Design Methodology for Assembly and Disassembly Based on Rating Factors

2005 ◽  
Author(s):  
Devdas Shetty ◽  
Vishwesh Coimbatore ◽  
Claudio Campana
Keyword(s):  
Spare Parts ◽  
Evaluation Methodology ◽  
Design For Assembly ◽  
Contributing Factors ◽  
Assembly Design ◽  
Design Engineers ◽  
Innovative Products ◽  
Product Recycling ◽  
Tools And Techniques ◽  
Automated Tool

Design engineers need an automated tool to effectively analyze the ease of assembly & disassembly of the subassemblies and the innovative products they create. A good assembly design makes it easier to service, easier to repair and maintain. Due to current environmental regulations the designers are forced to think about the life cycle of a product, recycling and reuse aspects of the products from the very beginning. This creates an environment for efficient implementation of design for manufacturing tools and techniques. A New Design for Assembly / Disassembly (DFA/DFD) Evaluation methodology explained here enables the designer to review the design for assembly and disassembly difficulties by considering several contributing factors and their importance to successful product creation. The technique is based on the criteria of “Rating Factors”. A spreadsheet format is used to create the front end interface for the user and to include all the influencing factors. The major parameters considered for the study are access, tool, task, re-use, removal, recyclability. Since the product maintenance is an important factor additional maintenance related issues such as spare parts, waiting time, priority and cost are considered as rating factors. The new methodology was compared with other existing techniques and found to be valid and useful to manufacturing industries.

A new design tool for DFA/DFD based on rating factors

2015 ◽  
Vol 35 (4) ◽  
pp. 348-357 ◽  
Author(s):  
Devdas Shetty ◽  
Ahad Ali
Keyword(s):  
Design Tool ◽  
Design For Assembly ◽  
Evaluation Tool ◽  
New Approach ◽  
Content Type ◽  
Assembly Design ◽  
Design Engineers ◽  
Life Cycle Design ◽  
Score Method ◽  
Manufacturing Assembly

Purpose – The purpose of this paper is to develop a tool design for assembly and disassembly using rating factors. Design engineers need an automated tool to effectively analyze the ease of assembly and disassembly of the products or subassemblies. A good assembly design helps in easier disassembly and thus makes it easier to service, repair and maintain. Reuse and recycling aspects are given importance in the present days due to environmental regulations. Designers now use the life cycle design of the products. This creates an environment for the successful application of design for manufacturing, assembly and disassembly tools. This paper addresses some of those issues. Design/methodology/approach – The analysis of a product design for ease of assembly/disassembly depends largely on whether the product is to be assembled/disassembled manually, with automation or a combination of these. For example, the criteria for ease of automatic feeding and orienting are much more stringent than those for manual handling of parts. The new design for assembly/disassembly (DFA/DFD) evaluation tool explained here enables the designer to review the existing design. This paper examines the existing techniques in the area of DFA/DFD and suggests a new methodology based on rating factors. Excel is used to create the interface for the user. Other popular methods were examined such as Boothroyd-Dewhurst, Lucas. Access, reuse, removal, tool, task and time method and assembly score method (Poli) were used as a base for this study. Findings – The end result of this research is a new approach linked to assembly/disassembly rating score. Originality/value – The new DFA/DFD evaluation tool enables the designer to review the existing DFA and DFD difficulties.

scholarly journals DESIGN THINKING: CONCEPTUAL FRAMEWORK, ADVANTAGES AND RESTRICTIONS

2021 ◽  
pp. 43-48
Author(s):  
Sytnik N.
Keyword(s):  
Corporate Culture ◽  
Design Thinking ◽  
Team Building ◽  
Deep Understanding ◽  
Customer Experience ◽  
Organizational Goals ◽  
Innovative Products ◽  
Creative Abilities ◽  
Stanford Model ◽  
Tools And Techniques

The need to develop competitive innovative products and services encourages modern organizations to search for new ways to enhance the creative abilities of their personnel. Design thinking is one of the promising tools to elaborate organi-zational potential in generating ideas and developing new products which satisfy customer requirements to the most extent. Over last years design thinking has been developed as a practically­oriented approach aimed at solving customer problems. Within the frame of design thinking, deep understanding of their values, reactions, experience in interaction with the company and behavioral habits serves as a basis for focused ideation, fast prototyping and testing. Although the key characteristics, main stages, tools and techniques of design thinking are well established in the literature, far less attention has been paid to the restrictions and conditions of design thinking application within organizational environment. These issues determined the purpose of the study. First, the paper considered the evolution of the term design thinking, as well as portfolio of its tools and techniques applied at different stages of design thinking process. Further, the advantages, restrictions and conditions of design thinking application were specified. Design thinking allows to achieve 1) externally oriented organizational goals: development of innovations, improvement of products and services in accordance with customer needs, better interaction with customers; 2) internally oriented organizational goals: development of staff experience and creative abilities, team building and enchancing a creative corporate culture. The restrictions of design thinking implementation related to its key features (focus on customer experience, fast ideation, prototyping and testing) were established. Important conditions for design thinking implementation are as follows: understanding and taking into account its restrictions, introduction of a flexible format for design sessions, and formation of design teams in accordance with the experience, competencies and thinking style of their participants. Thus, design thinking is a useful approach for development of customer­oriented innovative solutions, although it should not be considered as a universal tool for solving all organizational problems.Keywords: design, design thinking, creativity, customer experience, Stanford model, «wicked» problems, design thinking techniques. Дизайн­мислення є перспективним напрямом дослідження для науковців і фахівців із менеджменту, ураховуючи позитивний досвід його використання і зростаючу популярність серед провідних компаній світу. Нині відомі характерні риси, етапи, інструменти та техніки дизайн­мислення, однак малодослідженим залишається питання щодо меж практичного застосування цього підходу, його переваг і недоліків. У статті виявлено переваги дизайн­мислення, зокрема: оперативне вдосконалення продуктів і послуг відповідно до потреб клієнтів, тімбілдинг, новий досвід і розвиток креативних здібностей персоналу, формування креативної корпоративної культури. Для успішного застосування дизайн­мислення під час організації дизайн­сесій необхідно враховувати його обмеження, упроваджувати гнучкий формат дизайн­сесій та підбирати учасників дизайн­команд за досвідом, компетенціями і стилем мислення. Ключові слова: дизайн, дизайн­мислення, креативність, клієнтський досвід, Стенфордська модель, wicked­проблеми, техніки дизайн­мислення.

Design for Manufacturing & Assembly Approach in Realisation of Cryogenic Thrust Chamber

2015 ◽  
Vol 830-831 ◽  
pp. 95-99
Author(s):  
Alok Singh ◽  
Ravi Ranjan Kumar ◽  
Ashish Kumar Pande ◽  
P.V. Venkitakrishnan
Keyword(s):  
Holistic Approach ◽  
Design For Manufacturing ◽  
Product Launch ◽  
Design For Assembly ◽  
Thrust Chamber ◽  
Design Engineers ◽  
Full Production ◽  
Industrial Designers ◽  
Functional Teams ◽  
New Good

In the olden days the motto was "I designed it; you build it!" Design engineers worked alone and Designs were then thrown over the wall leaving manufacturing people with the dilemma how to manufacture. Often this delayed both the product launch and the time to ramp up to full production. In the new good days manufacturability can be assured by developing products in multi-functional teams with early and active participation from Manufacturing, Marketing (and even customers), Finance, Industrial Designers, Quality, Service, Purchasing, Vendors and factory works. The need for a holistic approach between design and manufacturing is required. The two concepts Design for Manufacturing & Design for Assembly has become the need of the hour. The heart of any design for manufacturing system is a group of design principles or guidelines that are structured to help the designer reduce the cost and difficulty of manufacturing an item.Realisation of Cryogenic thrust chamber includes various manufacturing processes like Forming, Welding, Machining and Brazing. During initial stages of Thrust chamber realisation problems like Forming of 1.7m long nozzle divergent from thin sheets, welding of various intricate geometries & assembly of critical parts were observed. Subsequently these problems were studied based on the holistic approach of Design for manufacturing & design for assembly. Improvements based on the above study were considered in design & critical processes modifications resulting in successful and timely realization of the thrust chamber.

Integration of Modern Software Tools for Production Design

2006 ◽  
Author(s):  
Devdas Shetty ◽  
Tom Eppes ◽  
Lifeng Chao ◽  
Claudio Campana
Keyword(s):  
Life Cycle ◽  
Product Design ◽  
Product Life Cycle ◽  
Software Tools ◽  
Assembly Design ◽  
Design And Manufacturing ◽  
Motion Paths ◽  
Comprehensive Manner ◽  
Tools And Techniques ◽  
Efficient Manufacturing

Engineers, irrespective of their disciplines, need effective tools to comprehensively design, model, synthesize and analyze the design a product. This is often closely followed by the need to fabricate a working prototype. Engineers need useful methodologies and tools that can be used in preparation for manufacturing. These tools need to effectively analyze assembly & disassembly since a good assembly design makes a product les expensive to service, repair and maintain. A suite of well-integrated tools assists designers to create, simulate and test in a comprehensive manner. Modern software tools can be used at each stage to create conceptual designs, simulate part geometries, analyze key parameters, and generate motion paths for efficient manufacturing. This paper presents a set of comprehensive procedures and tools that can easily be incorporated into product design and manufacturing from early design through analysis. They consider assembly and disassembly factors up to and including the creation of a working prototype. Due to environmental regulations, designers must think about the product life cycle, recycling and reuse aspects from the very beginning. There is a continuing need for more efficient and rapid design processes which can best be driven by better tools and techniques.

scholarly journals An Overview and Classification of Tolerance Compensation Methods

2019 ◽  
Vol 1 (1) ◽  
pp. 3471-3480
Author(s):  
Alexander Aschenbrenner ◽  
Benjamin Schleich ◽  
Sandro Wartzack
Keyword(s):  
Production Process ◽  
Dimensional Accuracy ◽  
Design Guidelines ◽  
Production Costs ◽  
Product Complexity ◽  
Design Engineers ◽  
Technological Advances ◽  
Compensation Methods ◽  
Innovative Products

AbstractTechnological advances as well as novel manufacturing and design paradigms, such as industry 4.0 and digitalization, offer new opportunities for innovative products. However, they also increase the product complexity and cause new challenges in the production process. Therefore, agile production approaches are crucial. Tolerance compensation provides more flexibility in the production process, as demands on dimensional accuracy of the components are reduced. As a result, tolerance compensation also offers the possibility of reducing production costs without compromising product quality. Nevertheless, tolerance compensation is often considered a reactive intervention to reduce the number of out-of-spec parts a posteriori instead of including it in the early stages of Geometrical Variations Management. The contribution tackles this issue by characterizing and categorizing different methods of tolerance compensation as well as providing design guidelines for the application of tolerance compensation methods. This enables design engineers to select a suitable tolerance compensation method for different applications.

scholarly journals DFMA to RP, ASAP

1999 ◽  
Vol 121 (09) ◽  
pp. 72-74
Author(s):  
Jack Raplee
Keyword(s):  
Rapid Prototyping ◽  
Process Planning ◽  
Manufacturing Process ◽  
Design For Environment ◽  
Design For Assembly ◽  
Manufacturing Companies ◽  
Design For Manufacture ◽  
Assembly Design ◽  
Manufacturing Process Planning

Manufacturing companies are turning increasingly to rapid prototyping (RP) to perform pre-assembly testing and improve the quality of the final product. Manufacturers also have begun to complement their RP practices using design for manufacture and assembly methodology. Design for assembly lowers the complexity of products through parts reduction and enables manufacturers to quantify assembly times and costs. Users are prompted to consider each part and decide if it must be separate from others in the assembly, leading to systematic simplification of design. The four approaches by which design for manufacturer (DFMA) software analyzes product configurations incorporate design for assembly, design for manufacture, design for service, and design for environment. Using design for assembly can reduce the number of parts in the product, but can increase the complexity of the parts that remain. Rapid prototyping combined with DFMA tools not only can determine if a product will perform its desired functions. According to an expert, when early manufacturing process planning is performed using DFMA and RP, it is synergistic.

Balance between Lean and Sustainability in Product Development

2012 ◽  
Vol 502 ◽  
pp. 37-42 ◽  
Author(s):  
Mikel Sorli ◽  
A. Sopelana ◽  
M. Salgado ◽  
G. Peláez ◽  
E. Ares
Keyword(s):  
Life Cycle ◽  
Product Development ◽  
Product Life Cycle ◽  
Design Stage ◽  
Future Research ◽  
Product Life ◽  
Lean Principles ◽  
Sustainable Culture ◽  
Innovative Products ◽  
Tools And Techniques

Companies require tools to change towards a new way of developing and producing innovative products to be manufactured considering the economic, social and environmental impact along the product life cycle. Based on translating Lean principles in Product Development (PD) from the design stage and, along the entire product life cycle, it is aimed to address both sustainability and environmental issues. The drivers of sustainable culture within a lean PD have been identified and a baseline for future research on the development of appropriate tools and techniques has been provided. This research provide industry with a framework which balance environmental and sustainable factors with lean principles to be considered and incorporated from the beginning of product design and development covering the entire product lifecycle.

scholarly journals USING COST ANALYSIS AS A TOOL FOR COMBINING DESIGN FOR ASSEMBLY AND DESIGN FOR DISASSEMBLY AT THE EARLY STAGE OF SUSTAINABLE PRODUCT DEVELOPMENT PROCESS

2011 ◽  
Author(s):  
Reza Memary
Keyword(s):  
Early Stage ◽  
Life Cycle Management ◽  
Product Development Process ◽  
Design For Assembly ◽  
Design For Disassembly ◽  
Assembly Design ◽  
Design For Sustainability ◽  
Sustainable Product Development ◽  
Sustainable Product ◽  
Lifecycle Management

A model for Integration of Assembly and Disassembly in Lifecycle Management is proposed and its efficiency is evaluated using case studies. The feasibility of considering assembly and disassembly together in the way that End of Life Option gives the highest profit and promotes recycling profitability is investigated. Keywords; Design for Sustainability, Design for Assembly, Design for Disassembly, Life Cycle Management

Wheel Wear Management on High-Speed Passenger Rail: A Common Playground for Design and Maintenance Engineering in the Talgo Engineering Cycle

Joint Rail ◽  
2004 ◽  
Author(s):  
Fernando Pascual ◽  
Jose-Antonio Marcos
Keyword(s):  
High Speed ◽  
Cutting Parameters ◽  
Daily Basis ◽  
Wheel Wear ◽  
Assembly Design ◽  
Design Engineers ◽  
Passenger Rail ◽  
Maintenance Program ◽  
Wheel Turning ◽  
Maintenance Engineering

Talgo’s focus on engineering excellence has helped the group to deliver innovative rail products to the market since 1942. Patentes Talgo S.A. (PTSA) provides passenger rail administrations around the world with high speed cars and locomotives, car maintenance equipment and maintenance services. The paper outlines the US experience of Talgo’s Total Logistics Care (TLC) maintenance program, summarizing Talgo’s maintenance approach, practice and overall results. The preventive and corrective maintenance program, the continuous trainset monitoring and the maintenance & design engineering cycle will be covered among other topics. Rolling assembly maintenance and wheel wear management are the two focal points of this paper. Talgo’s rolling assembly design has evolved over 60 years taking full advantage of the design-maintenance engineering cycle. Maintenance engineers and technicians, wheel assembly design engineers and maintenance equipment design engineers work together on a daily basis to improve the design of the rolling assembly and reduce maintenance costs and wheel wear. Enhanced guidance systems and other design improvements help to reduce flange wear on independent axle wheelsets. Also, five decades of in-house maintenance and wheel turning experience using Talgo pit lathes revealed the cutting parameters and frequencies to maximize wheel life. Both wheel wear management design and maintenance practices will be reviewed in the paper.

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