DESIGN FOR MANUFACTURE Semester II Session 2008/2009 BDD 4013 DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA)

Information Lecturer : BACHIK BIN ABU BAKAR E-mail : bachik@uthm.edu.my Off. No. : 07-453 7719 H/P : 019-7305954 Room : E5– 01-08

GOAL & OBJECTIVE Goal This course is design to provide knowledge and exposure of the application of design for manufacture and assembly principles in Objective Analyse and understand the cost effects of design decision by means of product simplification. Improve design efficiency and profitability via selection of optimal material and manufacturing process for each part in design. Demonstrate principles of design of complex manufacturing tools such as injection moulding and press tools.

ASSESMENT SCHEME Quizzes/Assignments : 10% Test 1 : 10% Test 2 : 15% Projects : 15% Final Examination : 50%

REFERENCES Geoffrey Boothroyd, Peter Dewhurst And Winston Knight,”Product Design For Manufacture And Assembly”, 2nd Edition, Marcel Dekker Inc., 2002 Carrado Poli, “Design For Manufacturing”, Butterworth-Heinemann Pub., 2001

CHAPTER 1 Introduction To Product Development

What is product ? Something sold by an enterprise to its customer

Defining a Product There are two general types of products: Physical Goods Goods which are easily understood because the buyer can see and often experience their benefits prior to buying Actions that companies offer to customers for the purpose of transaction Services

Stage-Gate Product Development Process Once the decision to develop a new product is made, the actual product development process begins Idea Generation Idea Screening Concept Development Business Analysis Product Design Prototype Development Test Market Commercialization Management Review Management Review Management Review

Characteristics of Successful Product Development Product quality How good is the product resulting from the development effort? Product cost What is the manufacturing cost of the product? Development time How quickly did the team complete the product development effort? Development cost How much did the firm have to spend to develop the product? Development capability Are the team & the firm better able to develop future products as a result of their experience with a prod. dev. project?

Who design & develop products? Manufacturing Engineer Marketing professional Purchasing specialist Team leader Industrial designer Electronics designer Mechanical designer

Product Development Divergent and Convergent Thinking Separation between the idea generation and screening phases allows for appropriate levels of divergent and convergent thinking 2. Idea Screening 1. Brain Storming T A S K E P R I O N Divergent Thinking Convergent Thinking Number of Ideas Start Finish Ideas Expand Over Time Critical Evaluation Narrows the Focus Over Time Time

Design In general we can analyze design in four phases :- Conceptual design Detailed design Manufacturing Distribution, servicing, disposal etc What is the most important design phase? Which one of these stages effects the success of a new product?

Importance of Design Stage Total Cost (%) 100 80 60 40 20 Distribution, service, and disposal Manufacturing Detailed Design Prototype Conceptual Design Life-cycle cost committed Cost incurred Ease of change Product Life-Cycle Includes Design Phase Manufacturing Phase Product usage phase Disposal phase Design phase determines the most of the cost associate with delivering a product Typically, 80% of the cost of a product is fixed at the design stage

Product Design An activity that starts with sketches of parts and assemblies Progresses to the drawing board or CAD workstation where assembly drawings and detailed part drawings are produced These drawing then passed to the manufacturing and assembly engineer whose job it is to optimize the processes used to produce the final product

The Product Design Process The product design usually begins with the motive that a new product is needed to meet the market or customer’s demand Product Design Process consists of; Understanding of Customer Needs/Requirements Analysis of future directions Generation of initial ideas Geometric modeling of possible options Analysis of options to obtain the best design that satisfy all the design requirements Selection of the optimal design Creating the detailed design with specifications

The Product Design Process A simple design process approach involves; Problem identification Should involve collection of field data, field surveys, experiments, intuition, judgment, personal observations and physical measurements determine the essentials of the design The product is the final outcome of the need identification process Eg. High-quality notebook-sized computer – light in weight, highly portable, self-contained etc.

The Product Design Process Preliminary ideas generate as many as possible design options (ideas) for further evaluations Brainstorming session should be used Refinement process Several good ideas are pursued using abstract drawings, specification determination and visual assistance (geometric modeling) Analysis of process Based on design criteria, evaluate the design options and to determine the best one

The Product Design Process Design criteria - cost, customer needs, engineering requirements, finite-element analysis, assembly/disassembly, compatibility with current manufacturing tools etc. Decision process Select the best option that satisfies customers, engineers and manufacturers A decision matrix approach can be employed Implementation process Detailed design - specification, dimensions, tolerances, materials, etc.

The Product Design Process Customer Requirements, Customer Needs Problem Identification Future Directions Preliminary Ideas Refinement Process Refinement Process NO Criteria Satisfied Analysis and Decision Process YES Implementation

Product Cycle Traditionally after the design of the product, the part prints are released for production The production engineering section make the feasibility of production of the product After process planning is done, the product can be manufactured at the lower possible cost Any design improvement to be done at this stage without compromising on its functionality Having decided on the process plan for manufacture such as tooling, new equipment, raw material, detailed operational instructions to shop floor

Product Cycle Product Cycle Design Manufacturing

Product Cycle in a Conventional Manufacturing Environment Preparing Part Print Need Forecast Product Concept Design Order Material, Machines Customer Feedback Order Tooling Process Planning Tool Tryout Scheduling Manufacturing Operations Establishing Work Standards Marketing Quality Control Actual Production Production

Product Cycle in a Computerized Manufacturing Environment Geometric Modeling Finite Element Analysis CAD Need Forecast Product Concept Computer Aided Design Product Proving (Simulation) Computer Aided Drafting Customer Feedback Order New Equipment Computer Aided Process Planning Computer Aided Tool Design Tool Mnfg. and Tryout Marketing Material Requirement Planning Computer Aided CNC Part program Generation Computer Aided Scheduling Computer Aided Work Standards CNC Machines Robot and other Material Handling Equipment Computer Aided Inspection and Quality Control Actual Production CAM

Products in Various Stages of Life Cycle

Product Life Cycle Introduction Fine tuning research product development process modification and enhancement supplier development Growth Product design begins to stabilize Effective forecasting of capacity becomes necessary Adding or enhancing capacity may be necessary

Maturity Decline Competitors now established High volume, innovative production may be needed Improved cost control, reduction in options, paring down of product line Decline Unless product makes a special contribution, must plan to terminate offering

Product Life Cycle, Sales, Cost, and Profit

BDD 4013 DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA) Questions? Course Introduction BDD 4013 DESIGN FOR MANUFACTURE AND ASSEMBLY (DFMA) Questions?