DESIGN PRINCIPLES FOR MANUFACTURABILITY

Presented by M.Saravana Kumar

General Guidelines
1. Simplify the design and reduce the number of parts 2. Standardize and the use of common parts and materials 3. Design for ease of fabrication

4. Design within process capabilities and avoid unneeded surface finish requirements
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General Guidelines
5.Mistake proof product design and assembly. 6.Design for parts orientation and handling.

7.Minimize flexible parts and interconnections.

8.Design for ease of assembly. 9.Design for efficient joining and fastening.
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General Guidelines
10.Design modular products 11.Design for automated production. 12.Design printed circuit board and assembly.

Simplify The Design And Reduce The Number Of Parts

The probability of perfect product goes down exponentially as the number of parts increases.
Chance of ------ Cost increases. Automation is more difficult with more number of parts
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Assembly error, Defective parts

Simplify The Design And Reduce The Number Of Parts

Whether a part can be eliminated, or combined with the other part, or the function can be performed in another way.
Lead time reduces.

Standardize And The Use Of Common Materials

Common parts will result
Lower inventories Reduced costs Higher quality Operator learning is simplified Opportunity for automation Higher production volumes
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Standardize And The Use Of Common Materials

Product Data Management + Component Supplier Management (CSM) = Retrieval of design and material information

Design For Ease Of Fabrication

Select the process compatible with the materials and production volume.
Select materials compatible with the production process Avoid unnecessary features
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Design For Ease Of Fabrication

For higher volume parts, consider castings or stampings to reduce machining Avoid designs requiring sharp corners or points in cutting tools - they break easier

Avoid tapers & contours as much as possible in favor of rectangular shapes

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Rearrange connected items to improve assembly efficiency and reduce costs

Increased Efficiency

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Approximate Relative Cost of Progressively Tighter Dimensional Tolerances

Rough machining, +/- 0.030 Standard machining, +/- 0.005 Fine machining, +/- 0.001 Very fine machining, +/- 0.0005 Fine grinding, +/- 0.0002 Very fine grinding, +/- 0.0001 Lapping, polishing, +/- 0.00005 100 1000 Approximate Relative Cost, % 101 200 440 720 1400 2400 4500 10000

N.E.Woldman, Machinability and Machining of Metals

Surface Finish

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