DESIGN FOR X

Dr. M.K. Herliansyah, ST. MT.

Program Studi Teknik IndustriJurusan Teknik Mesin dan Industri

Fakultas Teknik Universitas Gadjah Mada2010

Design for X Topics

Design for Manufacturing Design for Assembly Design for Production Design for Recycling/Disposal Design for Life Cycle Prototyping Design for Automation

Gathering DFM Information Design documents:

– Sketches, – Drawings, – Spesifikasi produk, dan – Alternatif-alternatif desain.

Pemahaman dan informasi detil mengenai proses produksi dan perakitan/assembly

Perkiraan:– manufacturing costs, – production volumes, dan – ramp-up timing.

DFM Method Memperkirakan manufacturing costs. Mengurangi biaya-biaya untuk

mempersiapkan/pembuatan components. Mengurangi biaya-biaya untuk proses

perakitan/assembly. Mengurangi biaya-biaya pendukung proses

production. Mempertimbangkan dampak/pengaruh DFM

decisions pada faktor-faktor yang lain.

DFM Method

Reduce the Cost of Supporting Production

Consider the Impact of DFM Decisions on Other Factors

Proposed Design

Estimate The Manufacturing Cost

Reduce the Cost of Components

Reduce the Cost of Assembly

Recompute the Manufacturing Costs

Good Enough?

N

Y

Acceptable Design

Estimate the Manufacturing Costs

Finished GoodsManufacturing System

Equipment Information Tooling

WasteServicesSuppliesEnergy

Raw Materials

Labor

PurchasedComponents

Manufacturing Costs Defined• Menghitung seluruh pengeluaran untuk

input system (sebagai contoh: pembelian komponen-komponen, energi, raw materials, dan lain-lain) dan pengeluaran untuk penanganan limbah yang dihasilkan oleh sistem.

Elements of the Manufacturing Cost of a Product

Manufacturing Cost

OverheadAssemblyComponents

Standard Custom LaborEquipmentand Tooling

SupportIndirect

Allocation

RawMaterial

Processing Tooling

Manufacturing Cost of a Product Component Costs (komponen-komponen dari

produk yang dibuat)– Komponen-komponen yang dibeli dari supplier– Custom parts yang dibuat didalam shop floor-nya sendiri

atau shop floor para supplier sesuai dengan spesifikasi desain dari manufacturer’s

Assembly Costs (labor, equipment, & tooling) Overhead Costs (all other costs)

– Support Costs (material handling, quality assurance, purchasing, shipping, receiving, facilities, etc.)

– Indirect Allocations (tidak berhubungan secara langsung dengan suatu particular product tetapi harus dibayar dalam proses bisnis)

Fixed Costs vs. Variable Costs

Fixed Costs – ditentukan terlebih dahulu dalam suatu jumlah tertentu tanpa memperhatikan jumlah unit yang diproduksi (i.e. setting up the factory work area or cost of an injection mold)

Variable Costs – ditentukan secara langsung dalam jumlah yang proporsional dengan jumlah unit yang diproduksi (i.e. cost of raw materials)

Reduce the Cost of Components

1. Understand the Process Constraints and Cost Drivers

2. Redesign Components to Eliminate Processing Steps

3. Choose the Appropriate Economic Scale for the Part Process

4. Standardize Components and Processes5. Adhere to “Black Box” Component

Procurement

Redesign costly parts with the same performance while avoiding high manufacturing costs.

Work closely with design engineers—raise awareness of difficult operations and high costs.

1. Understand the Process Constraints and Cost Drivers

2. Redesign Components to Eliminate Processing Steps Reduce the number of steps of the

production process– Will usually result in reduce costs

Eliminate unnecessary steps. Use substitution steps, where applicable. Analysis Tool – Process Flow Chart and

Value Stream Mapping

3. Choose the Appropriate Economic Scale for the Part Process

Economies of Scale – As production volume increases, manufacturing costs usually decrease.

Fixed costs divided among more units. Variable costs are lower since the firm can

use more efficient processes and equipment.

4. Standardize Components and Processes Economies of Scale – The unit cost of a

component decreases as the production volume increases.

Standard Components—common to more than one product

Analysis tools – group technology and mass customization

5. Adhere to “Black Box” Component Procurement Black box—only give a description of what

the component has to do, not how to achieve it

Successful black box design requires clear definitions of the functions, interfaces, and interactions of each component.

Summary What is DFM?

DFM is product design considering manufacturing requirements

DFM is the first step in which a team approach is taken to develop the product

DFM is an umbrella which covers a variety of tools and techniques to accomplish a manufacturable product

Why DFM? Lower development cost Shorter development time Faster manufacturing start of build Lower assembly and test costs Higher quality

Summary How do all the pieces fit together?

The objective of DFM is to identify product concepts that are easy to manufacture

Focus on component design for ease of manufacture and assembly

Integrate manufacturing to ensure the best match of needs and requirements.

DFM in industry is typically divided into 2 main activities:

A team which will be responsible for the product development and delivery. (cross functional team: ME, EE, MFG., CE, PE, Quality)

The tools and methods to enable DFM that ensure the design meets the objectives.

Manufacturing Today Global Competition

Trade barriers have been removed (NAFTA) Must compete with the best from all over the world

Japan, Europe, India, Mexico, etc Infrastructure's forming off shore

Quality Requirements ISO 9000 Six Sigma (Motorola Inc)

Product Cycles Every generation is faster Rate of change is increasing

Cost Costs decrease every year (customers expect costs to go down) Performance increasing every year

DFM Typical Approach

DesignTest Tool Build

Launch

finishstart

Product Development Steps

Product Development team making it happen!!- Product requirements and deliverables- DFM tools and methods

Product Development Process Conceptual DESIGN and development Product optimization, TEST TOOL BUILD (ease of assembly) LAUNCH, ramp, ship, and deliver

Product Team Product requirements and deliverables Collaborative cross functional team

(ME, EE, MFG, Test, Quality, etc.). Not “designed in a vacuum”

Uses DFM tools and methods

DFM Product Considerations Product Considerations

Environmental Ergonomics Safety Pollution Recycling Shock/vibration Temperature

Customer Depth of product line Customization Test requirements

Process and Tooling Cycle time Quality Ease of Assembly Ease of Testing Rework Shipping and Handling Tooling Costs

Suppliers Partnerships Supplier tolerance capability Merging mechanical sub-assemblies Costs

DFM Tools and Methodology Tools and Methodologies

Design For Assembly (DFA), (IBM experience) Failure Mode and Effect Analysis (FMEA), (Sun

example) Taguchi Method, (Hitachi experience) Value Analysis--”Value Engineering” (HP example) Quality Function Deployment (QFD), Going to the

Gemba (Hitachi) Group Technology, (IBM example) Cost management and optimization, SPC, Six-Sigma

(Motorola), TQC, etc

DFA Systems

Boothroyd Dewhurst DFM & A Munro & Assoc. (Design Prophet/Profit) Others

Product Design Today Development Cycle

Endless engineering changes Non standard parts have long lead times

Quality “Designed and thrown over the wall” Lower due to more parts, manual processes, and

untested parts Customer configuration management

Cost Higher due to unique designs and specialized parts

Equipment and Tooling Reliability and quality problems

DFM/A System In Global Manufacturing

Commercial Airplanes - Military Aircraft & Missiles - Space & Communications - Air Traffic Management - Boeing Capital Corporation - Shared Services Group - Phantom Works

747 Final Assembly at Everett, Washington

747 Freighter

747 Freighter

DFM Tools: DFA Guidelines

- Standard parts (one screw type)

- Parts are self-guiding

-Die cast with minimal amount of holes (debris chip)-Standard cutters -Guide features- Common datum’s for all fixtures

-One common plane for assembly- Tabs for robotic lift

- One assembly direction “tops down”-No adjustments required-No hidden features

- bottom rails for conveyor

- Test direction access from top

- Easy to fabricate parts

- Sub-assemblies reduce handling of small hard to grip parts

- Symmetry in two axis

- Holes large enough (straightness issues if too deep)

- Avoid tangle with use of fixtures

DFM Tools: DFA Guidelines Summary of DFA Guidelines

1. Minimize the number of parts2. Standardize and use as many common parts as possible3. Design parts for ease of fabrication (use castings without machining

and stampings without bend)4. Minimize the number of assembly planes (Z-axis)5. Use standard cutters, drills, tools6. Avoid small holes (chips, straightness, debris)7. Use common datum’s for tooling fixtures8. Minimize assembly directions9. Maximize compliance; design for assembly10. Minimize handling 11. Eliminate adjustments12. Use repeatable, well understood processes13. Design parts for efficient testing14. Avoid hidden features 15. Use Guide features16. Incorporate symmetry in both axis17. Avoid designs that will tangle.18. Design parts that orient themselves

DFM Tools and Methodology FMEA (Failure Mode and Effects Analysis)

Method for analyzing the causes and effects of failures. Highlights designs and assemblies most likely to cause failures. Helps identify and prioritize corrective action Indicates where the most improvement in terms of severity,

frequency, and detectability can be made. Widely used manufacturing technique (Mil standards, SAE, ANSI

Specs)

Reduce the Costs of Assembly

1. Design for Assembly (DFA) index

2. Integrated Parts (Advantages and Disadvantages)

3. Maximize Ease of Assembly

4. Consider Customer Assembly

1. Design for Assembly Index

Determining the Theoretical Minimum Number of Parts Does the part need to move relative to the

rest of the assembly? Must the part be made of a different

material from the rest of the assembly for fundamental physical reasons?

Does the part have to be separated from the assembly for assembly access, replacement, or repair?

2. Advantages of Integrated Parts

Do not have to be assembled Often less expensive to fabricate rather than

the sum of each individual part Allows critical geometric features to be

controlled by the part fabrication process versus a similar assembly process

2. Disadvantages of Integrated Parts

Conflict with other sound approaches to minimize costs

Not always a wise strategy

3. Maximize Ease of Assembly

Part is inserted from the top of the assembly Part is self-aligning Part does not need to be oriented Part requires only one hand for assembly Part requires no tools Part is assembled in a single, linear motion Part is secured immediately upon insertion

4. Consider Customer Assembly

Customers will tolerate some assembly Design product so that customers can easily

and assemble correctly Customers will likely ignore directions

Reduce the Costs of Supporting Production Minimize Systemic Complexity (inputs, outputs,

and transforming processes)– Use smart design decisions

Error Proofing (Poka Yoke)– Anticipate possible failure modes– Take appropriate corrective actions in the early

stages– Use color coding to easily identify similar

looking, but different parts

Consider the Impact of DFM Decisions on Other Factors Development Time Development Cost Product Quality External Factors

– Component reuse– Life cycle costs

DFM&A Road Map Membentuk sebuah multifunctional team Menetapkan sasaran produk melalui competitive

benchmarking Melakukan DFA analysis Melakukan segmentasi produk hingga mencapai

manageable subassemblies atau levels of assembly Sebagai sebuah team, menggunakan prinsip-prinsip DFA Menggunakan teknik-teknik kreatif untuk meningkatkan

desain yang dihasilkan Sebagai sebuah team, melakukan evaluasi dan memilih ide

rancangan yang terbaik Memastikan bahwa setiap bagian komponen diproduksi

pada level yang ekonomis Menentukan target cost untuk setiap komponen dalam

desain produk yang baru

DESIGN FOR PRODUCTION

Design for Production

1. Design Organization

2. Timing of Production

3. Material Identification

4. Specific Design Details (outputs)

Production Input

At various design stages– Concept

• Production Input

– Functional• None

– Transition• Tactics

– Work Instruction• Production Preparation

New Idea: Provide Production Inputs

1. In proper level of detail at proper stage

2. In proper form

3. Just-in-time

Problems with Old Approach

Work is carried out from beginning to end at each stage

Too slow Needs continuous recycling

Design for Production General Principles

1. Use Common Sense

2. Plan and Define

3. Consider Available Facilities

4. Consider Available Tools

5. Consider Available Worker Skills

6. Employ Simplicity

7. Standardize

Design for Production Guidelines

1. Minimize Total Number of Parts

2. Develop a Modular Design

3. Minimize Part Variations

4. Design Parts to be Multifunctional

5. Design Parts for Multiuse

6. Design Parts for Ease of Fabrication

7. Avoid Separate Fasteners

Design for Production Guidelines

8. Minimize Assembly Direction (Top Down Direction Preferred)

9. Maximize Compliance in Assembly10. Minimize Handling in Assembly11. Minimize complexity of Design12. Maximize common Jigs and Fixtures13. Optimize Work Position14. Ease Access

PROTOTYPES

Types of Prototypes

Two dimensions– Physical vs. Analytical– Comprehensive vs. Focused

Physical vs. Analytical

Physical– Tangible artifacts created to approximate the

product– Used for testing and experimentation

Analytical– Represents the product in a nontangible, usually

mathematical manner– Product is analyzed, not built

Comprehensive vs. Focused

Comprehensive– Implement all (or most) of the attributes of the product

– Full-scale

– Fully operational version of the product

Focused– Implement a few of the attributes of the product

– Use two or more focused prototypes together to investigate the overall performance of a product

Prototype Uses Learning

– Will it work?– How well does it meet the customer needs?

Communication– Within the company– With customers, vendors, and suppliers

Integration– Subsystems and components work together

Milestones– Product achieved a desired level of functionality

Principles of Prototyping Analytical Prototypes are generally more flexible

than Physical Prototypes Physical Prototypes are required to detect

unanticipated phenomena A Prototype may reduce the risk of costly

iterations A Prototype may expedite (make it faster) other

development steps A Prototype may restructure task dependencies

Use of comprehensive prototypesT

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Hig

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Cost of Comprehensive Prototype (Time or Money)

Low High

One prototype may be builtfor verification.

Examples: printed goods

Few or no comprehensiveprototypes built.

Examples: commericalbuildings, ships

Many comprehensiveprototypes built.

Examples: software,consumer products

Analytical prototypes usedextensively.

Carefully plannedcomprehensive prototypes.

Sometimes the first unitbuilt is actually sold.

Examples: airplanes,satellites, automobiles

Prototyping Technologies

3D Computer Modeling– Easily visualize the 3D form of the design– Automatically compute physical properties– Other more focused descriptions can be created

based on one design– Detect geometric interference among parts

Prototype Technologies

Free-Form Fabrication (or Rapid Prototyping)– 3D printers that create physical objects directly

from 3D computer models– Less expensive– Reduce product development time, improve

resulting product

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

3D Printing

Planning for Prototypes

1. Tentukan kegunaan dari prototype yang akan dibuat.

2. Menetapkan level kedekatan/kemiripan prototype yang akan dibuat.

3. Tentukan garis besar/outline rencana experiment menggunakan prototype tersebut

4. Membuat schedule untuk procurement, construction, dan pengujian prototype

Define the Purpose

List specific learning and communication goals

List any integration needs Determine if the prototype is intended to be

one of the major milestones of the overall product development project

Establish the Level of Approximation

Determine physical or analytical prototype Choose the simplest prototype that will

serve the purpose established in step 1. Consider existing prototypes or a another

prototype being built that can be borrowed

Outline an Experimental Plan

Menggunakan prototype untuk pengujian/ experiment

Menggali maximum value dari aktivitas prototyping.

Mengidentifikasi variable-variable yang digunakan dalam experiment, test protocol, rencana proses analisa terhadap data-data yang dihasilkan.

Create a Schedule for Procurement, Construction, and Test

Menentukan kapan komponen-komponen yang akan digunakan siap untuk dirakit/diassembly

Menentukan waktu kapan prototype akan diuji pertama kalinya

Menentukan harapan-harapan untuk completed testing and final results (termasuk dalam hal ini performance yang diharapkan dari produk tersebut)

Milestone Prototypes Alpha Prototypes – memperkirakan

apakah produk yang dirancang dapat berfungsi/bekerja sesuai dengan yang direncanakan/dirancang

Beta Prototypes – memperkirakan keandalan/reliability dan mengidentifikasi kemungkinan adanya kesalahan-kesalahan/bugs dalam produk yang dirancang

Preproduction Prototypes – produk pertama yang dibuat/dihasilkan dengan keseluruhan proses produksi

Reference

Ulrich, K. & Eppinger, S. (2000). Product Design and Development. Boston,

MA: Irwin McGraw-Hill.

TERIMA KASIHATAS PERHATIAN DAN KERJASAMANYA

Dr. Muhammad K. Herliansyah, ST. MT.

mkherliansyah@gadjahmada.edu

herliansyah@ugm.ac.id

http://herliansyah.staff.ugm.ac.id

Tugas Mandiri:

Define each of the following parameters and what they mean in a design for manufacturing system: – • Rate – • Quality – • Cost – • Flexibility

You are the decision-maker at an automobile manufacturer. Describe one change for each of the terms above that you might make to improve that parameter. What trade offs would be associated with each of those changes?