Design for manufacturability and assembly. Design for Manufacturability and Assembly (DFM/A) 2022-10-04
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Design for Manufacturability and Assembly (DFMA) is a systematic approach to designing products that are easy to manufacture and assemble. The goal of DFMA is to reduce production costs and increase efficiency by making the manufacturing process as smooth and straightforward as possible.
One important aspect of DFMA is the use of standard, off-the-shelf components whenever possible. This allows manufacturers to take advantage of economies of scale and reduces the need for custom tooling and fixtures. Standard components are also often easier to source and replace, which can be important for maintaining a consistent production process.
Another key aspect of DFMA is the use of modular design. Modular design involves breaking a product down into smaller, interchangeable components that can be easily assembled and disassembled. This allows manufacturers to build products in a flexible and efficient manner, as they can easily swap out components as needed without having to redesign the entire product. Modular design also makes it easier to repair and upgrade products, as individual components can be replaced without having to throw away the entire product.
DFMA also involves careful consideration of the assembly process. This includes designing components and assemblies that are easy to handle and manipulate, using clear and intuitive markings and instructions, and minimizing the number of required steps. By streamlining the assembly process, manufacturers can reduce the risk of errors and increase the speed of production.
In addition to these considerations, DFMA also involves designing for ease of testing and inspection. This includes designing in features that allow for easy access to test points, as well as ensuring that components are easy to inspect for defects. By designing for testability and inspection, manufacturers can reduce the time and cost of quality control processes.
Overall, DFMA is a critical aspect of product design that can have a significant impact on the efficiency and cost-effectiveness of the manufacturing process. By designing products that are easy to manufacture and assemble, companies can reduce production costs, increase efficiency, and improve the overall quality of their products.
Design for Manufacturability and Assembly
Some clearance is required to get a 90-degree bend when the required bend is flush with another bend on a part. In the following section, Sect. Results show that DFMA methods have been mainly applied to simple products during the late design phase. Having a larger tolerance results in a part that is easier and cheaper to produce. PRODUCT DESIGN GUIDELINES A number of general design guidelines have been established to achieve higher quality, lower cost, improved application of automation and better maintainability. Results related to the general questions To answer the first general question, only papers in which a case study is presented have been analysed.
Design for Manufacturability and Design for Assembly
This is shown in Figure 4. With Tonnage Limitations When punching or forming, tonnage limitations exist. Benefits of DFMA A well-structured DFMA application provides both short-term and long-term advantages. Having all stake-holders involved during the design process will help potential problem areas come to light earlier in the process. Although this is a relatively simple example, there are some interesting things to take away. This eliminates guesswork, rejected parts, resulting in excess cost. Time-based DFMA indices rely on tables to convert time-related assembly parameters into scores.
It is an engineering methodology that focuses on optimising the manufacturing and assembly aspects of a product. Figure 1: Four Holed Part Assembly If we were to use coordinate dimensions, the position tolerance zone of the hole would be a square, as shown in Figure 2. Materials possess properties that may require special consideration when used in the design of certain parts or products. Finally, there is no substitute for talking with vendors and manufacturers early to better align with their manufacturing capabilities. In both processes the final assembly is composed of one of each unique part.
The exclusion of non-academic works i. Only a few authors have investigated the adoption of enabling technologies for Industry 4. Some of the common principles in DFMA that can be applied to a wide variety of products are as follows: Simple design Keeping the design simple is one of the tenets of design for manufacture and assembly DFMA. However, the thickness could be uniform and the mirror be shaped like a potato chip! Given the same final COGS and assembly cost, the parallel process without dependencies is 33% faster per unit. The systematic review was conducted to collect, analyse, and summarize the knowledge acquired until today, as well as to identify future research areas, following the results of relevant research works on this subject to answer specific research questions.
Since this review is focused on DFMA methods for mechanical products, most of the presented case studies refer to the mechanical and electro-mechanical fields. The paper tried to develop products using product design techniques. Full size image Both paper types published in journals and conference proceedings have been considered. Before diving into DFMA, it can be helpful to take a look at product development costs more generally. DFMA can help us leverage the advantages of both these methodologies without the disadvantages of either. Similarly, many DFM guidelines can reduce the effectiveness of a DFA technique. A complicated product geometry is unattractive besides being uncomfortable to use.
Design for manufacturing and assembly methods in the product development process of mechanical products: a systematic literature review
In DFMA, the product design is continuously modified while keeping certain end goals in mind to arrive at a product that requires less time, money and effort to produce. Design for Parts Handling. We can help organize the needed data gathering, guide this analysis, structure the organization of guidelines,assist with their development, and orchestrate their deployment. Sometimes slots or larger hole diameters for the attachment hardware are required. Design for Manufacturability Guidelines Reduce Unique Part Count and Standardize The highest value step to reducing cost in manufacturing is to minimize the number of unique parts being manufactured. According to the type of parameters and the developed method, the DFMA index can assume a different meaning.
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Who should be involved in designing for manufacturability? More parts will require more prototypes, manufacturing, individual analysis and assembly steps. Once the designer acquires a basic DFM background, the designer must learn to work more closely with manufacturing engineers and others who can provide him with feedback on DFM design issues. Full size table The size of the bubble represents the total number of publications for each topic during the period under consideration i. An additional benefit is that updates can be made to the subassembly design without affecting the top-level design. This is how DFMA came to be.