Design For Assembly

Fachhochschule Ingolstadt
g
Advanced industrial engineering Prof. Dr.-Ing. Maximilian Schmidt
lecture 6
design for assembly
Advanced industrial engineering – design for assembly

page 1
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6. design for assembly
6.1 importance
6 2 rules
6.2 l
6.3 exercise (not subject)
6.4 evaluation with PROKON

page 2
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6.1. the importance of design for assembly
assembling is a substantial expense factor of the production (25-75%)

♦ e.g. about 45% of truck engines
♦ e.g.
e g about 65% of electrical equipment
in order to raise p
productivity
y in assembling
g systems,
y , three steps
p can be applied
pp
1. Reorganize the system (target first!)
2. Speed up processes
3. Change product design

page 3
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Firts Step: Reorganize the system
enlarge the percentage of

T t time
Tact ti assembling
bli a milling
illi machine
hi
value adding workload
120%
Value adding work - 100%
useful for the customer 80%
60% Non value adding work
f.ex.
Welding 40%
20%
gluing % of value adding work
0%
joining
. . . . . . . . . .
non value adding work:

walking, searching, handling

page 4
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Firtst step: Reorganize the system
enlarge the percentage of

value adding workload
Quelle:SIGMA
asslembling Assembling in lots

one product
savings up to 40%

page 5
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First step: Reorganize the system
Tact time assembling a milling machine

rebalance the system
120%
by Losses in tact
changing the workload in all 100%
the tacts 80%
60% Non value adding work
only the slowest tact 40%
decides
20%
Value adding work
0%
. . . . . . . . . .

page 6
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Second Step:
♦ speed up processes by
♦ mechanisation
♦ automation
Third step:
from 355 examined assembly operations (THD EMK) the possibility to automise was
♦ 23% without constructional modifications

♦ 60% with
ith changes
h
♦ 17% not a all
design for assembly is often requirement for a successful automation STOP

page 7
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reasons for the low level of automation in the assembly are:
♦ high complexity of the products (quantity

(quantity, type of parts/assembly groups)
♦ complex assembly sequences (difficult planing)
♦ poor frequency of repetition of processes
♦ gq
fluctuating quality
y of the p
production
possible reduction of costs in the assembly in percentage are (IPA)
material changes about 4%

allowed time about 6%
work sequences about 9%
new production
d ti ttechnologies
h l i about
b t 10%
product developement and mechanisation about 40%

page 8
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design for assembly has to be implemented at a very early stage

of the product design
Possibility to
costs of redesign
Productt costs
influence costs
D i
Design planning
l i manufacturing
f t i assembly
bl
source: Lotter
page 9
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6.2.Rules: design for assembly
6.2.1 rules for product design
622
6.2.2 rules
l ffor handling
h dli
6.2.3 rules for joining
source:Siemens
page 10
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avoid variants, generate them in the end
♦ create components unattachedh d ffrom variants

i
♦ allow multiple usage of parts
♦ generate a consistent order
♦ assemble variants in the end
source:Benetton
page 11
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avoid variants, generate them in the end
♦ create components unattachedh d ffrom variants

i fully automated
♦ allow multiple usage of parts production
♦ generate a consistent order of the consistent
base plate
♦ assemble variants in the end
manual generation
of variants
source:LEGO
g
minimise the number of parts
♦ question
i the
h usage off every single
i l part
♦ merge functions
♦ avoid connecting elements
♦ avoid security elements
source:Siemens
page 13
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minimise the number of parts
♦ question
i the
h usage off
every single part
♦ merge functions
♦ avoid
id connecting
ti elements
l t
♦ avoid security elements
Advanced industrial engineering – design for assembly source:Siemens

page 14
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building assembly groups
♦ lilimiti the
h number
b off parts per assembly
bl group
♦ aim for a construction kit
♦ create assembly group neutral to variants
♦ create unconnected assembly group
(in order to test them in advance)
♦ allow for a independent performance test
♦ enable easy joining

page 15
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building assembly groups
♦ lilimiti the
h number
b off parts per assembly
bl group
♦ aim for a construction kit
♦ create assembly group neutral to variants
♦ create unconnected assembly group
(in order to test them in advance)
♦ allow for a independent performance test
♦ enable easy joining
source:Siemens
Si

page 16
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provide assembly compatible base
base should
b h ld
♦ give coherence to the assembly group
♦ have component carrier function
♦ be adequately firm
♦ allow simple directing of joining
source:Siemens
Si

page 17
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provide assembly compatible base
base should
b h ld
♦ give coherence to the assembly group
♦ have component carrier function
♦ be adequately firm
♦ allow simple directing of joining
source:Lotter
L tt

page 18
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create simple assembling (order und direction)
♦ uniform
if assembling
bli methods
h d
♦ merge joining und connecting
♦ joining from above
♦ aids for joinig
♦ Independent assembling
source:Siemens
Si

page 19
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create simple assembling (order und direction)
♦ uniform
if assembling
bli methods
h d
♦ merge joining und connecting
♦ joining from above
♦ aids for joinig
♦ Independent assembling
source:Siemens
Si

page 20
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6.2.2 rules for handling
6.2.2.1 feeding
rule: keep existing order
negativ:
♦ handlingg costs in
production
♦ parts storage
advantage:
♦ simpler supply devices
♦ less interferences

source:Siemens page 21
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6.2.2.1 feeding
rule:
l keep
k parts
♦ pourable
♦ able to hang
♦ able to be strapped
♦ stackable
♦ break-proof
♦ in stabile condition
♦ clean
source:Siemens
page 22
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6.2.2 rules for handling ungünstig günstig
6.2.2.1 feeding
rule:
l keep
k parts
♦ pourable
♦ able to hang
♦ stackable
♦ break-proof
♦ clean
source:Siemens
page 23
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6.2.2 rules for handling ungünstig günstig
6.2.2.1 feeding
rule:
l keep
k parts
♦ pourable
♦ able to hang
♦ stackable
♦ break-proof
♦ clean
source:Siemens
page 24
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6.2.2.2 orientation
♦ reall symmetry
♦ distinct asymmetry
♦ characteristics at the outside contour
♦ selfdisposing parts
source:Siemens
page 25
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6.2.2.2 orientation
rule:
l reall symmetry
source:Siemens
page 26
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6.2.2.2 orientation
rule:
l reall symmetry or asymmetry
source:Siemens
page 27
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6.2.2.2 orientation
rule:
l reall asymmetry
source:Siemens
page 28
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6.2.2.3 gripping
♦ allow
ll ffor space to grip
i
♦ uniforme space to grip
♦ use position of center of gravity upper seam
handle
Vertical
V ti l
gripping
map case flute
source:Utz
page 29
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6.2.2.3 gripping
♦ allow
ll ffor space to grip
i
♦ uniforme space to grip
♦ Use position of center of gravity
source:Siemens
page 30
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6.2.2.4 positioning
♦ simple
i l movement against i the
h bl
block
k
♦ appropriate fitting surfaces or edges
♦ positioning with enough tolerance
♦ self centering of parts
source:Siemens
page 31
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6.2.2.4 positioning
♦ simple
h bl
block
k
STOP
source:Siemens
page 32
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6.2.2.4 positioning
♦ simple
h bl
block
k
source:Siemens
page 33
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♦ parts dimensionally stable

♦ use no bending parts
♦ aids
id ffor jjoining
i i
♦ avoid canting
♦ avoid threading/overlapping
♦ avoid blind assembling

page 34
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rule: aids für joining
source:Siemens
page 35
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rule:
use no bending parts
source:Siemens
page 36
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source:Siemens
page 37
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6.3. exercise – screw feeder in C023
6.3.1 define assembly groups of the screw feeder
632
6.3.2 develop
d l measuring
i scheme
h to
evaluate assembly
6.3.3 analyse assembly groups by

dismantling the feeder
6.3.4 brainstorming for solutions
6.3.5 reassemble the feeder

page 38
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6.3.1 define assembly groups of the screw feeder
- bunker and sorter
- Controller
- basic platform and fixation angle

page 39
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6.3.2 evaluate assembly
simple evaluation system (1)
assembly
bl difficulty
diffi l
long assembly time (?benchmarks)

how many different tools and human
effort is necessary to build the product
(f.ex. do I need both hands to assemble,
overhead work, many different screw drivers)

page 40
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handling
h dli
how often do you have to turn the product
how difficult are the movements
(3,4,6 axis necessary)
space to assemble
is there enough space to use the tools
and joining/securing elements
(as screws, bolts etc.)
joining directions (JD)

one JD ++, two JDs +, > two JDs or hidden joining o

page 41
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assemblybl difficulty
diffi l ++ (1Pt.)
(1P ) + (2Pt)
(2P ) o (3Pt)
(3P )
handling ++ (1Pt.) + (2Pt) o (3Pt)
space ++ (1Pt.) + (2Pt) o (3Pt)
directions ++ (1Pt.) + (2Pt) o (3Pt)
good acceptable NOK
add
dd the
th single
i l points.
i t
In the end, the addition of all four sorts the
product in
<8 product easy to assemble
8-10 product has to be improved
> 10 urgent need for redesign

page 42
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6.3.3 analyse assembly groups by

di
dismantling
tli the
th feeder
f d
three teams dismantle each assembly group in approx. 45 minutes and evaluate all groups
6.3.4 improvement brainstroming
approx.45 minutes to develop

improvemet proposials and
work out a presentation

page 43
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6.3.4 improvement brainstroming
approx.45 minutes to develop

improvemet proposials and
workk out a presentation
i
order of redesing
100
90
80
70
possible 60
costt 50
saving 40
30
20
hoch
10
mittel costs of
0
gering redesing
ell
schne
el
mitte
langfristig
time to redesing

page 44
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6.4 Evaluation with prokon
Construction
Status Quo Target Status
inside bearing cover cap bearing bracket
Simplification of parts
Positioning aids
Standardization of parts 4 parts 2 parts
Reduction off number off parts
tapping screws cover cap

Reduction/Standardization
off Positioning
P iti i AxesA
page 45
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Product/Part Influences on Assembly are:

♦ Weigth
♦ Size
Si
♦ Number of add. Positions
♦ Processes
♦ justages
product
basicvalue influences on assembly
w eight main parts number of w ith w rong adjust. w ithout direction
Prozess
1. jjoint size dimension jjoints problems
p ass. w ith w hlie jjoining
g change
g Justage/
g number
<8 >8 >300x300 > 800 2. 3. >3 posit. add. joining aids joining checking of
desciption sight space
daN daN mm mm Anz. possible fixture (x,y,z) P1 P2 P3 tools
Lagerbock 1 1 1
Blechschrauben 2 2 2 1
Abdeckkappe 1 1
how often at all 4 0 0 0 1 0 0 0 0 0 3 0 0 0 0 1 2 0 1
value 40 55 10 100 10 15 40 15 35 15 20 10 15 20 100 50 150 300 40
total value 160 0 0 0 10 0 0 0 0 0 60 0 0 0 0 50 300 0 40
total value 620

page 46
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uence of assembly
y
E l ti steps
Evaluation t
Step 2 evaluate influences on assembly
product
basicvalue influences on assembly
w eight main parts number of w ith w rong adjust. w ithout direction
Prozess
1. joint size dimension joints problems ass. w ith w hlie joining change Justage/ number
<8 >8 >300x300 > 800 2. 3. >3 posit. add. joining aids joining checking of
desciption sight space
daN daN mm mm Anz. possible fixture (x,y,z) P1 P2 P3 tools
Step 1 List parrts in sequ
Lagerbock 1 1 1
Blechschrauben 2 2 2 1
Abdeckkappe 1 1
how often at all 4 0 0 0 1 0 0 0 0 0 3 0 0 0 0 1 2 0 1
value 40 55 10 100 10 15 40 15 35 15 20 10 15 20 100 50 150 300 40
total value 160 0 0 0 10 0 0 0 0 0 60 0 0 0 0 50 300 0 40
total value 620
Step 3 get status value

page 47
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Next step Number of parts

5
Try to
T Number of add. Positions
4 Number of processes
Minimise 3
influences 2
1
Number of large parts 0 Number of Justages
Parts without positioning aid Prokon Value
Parts with difficulties

page 48

Design For Assembly

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Fachhochschule Ingolstadt

Advanced industrial engineering – design for assembly

6. design for assembly

6.3 exercise (not subject)

6.4 evaluation with PROKON

Advanced industrial engineering – design for assembly

6.1. the importance of design for assembly

assembling is a substantial expense factor of the production (25-75%)

1. Reorganize the system (target first!)

3. Change product design

Advanced industrial engineering – design for assembly

6.1. the importance of design for assembly

Firts Step: Reorganize the system

enlarge the percentage of

non value adding work:

Advanced industrial engineering – design for assembly

6.1. the importance of design for assembly

Firtst step: Reorganize the system

enlarge the percentage of

asslembling Assembling in lots

Advanced industrial engineering – design for assembly

6.1. the importance of design for assembly

First step: Reorganize the system

Tact time assembling a milling machine

Advanced industrial engineering – design for assembly

6.1. the importance of design for assembly

♦ 23% without constructional modifications