DESIGN FOR MANUFACTURING AND ASSEMBLLY

chep: 04 DFMA TOOL

Que: 02 Which Factor determine the choice of Material? Explain Any Two in Brief? (GTU-IMP)

OR Explain Factors Consider during Selection Of Materials?

→ Appropriate selection of material is significant for the safe and reliable functioning of a
part or component.
→ Engineering materials can be broadly classified as “metals such as” iron, copper,
aluminum, and their alloys etc., and “non-metals such as” ceramics , polymers ,
natural materials (e.g. wood, cotton, flax, etc.), composites (e.g. carbon fibers) etc.
→ Each of these materials is characterized by a unique set of physical, mechanical and
chemical properties, which can be treated as attributes of a specific material.
→ In particular, the selection of a specific engineering material for a part or
component is guided by the function it should perform and the constraints imposed
by the properties the material.
→ The problem of selection of an engineering material for a component usually
begins with setting up the target Function, Objective, Constraints, and Free
Variables.
→ Following Factors which would be consider during Materials selections:
1. Function of Component
2. Objective of component manufacturing
3. Free Variables of materials
4. Materials Index
5. Performance Of Equations
6. Properties of Materials
7. Cost of Materials etc.
8. Machinability Of Materials:
9. Availability of Materials:
10. Interchangeability of Materials

1. Function of Component:
→ The Function refers to the task that the component is primarily expected to
perform in service – for example, support load, sustain pressure, transmit heat,
etc.

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2. Objective of component manufacturing:

→ The Objective refers to the target such as making the component functionally
superior but cheap and light.
→ In other words, the Objective refers to what needs to be minimized or maximized
3. Material Index:
→ The Material Index (M) refers to an attribute (or a combination of attributes) that
characterizes the performance of a material for a given application.
→ The material index allows ranking of a set of engineering materials in order of
performance for a given application.

→ Development of a Material Index (M) for an intended service includes the following
steps.
1. Initial Screening of Engineering Materials.
2. Identification of Functions, Constrains, Objectives and Free Variables.
3. Development of a Performance Equation.
4. Use constraints to eliminate the free variable(s) from the performance
equation and develop the material index.
5. Rank a suitable set of materials based on the material index.

4. Cost of Materials:

5. Machinability Of Materials:

6. Availability of Materials:

7. Interchangeability of Materials

Que: 02 Explain DFMA as the tool for concurrent Engineering? (GTU-IMP)

→ Market Share and profitability are the Major determinants of the success of any
organization.
→ The Factors that influence and improve the competitive edge of company are Unit
cost of product, quality, and Lead time.
→ Concurrent engineering (CE) has emerged as discipline to help achieve the
objectives of reduced cost, batter quality, and Improve delivery performance.

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→ CE means that the design and development of the product, the associated
manufacturing equipment and processes, and repair tools and process are handled
concurrently.
→ Concurrent engineering also known as “Simultaneous engineering, is a method of
designing and developing products, in which the different stages run
simultaneously, rather than consecutively.
→ It decrease product development time and also the time to market, leading to
improve productivity and reduced cost.
1. Tools for concurrent Engineering:
2. DFM
3. DFA
4. Teguchi method for robust design
5. Group Technology
6. FMEA
7. Value Engineering etc…
→ Initially two of those can be outlined here;
(a) DFM
(b) DFA

(a) Design For Manufacturing:

 The Core of any Design for manufacturing OR Design for assembly is set of rules to
be followed at aiming at design efficiency in Terms of its manufacturing
engineering.
→ DFM (Design for Manufacturing) is a Set of Methods and tools that support
concurrent engineering.
→ Through the use of the DFM concepts, designers and engineers can attain
main target to satisfy the Customer’s Requirements in terms of functionality,
performance, style and quality at low cost.
→ Each DFM tool focuses on a manufacture specialty or on a manufacture
process family.
→ DFM or DFA Assembly is indicated to product architecture and assembly
 DFM BENEFITS:
1. Simpler fabrication and assembly
2. Improve economics
3. Reduced Rework

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4. Reduced Mass
5. Improve serviceability
6. Batter quality
7. Reduced logistic time
8. Reduced time to market launching
9. Less production problem etc..

(b) Design For assembly:

→ Design for assembly is a DFM specialty; It is structured method to improve
product components assembling.
→ Both DFM and DFA are essentials applications during product design and
also called DFMA (Design for manufacturing and assembly)
→ The following criteria are considered in a DFA.
1. Reduced and Optimize part counts and types.
2. Utilize optimum attachment method
3. Eliminates the need for adjustments
4. Design parts so that they are easy to self-align and locate.
5. Minimize the number of tools require etc..

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Requirements for the environments,

Recycling, easy to disassembly,

Life cycle, six sigma, & Manufacturability.

Conclusion:
→ Using DFMA tool in concurrent engineering has benefits of :
1. Reduce time to market
2. Reduced Press shop machinery and die stamping investments
3. Reduced indirect cost
4. Improve rack logistics
5. Reduced setup and increase productivity
→ Implementation of concurrent engineering in design and product development
should be done for the benefit of industries.

Que: 03 What is Poka-yoke? Write status and functions of Poka-yoke? Also write seven steps

To be followed for Poka-yoke attainment? (GTU-IMP)

(OR) What is meaning of Poka-Yoke? Which are seven steps to be followed by Poka-Yoke

Attainments? (GTU-IPM)

Definition:

→ Poka yoke is Japanese term that means “Mistake –proofing”

→ A Poka-yoke is any mechanism in a “lean manufacturing” process that helps an
equipment operator avoids mistakes.
→ i.e. There is no chances of mistake

Objective:

→ Understand definition of Poka-Yoke add its application in Lean management to

Identify & eliminate WASTE.
→ Build Quality in to process through early detection & Prevention of Defects.

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→ Know the three basic functions of Poka-Yoke device.

→ Understand Approach of Poka-Yoke & Its Application in Defect Prevention.
→ See Examples of Poka-Yoke devices in Defect management.
→ Learn to implement different Poka-Yoke approach.

Why Poka-Yoke:

→ Poka-Yoke was developed from Toyota Motors as a tool to achieve Zero Defects.
→ The process of Zero Defects is known as “Mistake Proofing” or “Fail-Safe”
→ By taking over repetitive tasks or actions that depend on vigilance or memory,
Poka-Yoke can free workers time and mind to pursue more value added
activities.

Purpose of Poka-Yoke:

→ Poka-Yoke overcome the in-efficiencies of inspection through the use of

automatic devices that seek to do three things:
1. Not accept a defect for the process.
2. Not create a Defect
3. Not allow a Defect to be passes to the next process
→ They do this a number of different ways but can be categorized as being either;
→ Control:- They take physical action to prevent a defect
→ Warning:- They sound an alarm or light up to tell us a mistake has been made.
→ Its purpose is to “Eliminate product defects by preventing correction or
drawing attention to Human Errors as they occur.
→ The concept was formalized and the term adopted by Toyota production
system.
→ It was originally described as” Baka-yoke”
Meaning “Fool-Proofing” or “Idiot Proofing” but the name was later
changed to the milder Poka-Yoke.
→ The “Toyota Production System” strive for efficient use of resource (4M) by
continually “Eliminating waste”.
→ Quality improves along with productivity as defects are discovered quickly and
eliminated.
→ It is also establishes the discipline to practice JUST IN TIME.
→ Leveled Production is the ability to produce different product models
simultaneously to the same production line.

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Distributing the production of many models evenly enables the efficient

use of manpower and equipment.

Eliminate of Waste:

→ The 5’S system eliminates Waste in the workplace making it easy to identify
abnormal conditions.
→ CAP Do approach also used to Eliminate the waste
Check ►Act► Plan ►Do ►Check
 Check: What is the waste?
 Act: Find root causes?
 Plane: Poka-Yoke, Kaizen, Continuous Improvements.
 Do: Implement Poka-Yoke & Measure Result.

Three Ways of Preventing Mistakes:

1. Shutdown the process

2. Control to prevent an error going ahead or Mistake occurring
3. Warning is sent to indicate an error may occur.

Why Mistake- Proofing Is Important:

→ Lean practice does not allow extra inventory to compensate for scrap.
→ Lean ideology focuses on speed…&…Speed cannot exist when defects and rework
prevail.
→ Cost pressure don’t tolerate continued mistakes :- Scrap, Rework, lateness
At Most Importantly:
→ Our Customers rightfully expect “Defect free product” and “Tradition won’t
provide 100% defect-free products.

Basic Function of Poka-Yoke:

A defect Exists in one of two states: from the standard.

(a) It is about to occur.

(b) It has already occurred.
→ Three basic Poka-Yoke Functions to use against defect:
1. Shutdown the process
2. Control to prevent an error going ahead or Mistake occurring
3. Warning is sent to indicate an error may occur.

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Steps of Poka-Yoke:

Step: 01 Describe the defect (Or. Potential Defect)

Step: 02 Determine where the defect is discovered Or. Where it is made.

Step: 03 Detail the sequence of events in the documented standard.

Step: 04 observed the process and detail the steps that differ from from the

standard.

Step: 05 Identify contributing conditions (Tools, Training, etc.)

(Refer to Step: 04 observations: ask the 5-Whys to determine root cause.

Step: 06 Identify the mist ake-proof device necessary to prevent the defect.

 Show the team the poka-yoke hints and examples of poka-yoke devices.

Step:07 Add the device to the process –Now !

Que: 04 What are the advantages of applying Design for Manufacture and Assembly (DFMA)

During a product design? (GTU-VIMP)

(OR) What is DFMA? State its tangible and intangible benefits. Also write DFMA principles.

(OR) What is design for manufacture and assembly? Write three main activities of DFMA.

What are the advantages of applying DFMA during product design?

 What Is Design for Manufacture and Assembly?

Definition:

 A Set of guidelines developed to ensure that a product is designed so that

it can be easily and efficiently “Manufactured and assembled” with a
minimum of effort, time and cost

→ The term “design for manufacture”(or DFM) means_____ the design for the ease
of manufacture of the collection of parts that form the product after assembly
→ “Design for assembly” (or DFA) means the design of the product for the ease of
assembly
→ Design for manufacture and assembly (DFMA) is a combination of DFA and DFM..
→ It is concurrent engineering team approach

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→ The best result occur, when DFMA used in the product conceptual stage

 DFMA provides a systematic procedure for analyzing a proposed design from the
point of view of assembly and manufacture.
 This procedure results in simpler and more reliable products that are less
expensive to assemble and manufacture.
 In addition, any
Reduction in the number of parts in an assembly produces a snowball effect
on cost reduction because of the drawings and specifications that are no longer
needed the vendors that are no longer needed, and the inventory that is eliminated.
 DFMA is used for three main activities:
1. As the basis for concurrent engineering studies to provide guidance to the design
team in simplifying the product structure to reduce manufacturing and assembly
costs, and to quantify the improvements.
2. As a benchmarking tool to study competitors’ products and quantify
manufacturing and assembly difficulties.
3. As a should-cost tool to help control costs and to help negotiate suppliers
contracts.

 Advantages / Tangible & Intangible Benefits:

 DFMA tools also encourage dialogue between designers and the manufacturing
engineers and any other individuals who play a part in determining final product
costs during the early stages of design. This means that teamwork is encouraged
and the benefits of simultaneous or concurrent engineering can be achieved.
1. Cost Reduction Through applying DFMA Principal in Existing Process
2. Reduction of project time line
3. Reduction of Resources needed for a project
4. Simplify Development cycle
5. Reduced Development cost due to Reduce in time
6. Simplification in design

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 There is a much better opportunity to meet predicted cost schedule and quality
targets, When the manufacturing process data is captured early.

1. Reduced –
- Production Cost
- Defects
- Reworks
- Assembly time
2. Improve Reliability
3. Shorter development schedules and reduce cycle times
4. Batter Quality
5. Development of robust product design
6. Batter supplier product integrations
7. More effective risk managements
 DFMA Principal:

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Que: 05 What is six sigma? Explain two key methodologies of six sigma. (GTU)

 A Statistically measure of the performance of the process or product.

 A goal that reaches near perfection for performance.

 In a process that has achieved six sigma capability, the variation is

small compared to the range of specification

 A six sigma process is one in which 99.9999966% of product

manufactured are statistically expected to be free of defects.
- 3.4 defect per millions

 Six Sigma projects follow two project methodologies:

1. DMAIC
2. DMADV

1. DMAIC :
→ DMAIC is used for projects aimed at improving an existing business
process.

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 DMAIC Methodology:

Define Measure Analyze Improve Control

1) Define:

→ Define the project goal and customer requirements (Internal

as well as external- customers)

2) Measure :

→ Measure key aspects of the current process and collect relevant data.

3) Analyze:

→ Analyze the data to investigate and verify cause and effect relationship
→ Determine what the relationship are and attempt to ensure that all
factors have been considered.
→ Analyze and determine root cause of the defect under
investigation.

4) Improve:

→ Improve the future process performance.

→ Improve or optimize the current process based upon data analysis
using techniques such as design of experiments, Poka yoke, Future
state process.
→ Set-up pilot run to establish process capability.

5) Control:

→ Control the future defect.

→ Control the future state process to ensure that any deviations from
target are corrected before they result in defects.

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→ Implement control system such as statistical process control,

production boards, visual workplaces, and continuously monitor the
process.

2. DMADV:
→ DMADV is used for projects aimed at creating new product or process
design.

 DMAIC Methodology:

Define Measure Analyze Design Varify

1) Define:

→ Define design goals that are consistent with customer demands and the
enterprise strategy.

2) Measure :

→ Measure and identify CTQs (characteristics that and critical to quality),

product capabilities, production process capability and risks.

3) Analyze:

→ Analyze to develop and design alternative.

4) Design:

→ Design an improved alternative, best suited per analysis in the previous

step.

5) Verify:

→ Verify the design, set up pilot run, implement the production process
and hand it over to the process owner(s).
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Que: 06 What is lean? List any five lean principles. State the benefits of using lean

Manufacturing. (GTU)

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