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

2. Information Lecturer : BACHIK BIN ABU BAKAR
Off. No. :
H/P :
Room : E5– 01-08

3. 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.

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

5. 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

6. CHAPTER 1 Introduction To Product Development

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

8. 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

9. 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

10. 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?

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

12. 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

13. 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?

14. 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

15. 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

16. 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

17. 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.

18. 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

19. 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.

20. 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

21. 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

22. Product Cycle
Product Cycle
Design
Manufacturing

23. 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

24. 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

25. Products in Various Stages of Life Cycle

26. 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

27. 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

28. Product Life Cycle, Sales, Cost, and Profit

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