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Design For Manufacturability

Final Presentation General Manufacturing Processes

Richard Forney, Ryan Loggins, Caleb Pan, C. Spencer Whittingham

What you will learn


What is the main idea behind Design for Manufacturability? Where is it used? Why is it used? How can products be designed using this concept? How can a manufacturing process be planed to use DFM? How does DFM save money?

Introduction
What is the main idea behind Design for Manufacturability?
The definition of Design for Manufacturability (DFM) is the general engineering art of designing products in such a way that they are easy to manufacture.

Where is DFM used?


DFM is utilized in many industries ranging from industrial products, microelectronics, scientific instruments, and the aerospace industry

DFM with respect to Product Design


Presented by Rick Forney

Objective
To design a product that can be easily, efficiently, and cost effectively be manufactured To reduce overall cost of a product warranty, engineering changes, factory floor space, unnecessary parts, and service

How
Reduce the total number of parts Modular design Standard components Multi-functional parts Multi use parts Ease of Fabrication Avoid Separate Fasteners Minimize Assembly Directions Maximize compliance Minimize handling

Reduce the Total Number of Parts


Designing a product with less parts means less
Purchases Inventory Handling Processing Time Development Time Equipment Engineering Time - Assembly Difficulty - Service Inspection - Testing

LEADS TO A CHEAPER PRODUCT

Develop a Modular Design


Using modules simplifies the manufacturing process Allows for the use of standard components Allows for tests to be conducted prior to the product being assembled

Use of Standard Components


Standard components less expensive than custom-made Testing already completed No need for development

Design Parts to be MultiFunctional


Reduce the total number of parts required
Reduce manufacturing time Reduce inventory required Example A part that acts as a heat dissipating element and as a structural support

Design Parts for Multi-use


Using parts for the same or different operations multiple times in a product Reduces the number of parts that need to be developed Less machines - Less usage of factory floor space

Design for Ease of Fabrication


Material Selection Avoid
Post process operations (painting, polishing) Excessive tolerance requirements

Avoid Separate Fasteners


Fasteners reduce manufacturing efficiency Expensive due to operations required to produce fasteners Instead use snap fits

Minimize Assembly Directions


Optimal assembly of a product occurs in one direction Preferred direction is from above using gravity to assist in the manufacturing process

Maximize Compliance
Errors in insertion due to positioning and dimensional variability cause damage to parts and to machinery Use tapers, chamfers and moderate radii to ease insertion Example utilization of a rigid base and tactile and visual sensors in assembly

Minimize Handling
Positioning, orienting, and fixing a part are time consuming and costly Use external guiding features to orient the part Ideally the part should be placed one time

Concurrent Engineering
The process of designing the product and the manufacturing process simultaneously to increase the efficiency and reduce the time to launch a product

DFM with respect to Manufacturing Processes


Presented by Caleb Pan

Manufacturing Processes
Casting, foundry, or molding Forming or metalworking Machining Joining and Assembly Surface Treatments Rapid Prototyping Heat Treating

Casting Design & Processes


Design Considerations Shrinkage, Parting Line, Draft Section Changes Features
Holes Ribs Fillets

Processes Permanent Metal Mold Expendable Sand Mold Centrifugal Plaster Mold Ceramic Mold Investment Casting Die Casting

Forming & Metalworking Processes


Extrusions Powder Metallurgy Forging Stampings Fine-blanked Parts Spring & Wire Parts Spun Metal Upset Rotary-Swaged Tube & Section Bends Electroformed Parts Cold Extrusion Rolled Form Metal Injection Molding (MIM)

Extruded Parts
Eliminate Irregularities Use standard cross sections Eliminate secondary drawing operation; eliminates additional tooling, handling, and cost.

Powder Metallurgy
Undesired Features Steps, Inserts, Screw Threads, Sharp Corners, Spherical Surfaces Limitations Holes, Inserts, Knurls, Lettering Desired features - Small radii, No draft.

Forged Parts
Features of Reduced Size Radii are necessary Draft Parting Line
Perpendicular to the axis of motion If not, no more than 75

Machining Processes
Milling Planing, Shaping, Slotting Broaching Flame-Cutting Electrochemical Chemical

Machined Parts
General Guidelines
If possible, avoid machining at all costs; the most expensive form of manufacturing Parts must be easily fixtured and must be rigid enough to withstand the forces of clamping; thin walls and deep pockets must be avoided. Difficult to machine materials must be avoided. Avoid features such as tapers, undercuts, projections, sharp corners.

DFM with respect to Cost Management


Presented by C. Spencer Whittingham

Cost Management (Design)


The machines + processes used The materials used The form of the materials The quantity being manufactured The dimensional tolerances + strength The design and shape The desired quality of the final product

Cost Management (Manufacturing)


Number of workers Escalation Risk Contingency or management reserve Travel and transfer of materials/products Fees + profit

Cost Management (Solutions)


Substitute for less expensive materials Assign a person with greater expertise or more experience to perform or help with the project/activity to get it done more efficiently Reduce the scope or requirements of the work package or for specific activities Improve methods or technology

DFM Case Study: Car Engine


Presented by Ryan Loggins

Overview
A car engine is a very complex product with many parts Due to the large magnitude of the automotive industry, it is very important that these parts are easy to manufacture and as least expensive as they can be. It is also important that these parts can be easily and quickly assembled

Engine for a 2010 Corvette ZR1

Design
It normally takes between three and five years to design a car engine The design team consists of several engineers These engineers usually stay on the same page in terms of the overall design of the engine. But what about the people who are responsible for designing the processes to produce that engine Or what about the people who are responsible for putting that engine together It is important to keep in mind the entire production process when designing a good of this magnitude

DFM for Manufacturing Processes


When designing a car engine it is important to keep in mind how the parts you are designing are going to be produced The manufacturing engineers need to be able to take your design and design the processes used to create each and every part This can be done by:
Creating the most simple parts possible Using a material that is easily manufacturable

DFM for Assembly


The harder a product is to assemble: The longer it takes to produce The more likely the chance that something will go wrong In most cases, it costs more to produce

DFM for Quality Control


As the design for a part gets more complicated:
The harder it is to keep high quality standards The more complex the manufacturing process has to be The more critical dimensions the design has, therefore greater frequency of sampling and inspections has to occur

Conclusion
To review:
Design for Manufacturability is a concept that is used in many industries Its purpose is to make it easier to manufacture products on large scales By adjusting both the product design and the production design, the ability to produce parts can be greatly improved This increase in efficiency will also reduce costs

Questions?

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