DESIGN FOR X- DFMA, DESIGN FOR X- DFMA ORG

Applications of Design for Manufacture and Assembly

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CONTENTS Slide No
• INTRODUCTION 3-5
• LITERATURE SURVEY 6-8
• METHODOLOGY 9-17
• RESULTS AND DISCUSSION 18
• CONCLUSION 19
• REFERENCES 20

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INTRODUCTION
• Twenty percent of the world’s population, or 1.4 billion people, live
on less than $1.25 a day.[1]
• Engineers have the skills to design products that can help solve the
challenges faced by poor individuals. Products designed for this
group will generally be more effective as engineers consider the
principles of Design for Manufacture and Assembly (DFMA).
• The DFMA principles can help lower costs, but the principles used
in the developed world do not always apply in the developing world.
• Design for manufacturing and assembly is usually used in the early
product design stage for both system and detailed design levels in
determining the components, subassemblies, fasteners. etc.[2]

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• Redford and Chal state that any DFA method should have the
following features [3]
 It should be a complete method as regards to procedures for
evaluating assemblability and should be creative enough to
obtain procedures for improving assemblability.
 It should be a systematic step-by-step procedure, which
considers all relevant issues.
 It should be able to measure assemblability objectively,
accurately, and completely.
 It should be user friendly and should have good quality.
• DFA methods employing knowledge-based approaches

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• The researcher Boothroyd and Dewhurst have developed a
successful method to help designers to redesign their products,
to cut costs, improve performance and reduce assembly time. It
is called Design for Assembly. [4]
• The methodology DFMA has had great success in a good
number of leadings design companies around the world.

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LITERATURE REVIEW
• Amy E. Wood et al [1] redesigned a pineapple juicer
using the modified DFMA principles. In comparing
the two designs, he concluded that the second juicer
had better performance, easier to use and clean, less
expensive to produce, and was significantly easier to
manufacture because the modified DFMA principles
were considered.

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• Pedro Perez V and Luis Torres T [4] The application of the
Fuzzy-Evolutionary method to the well known Boothroyd-
Dewhurst Design for assembly methodology is proposed. This
hybrid methodology analyzes and optimizes manual assembly for
different assembly situations and conditions, identifies sources of
variability in process assembly time to new products.
• The experimental results show that is possible to conclude that
the Fuzzy-Evolutionary Strategy method is a suitable
methodology for predicting and optimizing the assembly time of
new products.
• Wenlei Zhang et al [5] Assembly feasibility of aero engine is of
vital importance. In this paper Design for Assembly system
dedicating to aero engine is presented. Applications of this system
have proved it operates efficiently, effectively, easily and smartly.

8
• Chris Fell. [6]The Successful development of a MEMS
gyroscope, targeted at high volume, low cost applications. For
this he uses Design for manufacture approach and applied it to
silicon MEMS gyroscope. A second generation MEMS
gyroscope has satisfied emerging market requirements for
lower cost, high volume rate sensors.
• Bhavesh Mistry et al [7] It mainly concentrates on how to
apply DFMA in development of a product or to improve the
already existed design of the products. Here an attempt is made
to use the concept of DFMA on dual plate check valve. This
research explored the application of DFMA to improve the
assembly.
• Based on several application of DFMA it can be seen that Part
count, design and process are simplified.

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Fig.1 Modified DFMA Principles for the developing world
METHODOLOGY

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• Simplify the design and reduce the number of parts as
necessary.
• Standardize and use parts and materials that are common in
the context where the product is to be manufactured, along
with supporting tools.
• Mistake-proof product design or include barriers to reverse
engineering as necessary.
• Design for automated production when local manual
production is cost prohibitive.

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Fig.3 A flow chart of selecting parts [3]

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Table. 1 Information structure of stapler A & stapler B [3]

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Table.2 Information structure of stapler C

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Table.3 Information structure of a new stapler

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Fig 4.Boothroyd and Dewhurst DFMA procedure [8]

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Fig. 5 Influential factors in DFMA of weldments

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Fig. 6 Integrated DFMA–PDM procedure of for welded structures.

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Results & Discussions
• In comparing the two designs, the second juicer had better
performance, was easier to use and clean, was less expensive to
produce, and was significantly easier to manufacture in because
the modified DFMA principles were considered. One
unanticipated problem that we encountered in their experiment
in Brazil was a lack of quality control in the production of the
20 pineapple juicers. [1]
• The part count is reduced from 13 to 11 and total assembly time
is reduced from 69.96 sec to 63.01 sec. [3]

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Conclusion
• Design for Manufacture and Assembly principles play an
important role in designing a product that can be manufactured
in a developing world context. These principles do not always
apply and are sometimes in conflict, especially in the
developing world. With minor modification and clarification,
the principles can be applied more robustly to design for
customers that have different cultures, traditions, customer
needs, and manufacturing capabilities.

21
References
1. Amy E Wood, Charls D Wood and Christopher A. Mattson. ‘Application and Modification of
Design for Manufacture and Assembly Principles for the Developing World’, IEEE 2014 Global
Humanitarian Technology Conference, July 2014.
2. Justin J.Y. Lin. ‘Research on Collaborative Concept Design Integrating the Application of Virtual
Reality and DFMA’, IEEE, pp.727-732,2008.
3. XiuHua Ma and ManSig Kim. ‘A systematic Design for Assembly Method through the
Combination of Subassemblies in Product Family’, International Conference on Smart
Manufacturing Application, pp.261-266, April 9-11, 2008.
4. Pedro Pérez V., Luis Torres T. ‘Improving product design using a Fuzzy-Evolutionary approach to
predict and optimize the assembly time of a new product’ , Proceedings of the Electronics,
Robotics and Automotive Mechanics Conference (CERMA'06),IEEE,2006.
5. Wenlei Zhang, Cheng'en Wang and Jiapeng Yu. ‘A Design for Assembly System for Aero Engine’
International Conference on Computer and Automation Engineering, IEEE, pp.328-331 2009.
6. C.P. Fell. ‘Development of a second generation low cost MEMS gyroscope Design for anufacture’
The Institute of Engineering and Technology, pp.75-82.
7. Bhavesh Mistry, Dr. P. M. George and Saurin Sheth . ‘ Study and Scope of DFMA and GD&T in
manufacturing process: A case study on Dual Plate Check Valve’, IEEE, 2008.
8. H. Tasalloti , H. Eskelinen, P. Kah, and J. Martikainen, ’ An integrated DFMA–PDM model for
the design and analysis of challenging similar and dissimilar welds’ Materials and Design,
pp.421-431,1 oct 2015.

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