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Customer-Focused Quality
Published in John Nicholas, Lean Production for Competitive Advantage, 2018
DFMA considers features in the product’s design that will simplify its manufacture and assembly, and, usually, simplify the manufacturing process, reduce manufacturing costs, and improve manufacturing quality. DFMA includes methodologies and tools to make sure that the product’s design addresses matters such as materials usage, material forming and shaping procedures, machining processes, material handling, and machine and tool changeover procedures. DFMA offers guidelines to improve a product’s manufacturability, such as minimize the number of parts in a product, eliminate screws and fasteners, eliminate the need for special tools, and use standard parts. It also offers guidelines for assembling parts and the best sequence of assembly.
Effect of Manufacturing Processes on Design
Published in Mahmoud M. Farag, Materials and Process Selection for Engineering Design, 2020
DFMA seeks to minimize the cost of a product by designing components that are easier to manufacture DFM and designing components that are easier to assemble DFA. Although DFM and DFA are separate design activities, they are often interrelated and are best addressed at the configuration stage of the design, as discussed in Section 5.3. Changes during the detail design stage can also be introduced to further improve ease of manufacture and assembly. DFMA provides a structured procedure for analyzing a design from the point of view of manufacture and assembly. Such a procedure normally results in simpler designs with fewer components in an assembly. In addition to reduction in assembly time and cost, having fewer components means fewer detail drawings, smaller number of materials and specifications, less inventory, and lower overheads. Boothroyd et al. (1994) developed a DFA software to provide guidance in reducing the number of parts in an assembly. The software asks the following questions: (a) Is the part or subassembly used only for fastening or securing other items? (b) Is the part or subassembly used only for connecting other items? If the answer to either of these questions is “yes,” then the part or subassembly is considered theoretically unnecessary. If the answer to both questions is “no,” the following questions are then asked: Does the part move relative to all other parts? Must the part be made of different materials or isolated from other parts? If the answer is “no,” the part is considered theoretically unnecessary. The design team attempts to integrate the parts that are considered theoretically unnecessary with other parts, thus reducing the total part count and assembly time of the product.
General introduction
Published in Adedeji B. Badiru, Handbook of Industrial and Systems Engineering, 2013
Design for manufacture and assembly (DFMA) techniques may be used to supplement VE activities; DFMA involves the review of designs to identify the optimal choice of materials, component design, fabrication, and assembly for the most cost-effective and functional solution. DFMA is carried out with the participation of a multidisciplinary team-whereas in manufacturing environments the team includes manufacturing engineers, shop floor mechanics, suppliers' representatives and specialists in maintainability and reliability studies, construction projects would include building design engineers, architects, contractors, and maintenance personnel.
Efficient design of a prefabricated steel structure integrating design for manufacture and assembly concepts
Published in Australian Journal of Structural Engineering, 2022
Muhammad Wasim, Osmar Oliveira
The emphasis on the application of DfMA in prefabrication is to optimise the architectural design and promote the assembly efficiency of structural elements. DfMA is an integrated process to guide the design of the module’s basic components and their connections, assembly sequence, and finally the manufacturing and assembly of these components in a controlled environment. The results of DfMA analysis for the module indicated that the wall-integrated plumbing system has the potential to increase the efficiency in the manufacture and assembly process and overcomes the limitations of existing design and assembly procedures. The difference in assembly time between the observation and the estimation mainly resulted from an inefficient fastening method whereby the process of screw fastening was the most time-consuming operation. The proposed design shortened the assembly time and increased the DfA index by cutting down the requirement of unnecessary secondary operations and promoting the snap-fit securing method. The benefits of time savings achieved by the elimination of parts are shown in Figure 8.
Integration of DFMA and sustainability - A case study
Published in International Journal of Sustainable Engineering, 2021
Arunkumar Subbaiah, Kishore M. Antony
The principles of DFMA and sustainability is gaining importance among industries to ensure productivity, economical use of resources and minimise the harmful effect on the environment. DFMA in particular provides guideline for reducing the number of parts through standardisation, selection of economical material without compromising the integrity of product and modification of design to reduce the assembly time. This results in the reduction of total cost of the product. However, part consolidation alone is not sufficient to survive in this competitive market, since the industries are required satisfy the environmental norms set by the local government. Hence, it is obligatory to integrate DFMA and sustainability concept in the early phases of product design. This case study has clearly illustrated the simultaneous application of DFMA and sustainability principles through the redesign of bike horn. The results indicated that the total cost the redesigned product and its harmful effect on the environment reduced significantly. These type of case studies must be carried out in large number to arrive at an optimised design tool or a frame work of integrated application of DFMA and sustainability, so that the designers can quickly pull out this guideline and implement it in the product design.
Examining the effect of design for additive manufacturing rule presentation on part redesign quality
Published in Journal of Engineering Design, 2020
Kenton Blane Fillingim, Richard O. Nwaeri, Christiaan J. J. Paredis, David Rosen, Katherine Fu
In recent years, an increasing number of designers have realised the benefits of concurrent engineering (Eastman 2012). This refers to a system in which the different disciplinary groups working on different phases of a product work closely together to ensure that all facets of the product are considered at every phase of product development. This is done in order to improve the likelihood of a successful product, while also reducing costs and enabling flexibility along the way. This has spawned an approach to design known as Design for X (DfX), which is an umbrella term for a group of more focused approaches which aim to help designers consider the later stages of the product, while still in the design phase. One of the most common of the approaches is Design for Manufacture and Assembly (DfMA), which is focused on helping designers create concepts that are easier to manufacture, helping to reduce costs further down the road. This is done by introducing them to the key features that should be considered in order to reduce manufacturing complexity, such as the expected assembly directions, and the number of fasteners (Kuo, Huang, and Zhang 2001).