Scribd
Upload
8 views

Module 4a

Uploaded by

chadrahul69
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
8 views

Module 4a

Uploaded by

chadrahul69
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 49

BE 102- Design and Engineering

Module 4
Module 4 - 15 % Marks
4 Hours Lecture
Design for “X”; covering quality, reliability, safety,
manufacturing/construction, assembly, maintenance, logistics,
handling; disassembly; recycling; re-engineering etc. List out the
design requirements(x) for designing a rocket etc.

4 Hours Project
Design mineral water bottles that could be packed compactly for
transportation.
DESIGN FOR “X”
 Initial design based on function, appearance & cost
 Other major objectives than those dealt in initial design
Design for “X” , Where, X= Design objective
( other than those dealt during initial stages of design )

Some of the objectives are :


Design for Manufacturing/Construction
Design for Assembly/Fitting
Design for Safety and Reliability
Design for Maintenance & Serviceability
Design for Logistics
Design for Disassembly and Recycling
DESIGN FOR MANUFACTURING/CONSTRUCTION
DFM is based on : Minimizing Cost of production
Minimizing Time to market while maintaining appropriate
level of quality.

 First design team is formed: include engineers, managers,


logistics specialists, accountants, marketing & sales professionals.

 Reduction in parts and their costs


 Use of standard parts/subcontracted items.
 Change in materials if possible.
 Use wider tolerances wherever possible.
 Design using Group Technology.
Who Casts the biggest shadow ?
Design for X
X=MANUFACTURING
X=ASSEMBLY
X=RELIABILITY
X=MAINTAINABILITY
X=SERVICEABILITY
X=ENVIRONMENT
X=LIFE CYCLE COST
DFM
Design for manufacturability (DFM)is the general
engineering art of designing products in such a
way that they are easy to manufacture.
Design for Manufacturing (DFM)
Designing or engineering a product in order to facilitate the manufacturing
process
Reduce manufacturing cost
Designer should consider the type of raw material and the form of the raw
material
Optimize all the manufacturing functions: fabrication, assembly, test,
shipping, delivery, service, and repair
Assure the best cost, quality, reliability, regulatory compliance, safety, time-
to-market, and customer satisfaction.
DFM GUIDELINES
1. Simplify the design and reduce the number of parts

The reduction of the number of parts in a product is probably the best opportunity for reducing
manufacturing costs. Less parts implies less purchases, inventory, handling, processing time,
development time, equipment, engineering time, assembly difficulty, service inspection, testing,
etc.
2. Develop a modular design
The use of modules in product design simplifies manufacturing activities such as
inspection, testing, assembly, purchasing, redesign, maintenance, service, and so on.
3.Use of standard components

Standard components are less expensive than custom-made items. The high availability of these components
reduces product lead times. Also, their reliability factors are well ascertained. Furthermore, the use of standard
components refers to the production pressure to the supplier, relieving in part the manufacture’s concern of meeting
production schedules.
3.Design parts to be multi-functional

Multi-functional parts reduce the total number of parts in a design, thus, obtaining the benefits
given in rule

Automobile chassis act as structural Bike engine casing act as heat


member as well as electricity earthing line dissipater
4. Design for ease of fabrication

Select the optimum combination between the material and fabrication process to minimize
the overall manufacturing cost. In general, final operations such as painting, polishing, finish
machining, etc. should be avoided. Excessive tolerance, surface-finish requirement, and so
on are commonly found problems that result in higher than necessary production cost.

5. Provide Tolerance
Each manufacturing process has an inherent ability to maintain a certain range of
tolerances, and to produce a certain surface roughness (finish).To achieve tolerances
outside of the normal range requires special processing that typically results in an
exponential increase in the manufacturing cost
Design for Assembly (DFA)
It is a subset of DFM which involves the minimization of cost of assembly

• To maximize ease of assembly


– Part is inserted from top
– Part is self aligned
– Part does not need to be oriented
– Part requires only one hand for assembly
– Part require no tool
– Part is assembled in single linear motion
– Part is secured immediately upon insertion
Design parts by considering access and visibility Uni-directional insertion
for ease of insertion

Design for uni-directional


assembly preferably
using gravity. Assembly to
a stable base

Self Aligned Parts Avoid separate fasteners: design the fastening


functions into the parts.
Use hustle free joining methods

Snap Joints
MISTAKE PROOFING ISSUES
(POKA-YOKE)

• Cannot assemble wrong part


• Cannot omit part
• Cannot assemble part wrong way around.
Design for Reliability
Reliability is defined as the probability that a component, equipment or system will
satisfactorily perform its intended function under given circumstances.

Improving Reliability
• Making failures less likely to happen in the first place
(e.g. By maintaining the equipment properly or fitting more reliable equipment)
• Making changes such that the overall system continues to function satisfactorily even
when a failure occurs
(e.g. By fitting standby equipment)
Reliability Network
DESIGN FOR SAFETY & RELIABILITY
 Product safety is to be ensured in design.
 This covers the materials used, design aspects on safety
in operation, fool proofing, warning systems etc.
 They prepare test plans and go accordingly.

..\Innovative designs\Video 17 Crash Test New Mercedes


SLS AMG 2010.mp4
..\Innovative designs\Video 18 Turbine engine explodes.mp4
Providing ordnance in space vehicles as ultimate safety tool.

In order to improve the reliability redundant systems are


used in specific designs.
Design for Maintainability & Serviceability
The objective of Design for Maintainability is to assure that the design will perform
satisfactorily throughout its intended life with a minimum expenditure of budget and effort.
Design for maintainability (DFM), Design for Serviceability (DFS), and Design for
Reliability (DFR) are related because minimizing maintenance and facilitating service can
be achieved by improving reliability.

An effective DFM minimizes


1. The downtime for maintenance,
2. user and technician maintenance time,
3. personnel injury resulting from maintenance tasks,
4. cost resulting from maintainability features, and
5. logistics requirements for replacement parts, backup units, and personnel
Types of Maintenance
Improving Maintainability

Minimize the number of serviceable design parameters (DPs) with simple procedures and
skills.
Provide easy access to the serviceable DPs by placing them in serviceable locations. This
will also enhance the visual inspection process for failure identification.
Use common fasteners and attachment methods.
Design for minimum hand tools.
Provide for safety devices (guards, covers, switches, etc.)
Design for minimum adjustment and make adjustable DPs accessible.
Placing projector bulb at
accessible location reduce
maintenance Providing protective
casing is DSM
Use standard fasteners

Easy access to Watch battery is a


Maintainability consideration
Design for Environment
Design for the Environment (DFE) is a design approach to reduce the overall human health and
environmental impact of a product, process or service, where impacts are considered across its life cycle.

Design for environmental processing and manufacturing


Design for environmental packaging
Design for disposal or reuse
Design for energy efficiency
DESIGN FOR LOGISTICS
 Design for packaging, handling, transportation and
storage.
 Design for seamless transportation.
 Optimal packaging to save space and damage.
 Provision for product handling with safety.
Design for Life cycle cost
Design for Disassembly & Recycling
Design for disassembly is the strategy that considering the
future need of a product that to be disassembled for repair,
refurbish or recycle
How Many Lifetimes?
Mixed Materials
Separating Materials
Disassembly Allows…
Race Against Time
Disassembly Strategies
Redesign for Disassembly
Biodegrading
Recycling/Reuse
Recyclability Strategies
Downcycling/Recycling/Upcycling
Redesign for Recycling
Take back Programs
Recycling & Reuse Save Materials

You might also like