1. Chapter 9 Product Evaluation for cost, Manufacturing, Assembly, and Other Measure

2. 9.1 Introduction 9.2 Cost Estimation in Design
9.2.1 Determining the Cost of a Product

7. 9.2.2 Making of Cost Estimation
Purchasing parts
Manufacturing
9.2.3 The cost of machined Components

8. 1, from what material is the component to be machined?
2. What type of machine is used to manufacture the component?
3. What are the major dimensions of the component?
4. How many machined surfaces are there, and how much material is to be removed.
5. How many components are made?
6. What tolerance and surface finishes are required?
7. What is the labor rate for machinist?

9. Example:

13. 9.2.4 The Cost of injection Molded Components

16. 9.3 Value Engineering
Step 1 For each feature of the component ask the question , what does it do?
Step 2 Identify the life cycle cost of the feature.
Step 3 Identify the worth of the function to the customer.
Step 4 Compare worth to cost to identify features that have low relative value

17. 9.4 Design for Manufacturing
Establishing the shape of components to allow for efficient, high quality manufacturing
9.5 Design for assembly evaluation

20. 9.5.1 evaluation of the overall assembly
Guideline 1 overall component count should be minimized

22. Guideline 2 Make minimum use of separate fasteners

24. Guide line 3 Design the product with a base component for locating other components

25. Guideline 4: do not require the base to be repositioned during assembly
Guideline 5: make the assembly sequence efficient.
Affords assembly with the fewest steps.
Avoids risk of damaging components
Avoid awkward, unstable, or conditionally unstable positions for the product and the assembly personnel and machinery during assembly.
Avoids creating many disconnected subassemblies to be joined later

27. Step 1 list all the component and processes involved in the assembly process Step 2 List the connections between components and generate a connections diagram step 3 select a base component

28. Step 4 recursively add the next component
Connection 3 must preced connection 4
Connection 1 must precede connection 5
Step 5 identify subassemblies
[2,[3,4],1,5]
Or [button, body, [head, tube, ink], cap]

29. 9.5.2 Evaluation of component retrieval
Guideline 6: Avoid component characteristics that complicate retrieval

31. 9.5.3 Evaluation of component handling
Quideline 8 design all components for end to end symmetry

33. Guideline 9 design all components for symmetry about their axes of insertion

34. Guideline 10 design components that are not symmetric about their axes of insertion to be clearly asymmetric

35. 9.5.4 evaluation of component mating
Guideline 11: design components to mate through straight line assembly

36. Guideline 12: make use of chamfer, leads, and compliance to facilitate insertion and alignment

38. Guideline 13: Maximize component accessibility

39. 9.6 Design for reliability
9.6.1 Failure-potential analysis
Step 1 identify the function affected
Step 2 identify the Effecte of failure on other parts of the system
Step 3 identify the failure modes effecting the function
Step 4 identify the corrective action

40. MTBF, reliability can be express
For
Thus t hours R
1.00
100
.999
1000
.987
8760(1 year)
.892
10000
.878
43800(5 years
.566

41. Failure rate:

42. 9.7 design for test and maintenance
Step 3A: For each error; is it possible to identify the parameters that could cause the failure?

43. 9.8 design for the environment

44. Guideline 1: be aware of the environmental effects of the materials used in product
Guideline 2: design the product with high seperabikity
Make fastener accessible and easy to release
Avoid laminating dissimilar materials
use adhesives sparing and make them water soluable if possible
Guideline 3 design components that can be reused to be recycled
Guideline 4: be aware of the environmental effects of the material not reused or recycled