yourself the following questions:

Must the parts move relative to each other?

Must the parts be electrically or thermally insulated?

Must the parts be made of different material?

Does combing the parts interfere with assembly of other parts?

Will servicing be adversely affected?

If the answer to all questions is NO, you should find a


way to combine the parts.

Ken Youssefi

SJSU: PDM II

DFMA Slide 20

Minimizing the Number of Parts


The concept of the theoretical minimum number of
parts was originally proposed by Boothroyd (1982).
During the assembly of the product, generally a part
is required only when;
1.

A kinematic motion of the part is required.

2.

A different material is required.

3.

Assembly of other parts would otherwise be prevented.

If non of these statements are true, then the parts do


not need to be separate entities and may be combined.
KISS Keep It Simple Stupid
Ken Youssefi

SJSU: PDM II

DFMA Slide 21

End
Design for Manufacturing
and Assembly

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