1. DFMA Paradigms as Applied to the Warring Juicer DFMA ME-6960 Presented by Team Alpha April 28 2003 Instructor Dr. A.K.Balaji

2. Overview  Juicer Properties/Specifications.  Manufacturing Processes.  MATLAB ® Code.  Injection Molding Analysis.  Assembly Analysis.  Conclusions.  Questions.

3. Product Specifications/Part List

4. Main Components Of the Juicer

5. Manufacturing Processes

6. MATLAB CODE FOR IM Parameters 1. Separating Forces for the Injection Molding Machine 2. Injection Molding Times 3. Mold Base Cost 4. Injection Mold Costs 5. Optimum Number of Cavities 6. Directs the User to the right tables and Figures based on the Book “ Product Design For Manufacturing Assembly”, Boothroyd, Dewhurst and Knight.

7. MATLAB CODE FOR Sheet Metal Parameters 1. Cost Of Die Set (C ds ) 2. Final Die Cost (C d ) NOTE : Calculates For All Bending, Piercing and Blanking operations.

8. Base Cover Design Changes New DesignOld Design

9. Base Cover Analysis Old Design Die Costs : $ 64,725 New Design Die Costs : $ 61,365 Difference $ 3,360

10. Motor Housing Design Changes Old DesignNew Design

11. Motor Housing Part Analysis Old Design Die Costs : $ 86,851 New Design Die Costs : $ 89,971 Difference $ 3,120

12. Juicer Cover Design Changes Old DesignNew Design

13. Juicer Cover Part Analysis Old Design Die Costs : $ 51,656/- New Design Die Costs : $ 42,668/- Difference $ 8,988/-

14. Juicer Container Design Changes Old DesignNew Design

15. Juicer Container Part Analysis Old Design Die Costs : $ 90,625/- New Design Die Costs : $ 86,185/- Difference $ 4,440/-

16. Solution To The Clips Solution to the Clip

17. Sheet Metal Analysis Results of the Clip Cost Of Die Set (C ds ): $ 193.87 Final Die Cost (C d ): $ 2004.12 Note: Part Eliminated.

18. Cost Analysis Comparison

19. Assembly Analysis Modular Assembly Layout Analysis for Original Design Analysis for Modified Design

20. DFA Analyses Results Time reduced from 246.74 s to 149.9 s. (39%) Part reduction from 43 to 29.( 33%) Assembly cost reduced from $1.07/unit to $0.63/unit. ( 41%) Over $190,000 saved on assembly of 500,000 units.

21. Conclusions Reduction in the number of parts from 43 to 29 Reduction in the die costs (IM) saved $13,660 Reduction in the die costs (SM) saved $ 2,500 Reduction in assembly costs saved 41% For a production run of 500,000 units, the overall savings are $ 207,160

22. Questions?