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Design for Manufacturing - Class 11 - Design for Manual Assembly Part 2: Boothroyd Dewhurst Method

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In this Design for Manufacturing lecture, we are focus on the Boothroyd Dewhurst Method of Design for Assembly. Much of the inspiration for this lecture comes from the following references.

- Product Design for Manufacturing and Assembly
- Designing Plastic Parts for Assembly

There are several other methods besides Boothroyd Dewhurst when looking at Design for Assembly but it is by far the most popular and wide-spread. The operating thesis behind this method is that the product cost is directly related to the assembly time so if you can put it together quicker, there is less of a labor rate. Additionally, the assembly time and quality are directly related to both the part count and the ease in which the parts go together.

The Boothroyd Dewhurst Method involves systematically looking at the part geometry and how they're fastened to estimate a time to put the different parts together. Then, adding it up and comparing it to a theoretical minimum part count (what's the fewest number of possible parts you could have to build the product). You will then get a ratio of the two to get an overall design efficiency. The actual number does not matter as it's intended as a benchmarking tool; as you improve the design you have some benchmarks or some comparison points so you know this design is better or worse than that your previous design.

Most importantly, this method forces you to take a step back because everything is so rushed to get the actual product working and you're thinking about so many things. The Boothroyd Dewhurst method lets you pop up a level and think specifically about assembly and ask questions: Do I really need two parts? Can I put them together with snap fit rather than screws? It is those key insights that are important.

Read more on this course: http://blog.dragoninnovation.com/2014/12/09/dfm-course-11-design-manual-assembly-part-2-boothroyd-dewhurst-method/

Learn more about Design for Manufacturing: http://blog.dragoninnovation.com/category/design-for-manufacturing-course/

About Dragon Innovation

Dragon Innovation works with entrepreneurs to launch hardware products and scale companies. Founded by a team of hardware experts, Dragon provides a clear path from prototype through production with unmatched manufacturing expertise and trusted connections. Dragon's client roster includes Coin, MakerBot, LIFX, Scout, Romotive, Sifteo, Orbotix, FormLabs and over 100 more companies paving the road for how new technology gets made.

Connect with Dragon Innovation

Website: http://www.dragoninnovation.com
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Design for Manufacturing - Class 11 - Design for Manual Assembly Part 2: Boothroyd Dewhurst Method

  1. 1. DRAGON INNOVATION, INC. DESIGN FOR MANUFACTURING (AND ASSEMBLY) COURSE 11: DESIGN FOR MANUAL ASSEMBLY PART 2: BOOTHROYD DEWHURST METHOD SCOTT N. MILLER | CEO | @DRAGONINNOVATE | WWW.DRAGONINNOVATION.COM
  2. 2. Recommended References Tutorial: www.dfma.com/support/tutorials.htm
  3. 3. BD Method
  4. 4. BD Overview •Product cost is directly related to assembly time. •Assembly time and quality are driven by the number of parts and their ease of assembly. •BD Method involves analyzing part count and geometry to calculate theoretical assembly time which is compared to the minimum theoretical assembly time to determine design efficiency. -Method can provide key insights into ways to reduce part count and improve part intelligence.
  5. 5. Factors Affecting Assembly Cost • Number of Parts • Ease of: – Handling – Insertion – Fastening
  6. 6. Boothroyd-Dewhurst Method • Design Product • Create Assembly Matrix – Handling: Size, Weight, Orientation – Insertion: Alignment & Securing Method • Calculate Theoretical Assembly Time (TAT) • Calculate Design Efficiency Index: 3s*Min_Parts / TAT - Iterate to Improve Design
  7. 7. Symmetry: Align & Orient • Alpha (Align): Max angle the part must be rotated perpendicular to axis of insertion (i.e. “end-for-end”) to repeat its orientation. • Beta (Orient): Max angle part must be rotated about axis of insertion to repeat its orientation. - Total Angle of Symmetry = Alpha + Beta
  8. 8. Additional Definitions • Thickness: • Length of shortest side of bounding box. • For (Cylinder or regular polygon > 4 sides) and (D<L), Thickness = enclosing Radius. - Size: Length of longest side of bounding box. Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  9. 9. Symmetry Examples Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  10. 10. Manual Handling Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  11. 11. Manual Insertion Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  12. 12. Example Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  13. 13. Improved DFA Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.
  14. 14. dragon@dragoninnovation.com
  15. 15. Full Manual Insertion Table Ref: Product Design for Manufacture and Assembly, Geoffrey Boothroyd, Peter Dewhurst and Winston A. Knight.

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