This article is describing how to use DFA (design for assembly) method to decrease the cost, time and difficulty in assembly processes of a product. the product which is selected as reference is a toaster. Reduction of components and redesign of parts are some of the DFA method to provide the ease of assembly process.
The document discusses various manufacturing processes and considerations for component design based on the selected process. It describes primary, secondary and tertiary manufacturing processes and provides details on casting, forging and sheet metal processes. Key factors for casting include part complexity, material properties and economics of production quantities. For forging, important considerations include parting lines, draft angles, fillets and corners to enable uniform metal flow. Sheet metal design must account for material thickness and formability limitations.
Top down assembly modeling involves first creating an assembly file with a skeleton layout sketch. Parts are then created within the assembly file and assembled using constraints. This approach allows designing from the overall assembly down to individual components. Benefits include having all design information centralized, reducing errors, and better managing large assemblies with thousands of parts. However, more upfront analysis is required compared to the bottom up approach of first creating individual parts separately before assembling them.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document summarizes a project on redesigning emergency lamps to improve manufacturing and assembly. The original lamp design had 27 components and took 5580 seconds to assemble, resulting in an assembly efficiency of 0.00645. The redesigned lamp was developed using DFMA methodology. It has 19 components and takes 4200 seconds to assemble, giving an assembly efficiency of 0.01071, an improvement of 39.76%. Material costs were reduced from INR 234,000 to INR 214,000, a savings of 8.54%. The redesign focused on reducing size, parts count and switching to more efficient LED lights.
The document provides a summary of a report analyzing the design for manufacturing and assembly (DFMA) features of an HP Deskjet printer. Key DFMA guidelines considered include minimizing parts, using standard parts, facilitating part handling, and encouraging modular assembly. The report examines the printer's design for automation and assembly, use of plastics, fastening methods, and sheet metal components. Figures are included to illustrate how the printer's design incorporates various DFMA principles such as pyramidal assembly, symmetry, and avoiding part jamming.
Sheet metal operations involve cutting, forming, and finishing processes to manufacture components from thin metal plates less than 5mm thick. Cutting processes like shearing, punching, and blanking apply forces to separate material, while forming processes like drawing, spinning, bending, and embossing shape the metal without cracking. Common sheet metals include steel, aluminum, and titanium used in automotive and aircraft bodies, appliances, and more. Key forming operations are stretching, spinning, bending, and embossing which deform the metal over dies into desired contours.
DFMA -Design For Manufacturing and AssemblySunith Guraddi
The document discusses applications of design for manufacture and assembly (DFMA) principles. It provides examples of how DFMA has been applied to improve products designed for developing world contexts. One example is a redesigned pineapple juicer that had fewer parts, lower production costs, and was easier to manufacture due to applying modified DFMA principles. Another example discusses reducing the part count and assembly time of a stapler through DFMA analysis. The document also outlines DFMA methodologies and principles that were developed to help designers lower costs and improve producibility, such as reducing part count, standardizing materials, and designing for automated production when feasible.
1. Forming is a metalworking process that shapes metal by deforming it without removing material. Common forming processes include rolling, extrusion, forging, and die forming.
2. Joining processes like welding, brazing, and adhesive bonding are used to connect metal components together. Welding involves melting materials to join them, while brazing uses a filler metal below the melting point of the base materials.
3. Machining removes material using tools like lathes, mills, drills and grinders to shape a workpiece. It allows for tight tolerances but incurs significant material removal and waste.
The document discusses various manufacturing processes and considerations for component design based on the selected process. It describes primary, secondary and tertiary manufacturing processes and provides details on casting, forging and sheet metal processes. Key factors for casting include part complexity, material properties and economics of production quantities. For forging, important considerations include parting lines, draft angles, fillets and corners to enable uniform metal flow. Sheet metal design must account for material thickness and formability limitations.
Top down assembly modeling involves first creating an assembly file with a skeleton layout sketch. Parts are then created within the assembly file and assembled using constraints. This approach allows designing from the overall assembly down to individual components. Benefits include having all design information centralized, reducing errors, and better managing large assemblies with thousands of parts. However, more upfront analysis is required compared to the bottom up approach of first creating individual parts separately before assembling them.
The document discusses various sheet metalworking processes including cutting, bending, and drawing. Cutting operations like shearing, blanking, and punching are used to cut sheet metal. Bending involves straining sheet metal around a straight axis using methods like V-bending and edge bending. Drawing forms sheet metal into convex or concave shapes. Key considerations in sheet metalworking are clearance, bending allowances, springback, and forces required for cutting.
This document summarizes a project on redesigning emergency lamps to improve manufacturing and assembly. The original lamp design had 27 components and took 5580 seconds to assemble, resulting in an assembly efficiency of 0.00645. The redesigned lamp was developed using DFMA methodology. It has 19 components and takes 4200 seconds to assemble, giving an assembly efficiency of 0.01071, an improvement of 39.76%. Material costs were reduced from INR 234,000 to INR 214,000, a savings of 8.54%. The redesign focused on reducing size, parts count and switching to more efficient LED lights.
The document provides a summary of a report analyzing the design for manufacturing and assembly (DFMA) features of an HP Deskjet printer. Key DFMA guidelines considered include minimizing parts, using standard parts, facilitating part handling, and encouraging modular assembly. The report examines the printer's design for automation and assembly, use of plastics, fastening methods, and sheet metal components. Figures are included to illustrate how the printer's design incorporates various DFMA principles such as pyramidal assembly, symmetry, and avoiding part jamming.
Sheet metal operations involve cutting, forming, and finishing processes to manufacture components from thin metal plates less than 5mm thick. Cutting processes like shearing, punching, and blanking apply forces to separate material, while forming processes like drawing, spinning, bending, and embossing shape the metal without cracking. Common sheet metals include steel, aluminum, and titanium used in automotive and aircraft bodies, appliances, and more. Key forming operations are stretching, spinning, bending, and embossing which deform the metal over dies into desired contours.
DFMA -Design For Manufacturing and AssemblySunith Guraddi
The document discusses applications of design for manufacture and assembly (DFMA) principles. It provides examples of how DFMA has been applied to improve products designed for developing world contexts. One example is a redesigned pineapple juicer that had fewer parts, lower production costs, and was easier to manufacture due to applying modified DFMA principles. Another example discusses reducing the part count and assembly time of a stapler through DFMA analysis. The document also outlines DFMA methodologies and principles that were developed to help designers lower costs and improve producibility, such as reducing part count, standardizing materials, and designing for automated production when feasible.
1. Forming is a metalworking process that shapes metal by deforming it without removing material. Common forming processes include rolling, extrusion, forging, and die forming.
2. Joining processes like welding, brazing, and adhesive bonding are used to connect metal components together. Welding involves melting materials to join them, while brazing uses a filler metal below the melting point of the base materials.
3. Machining removes material using tools like lathes, mills, drills and grinders to shape a workpiece. It allows for tight tolerances but incurs significant material removal and waste.
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
This seminar report discusses shell molding, also known as shell mold casting. Some key points:
1) Shell molding uses a resin-covered sand to form molds for casting small to medium metal parts, providing better dimensional accuracy and productivity than sand casting.
2) The process involves creating a pattern, applying a heated sand-resin mixture to form a shell around the pattern, curing the shell, assembling two shell halves, and pouring molten metal to form the casting.
3) Shell molding allows casting of both ferrous and non-ferrous metals for parts requiring precision, such as gear housings and cylinder heads.
4) The sand used is finer
This document discusses various types of casting defects including their causes and remedies. It describes defects such as mismatch, misrun, cold shuts, shrinkage cavities, blow holes, porosity, hot tears, metal penetration, pin holes, swell, drop, and rat tails/buckles. The document explains that casting defects occur due to issues in the casting process involving gases, moulding materials, pouring metal, and metallurgy. Remedies involve modifications to the gating system, pouring process, sand properties, alloy composition and casting design.
Lo #1 design factors in manufacturing processes (sept 2015)Abdulaziz AlSuwaidi
The document discusses design for manufacturing and assembly (DFMA). It provides 11 general principles for DFMA, including minimizing the number of components, using standard parts, designing for ease of manufacturing and assembly, establishing tolerances within production capabilities, using modular designs, and eliminating unnecessary adjustments. Following DFMA principles leads to benefits like shorter time to market, lower production costs, higher product quality, and greater customer satisfaction.
The document discusses tools and equipment used in a sheet metal shop. It describes various hand tools for measuring, marking, cutting, and striking sheet metal. These include rules, squares, calipers, scribes, snips, chisels, and hammers. Bench tools like the straight edge and stakes are also discussed. Machine tools covered are the shearing machine and fly press. Common sheet metal operations like marking, cutting, bending, and joining are summarized.
Roll forming Long parts with constant complex cross-sections; good surface finish; high
production rates; high tooling costs.
Stretch forming
Large parts with shallow contours; suitable for low-quantity production; high
labor costs; tooling and equipment costs depend on part size.
Drawing Shallow or deep parts with relatively simple shapes; high production rates;
high tooling and equipment costs.
Stamping Includes a variety of operations, such as punching, blanking, embossing,
bending, flanging, and coining; simple or complex shapes formed at high
production rates; tooling and equipment costs can be high, but labor costs
are low.
Rubber-pad
forming
Drawing and embossing of simple or complex shapes; sheet surface protected
by rubber membranes; flexibility of operation; low tooling costs.
Spinning Small or large axisymmetric parts; good surface finish; low tooling costs, but
labor costs can be high unless operations are automated.
Superplastic
forming
Complex shapes, fine detail, and close tolerances; forming times are long,
and hence production rates are low; parts not suitable for high-temperature
use.
Peen forming Shallow contours on large sheets; flexibility of operation; equipment costs
can be high; process is also used for straightening parts.
Explosive
forming
Very large sheets with relatively complex shapes, although usually axisymmetric;
low tooling costs, but high labor costs; suitable for low-quantity
production; long cycle times.
Magnetic-pulse
forming
Shallow forming, bulging, and embossing operations on relatively lowstrength
sheets; most suitable for tubular shapes; high production rates;
requires special tooling.
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
The document discusses various metal forming processes used to change the shape of metal workpieces through plastic deformation exceeding the metal's yield strength, including bulk deformation techniques like rolling, forging, and extrusion that involve significant shape changes with lower surface area to volume ratios, and sheet metalworking techniques like bending, drawing, and shearing that are performed on metal sheets or strips with higher surface area to volume ratios. Metal forming is an important manufacturing method that allows for net or near-net shape production, high production rates, profitability, and improved material properties.
Specification of lathe and operating parameterscpandiv
The document discusses the key parameters and specifications of a lathe machine. It describes the main components of a lathe including the head stock, spindle, bed, tail stock, and carriage. It lists the main turning parameters as speed, feed, and depth of cut. It then details five main specifications of a lathe: 1) the length between centers, 2) the height of the centers, 3) the swing diameter over the bed, 4) the swing diameter over the carriage, and 5) the maximum bar diameter.
Design for Assembly (DFA) is a vital component of concurrent engineering – the multidisciplinary approach to product development. You might think it strange to begin by thinking about the assembly before you have designed all the components, but you can often eliminate many parts at the conceptual stage, and save yourself a lot of trouble.
This slideshow provides an introduction to the rules that are used in industry to produce affordable, reliable products. It includes the in-depth analysis of two real-world products subjected to a "product autopsy", detailed in photographs, plus tutor notes and recommendations for additional activities including an assembly game.
+++
Thanks for all the interest shown in this presentation... visit Capacify and leave me a message if you have any questions or comments. Also let me know if you'd like to have me as a guest speaker: the in-class 'ease of assembly game' is always fun.
Metal forming processes involve plastic deformation of materials to shape them. The main bulk metal forming processes are forging, extrusion, and rolling. Forging involves compressing material between dies to impart the die shape. Extrusion uses a ram to force material through a die opening to shape its cross-section. Rolling reduces thickness by compressing material between rotating rolls.
1. The document describes different types of moulds used in plastic injection molding including two plate, three plate, split cavity, side core, and hot runner moulds.
2. A split cavity mould is suitable for moulding components with all-round external undercuts and uses sliding splits, angular lifts, or pins for actuation.
3. A side core or side cavity mould is used for components with local external undercuts and can be actuated via finger cams, dog leg cams, cam tracks, springs, or hydraulics.
This document provides definitions and explanations of various press tools and manufacturing processes. It discusses different types of press tools like molds, jigs, fixtures, and gauges. It defines common press tool operations like blanking, piercing, cutting, forming, and bending. It also provides details on tool elements, materials, and calculations for determining forces, clearances, and capacities involved in press tool operations.
Design for x : Design for Manufacturing,Design for Assembly Naseel Ibnu Azeez
Concurrent engineering is a contemporary approach to DFSS. DFX techniques are part of detail design and are ideal approaches to improve life-cycle cost, quality, increased design flexibility, and increased efficiency and productivity using the concurrent design concepts (Maskell 1991). Benefits are usually pinned as competitiveness measures, improved decision-making, and enhanced operational efficiency. The letter “X” in DFX is made up of two parts: life-cycle processes x and performance measure
This document discusses design considerations for additive manufacturing (AM) with metals. It outlines that while AM provides design freedom, there are still capabilities and limitations to consider. Key factors for metal AM include minimum feature size due to laser spot diameter, avoiding large overhangs and interior holes that require supports, minimizing supports through feature shape and part orientation, and preventing part distortion from residual stress. The document presents a case study comparing a conventional hydraulic manifold design to designs adapted and purposefully designed for AM, showing increased mass savings as the design leverages more AM capabilities. True design for AM allows for an extremely efficient design that consolidates parts and is self-supporting. Understanding AM characteristics is important for successful design.
This document discusses various types of casting defects, their causes, and potential remedies. It begins by defining a casting defect and categorizing them into gas defects, shrinkage cavities, moulding material defects, pouring metal defects, and metallurgical defects. Specific defects discussed include mismatch/mould shift, misrun & cold shuts, shrinkage cavity, blow holes, porosity, inclusions, hot tears/cracking, metal penetration, pin holes, swell, drop, flashes/fins, rat tails/buckles, warpage, cracked casting, bent/twisted casting, open blows & blow holes, fusion, runout, and cracks. For each defect, the causes and possible remedies are outlined.
Fettling is the process of preparing castings for use by removing unwanted material like gates, risers, fins, and imperfections. It involves several steps and techniques. First, dry sand cores are knocked out and gates and risers are removed through chipping, cutting, sawing, or abrasive machining depending on the material. Then fins and other projections on the casting surface are chipped off. Finally, the casting is cleaned through tumbling, shot blasting, or other modern blasting processes to produce a smooth, finished part meeting specifications. Fettling transforms crude castings into functional, high quality components through various removal and cleaning operations.
The document is a spare parts catalogue for a Bajaj Boxer-S motorcycle. It provides instructions on how to use the catalogue, order parts, and understand the part numbering system. The catalogue then presents pictorial indexes and numbered plates that show exploded diagrams of the motorcycle systems and lists the corresponding part numbers.
The document describes a project to build a Recyclebot machine that can recycle plastic waste and create new filament for 3D printers. It includes details on the components, design, and assembly of the machine, which uses an Arduino, motors, and heating elements to melt and extrude plastic into a continuous filament. Diagrams show the wiring and programming of the Arduino to control motor speeds via buttons and an LCD screen. The goal is to improve on an earlier prototype by obtaining a more consistent filament diameter and addressing cooling problems encountered.
Rod, wire and tube drawing is a metalworking process where a rod, wire or tube is pulled through a die to reduce its cross-sectional area and increase its length. It involves applying both tensile and compressive forces. Products include wire, rods, and tubes used in applications like electrical wiring, springs and hydraulic tubing. The process offers close dimensional control, lower costs than rolling or extrusion, and can produce very small cross-sections. Lubrication and annealing are important to control work hardening during multiple drawing passes. Dies are commonly made of alloy steels, carbides or diamond to withstand wear from the process.
This seminar report discusses shell molding, also known as shell mold casting. Some key points:
1) Shell molding uses a resin-covered sand to form molds for casting small to medium metal parts, providing better dimensional accuracy and productivity than sand casting.
2) The process involves creating a pattern, applying a heated sand-resin mixture to form a shell around the pattern, curing the shell, assembling two shell halves, and pouring molten metal to form the casting.
3) Shell molding allows casting of both ferrous and non-ferrous metals for parts requiring precision, such as gear housings and cylinder heads.
4) The sand used is finer
This document discusses various types of casting defects including their causes and remedies. It describes defects such as mismatch, misrun, cold shuts, shrinkage cavities, blow holes, porosity, hot tears, metal penetration, pin holes, swell, drop, and rat tails/buckles. The document explains that casting defects occur due to issues in the casting process involving gases, moulding materials, pouring metal, and metallurgy. Remedies involve modifications to the gating system, pouring process, sand properties, alloy composition and casting design.
Lo #1 design factors in manufacturing processes (sept 2015)Abdulaziz AlSuwaidi
The document discusses design for manufacturing and assembly (DFMA). It provides 11 general principles for DFMA, including minimizing the number of components, using standard parts, designing for ease of manufacturing and assembly, establishing tolerances within production capabilities, using modular designs, and eliminating unnecessary adjustments. Following DFMA principles leads to benefits like shorter time to market, lower production costs, higher product quality, and greater customer satisfaction.
The document discusses tools and equipment used in a sheet metal shop. It describes various hand tools for measuring, marking, cutting, and striking sheet metal. These include rules, squares, calipers, scribes, snips, chisels, and hammers. Bench tools like the straight edge and stakes are also discussed. Machine tools covered are the shearing machine and fly press. Common sheet metal operations like marking, cutting, bending, and joining are summarized.
Roll forming Long parts with constant complex cross-sections; good surface finish; high
production rates; high tooling costs.
Stretch forming
Large parts with shallow contours; suitable for low-quantity production; high
labor costs; tooling and equipment costs depend on part size.
Drawing Shallow or deep parts with relatively simple shapes; high production rates;
high tooling and equipment costs.
Stamping Includes a variety of operations, such as punching, blanking, embossing,
bending, flanging, and coining; simple or complex shapes formed at high
production rates; tooling and equipment costs can be high, but labor costs
are low.
Rubber-pad
forming
Drawing and embossing of simple or complex shapes; sheet surface protected
by rubber membranes; flexibility of operation; low tooling costs.
Spinning Small or large axisymmetric parts; good surface finish; low tooling costs, but
labor costs can be high unless operations are automated.
Superplastic
forming
Complex shapes, fine detail, and close tolerances; forming times are long,
and hence production rates are low; parts not suitable for high-temperature
use.
Peen forming Shallow contours on large sheets; flexibility of operation; equipment costs
can be high; process is also used for straightening parts.
Explosive
forming
Very large sheets with relatively complex shapes, although usually axisymmetric;
low tooling costs, but high labor costs; suitable for low-quantity
production; long cycle times.
Magnetic-pulse
forming
Shallow forming, bulging, and embossing operations on relatively lowstrength
sheets; most suitable for tubular shapes; high production rates;
requires special tooling.
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.
The document discusses various metal forming processes used to change the shape of metal workpieces through plastic deformation exceeding the metal's yield strength, including bulk deformation techniques like rolling, forging, and extrusion that involve significant shape changes with lower surface area to volume ratios, and sheet metalworking techniques like bending, drawing, and shearing that are performed on metal sheets or strips with higher surface area to volume ratios. Metal forming is an important manufacturing method that allows for net or near-net shape production, high production rates, profitability, and improved material properties.
Specification of lathe and operating parameterscpandiv
The document discusses the key parameters and specifications of a lathe machine. It describes the main components of a lathe including the head stock, spindle, bed, tail stock, and carriage. It lists the main turning parameters as speed, feed, and depth of cut. It then details five main specifications of a lathe: 1) the length between centers, 2) the height of the centers, 3) the swing diameter over the bed, 4) the swing diameter over the carriage, and 5) the maximum bar diameter.
Design for Assembly (DFA) is a vital component of concurrent engineering – the multidisciplinary approach to product development. You might think it strange to begin by thinking about the assembly before you have designed all the components, but you can often eliminate many parts at the conceptual stage, and save yourself a lot of trouble.
This slideshow provides an introduction to the rules that are used in industry to produce affordable, reliable products. It includes the in-depth analysis of two real-world products subjected to a "product autopsy", detailed in photographs, plus tutor notes and recommendations for additional activities including an assembly game.
+++
Thanks for all the interest shown in this presentation... visit Capacify and leave me a message if you have any questions or comments. Also let me know if you'd like to have me as a guest speaker: the in-class 'ease of assembly game' is always fun.
Metal forming processes involve plastic deformation of materials to shape them. The main bulk metal forming processes are forging, extrusion, and rolling. Forging involves compressing material between dies to impart the die shape. Extrusion uses a ram to force material through a die opening to shape its cross-section. Rolling reduces thickness by compressing material between rotating rolls.
1. The document describes different types of moulds used in plastic injection molding including two plate, three plate, split cavity, side core, and hot runner moulds.
2. A split cavity mould is suitable for moulding components with all-round external undercuts and uses sliding splits, angular lifts, or pins for actuation.
3. A side core or side cavity mould is used for components with local external undercuts and can be actuated via finger cams, dog leg cams, cam tracks, springs, or hydraulics.
This document provides definitions and explanations of various press tools and manufacturing processes. It discusses different types of press tools like molds, jigs, fixtures, and gauges. It defines common press tool operations like blanking, piercing, cutting, forming, and bending. It also provides details on tool elements, materials, and calculations for determining forces, clearances, and capacities involved in press tool operations.
Design for x : Design for Manufacturing,Design for Assembly Naseel Ibnu Azeez
Concurrent engineering is a contemporary approach to DFSS. DFX techniques are part of detail design and are ideal approaches to improve life-cycle cost, quality, increased design flexibility, and increased efficiency and productivity using the concurrent design concepts (Maskell 1991). Benefits are usually pinned as competitiveness measures, improved decision-making, and enhanced operational efficiency. The letter “X” in DFX is made up of two parts: life-cycle processes x and performance measure
This document discusses design considerations for additive manufacturing (AM) with metals. It outlines that while AM provides design freedom, there are still capabilities and limitations to consider. Key factors for metal AM include minimum feature size due to laser spot diameter, avoiding large overhangs and interior holes that require supports, minimizing supports through feature shape and part orientation, and preventing part distortion from residual stress. The document presents a case study comparing a conventional hydraulic manifold design to designs adapted and purposefully designed for AM, showing increased mass savings as the design leverages more AM capabilities. True design for AM allows for an extremely efficient design that consolidates parts and is self-supporting. Understanding AM characteristics is important for successful design.
This document discusses various types of casting defects, their causes, and potential remedies. It begins by defining a casting defect and categorizing them into gas defects, shrinkage cavities, moulding material defects, pouring metal defects, and metallurgical defects. Specific defects discussed include mismatch/mould shift, misrun & cold shuts, shrinkage cavity, blow holes, porosity, inclusions, hot tears/cracking, metal penetration, pin holes, swell, drop, flashes/fins, rat tails/buckles, warpage, cracked casting, bent/twisted casting, open blows & blow holes, fusion, runout, and cracks. For each defect, the causes and possible remedies are outlined.
Fettling is the process of preparing castings for use by removing unwanted material like gates, risers, fins, and imperfections. It involves several steps and techniques. First, dry sand cores are knocked out and gates and risers are removed through chipping, cutting, sawing, or abrasive machining depending on the material. Then fins and other projections on the casting surface are chipped off. Finally, the casting is cleaned through tumbling, shot blasting, or other modern blasting processes to produce a smooth, finished part meeting specifications. Fettling transforms crude castings into functional, high quality components through various removal and cleaning operations.
The document is a spare parts catalogue for a Bajaj Boxer-S motorcycle. It provides instructions on how to use the catalogue, order parts, and understand the part numbering system. The catalogue then presents pictorial indexes and numbered plates that show exploded diagrams of the motorcycle systems and lists the corresponding part numbers.
The document describes a project to build a Recyclebot machine that can recycle plastic waste and create new filament for 3D printers. It includes details on the components, design, and assembly of the machine, which uses an Arduino, motors, and heating elements to melt and extrude plastic into a continuous filament. Diagrams show the wiring and programming of the Arduino to control motor speeds via buttons and an LCD screen. The goal is to improve on an earlier prototype by obtaining a more consistent filament diameter and addressing cooling problems encountered.
Stihl ts 410 cut off saw service repair manualkfdjkskdmm
This document provides specifications and repair instructions for STIHL trimmers models TS 410 and TS 420. It includes sections on safety, specifications, troubleshooting, repair of major components, fuel system repair, and special tools. Tightening torques are listed for various fasteners. The document instructs technicians on testing, removal and installation of parts, with symbols used to indicate actions.
Stihl ts 420 cut off saw service repair manualfjskekqazdmmem
The document provides service and repair information for STIHL power tools models TS 410 and TS 420. It covers specifications, troubleshooting, maintenance and repair procedures for the various systems and components. The document contains detailed instructions on disassembly, inspection, repair and reassembly of parts like the cast arm, clutch, shortblock, ignition system, rewind starter, fuel system and other components. Safety precautions and tightening torques for fasteners are also provided.
This document provides specifications and troubleshooting information for STIHL models TS 410 and TS 420 cut-off machines. It covers topics such as the engine specifications, fuel system, ignition system, cutting wheels, and tightening torques. The document also details common problems, causes, and remedies for components like the cast arm with guard, rewind starter, and ignition system. Maintenance and repair procedures are provided for shortblock, fuel system, and other parts.
This document provides specifications and repair instructions for STIHL trimmers models TS 410 and TS 420. It includes sections on safety, specifications, troubleshooting, repair of major components, specifications, and tightening torques. The document contains detailed instructions on disassembly and repair of the shortblock, fuel system, ignition system, rewind starter, anti-vibration system, and other components.
Stihl ts 410 cut off saw service repair manualufjjdjjkskemme
The document provides service and repair information for STIHL power tools models TS 410 and TS 420. It covers specifications, troubleshooting, maintenance and repair procedures for the various systems and components. The document contains detailed instructions on disassembly, inspection, repair and reassembly. Safety precautions and tightening torques are also provided.
Stihl ts 420 cut off saw service repair manualfjjsfkskemem
This document provides specifications and repair instructions for STIHL trimmers models TS 410 and TS 420. It includes sections on safety, specifications, troubleshooting, repair of major components, specifications, and tightening torques. The document contains detailed instructions on repairing and replacing parts for the shortblock, fuel system, ignition system, rewind starter, anti-vibration system, actuating levers, and other components. Tables provide specifications for the engines and diagrams illustrate repair procedures.
This document provides specifications and troubleshooting information for STIHL models TS 410 and TS 420 cut-off machines. It covers topics such as the engine, fuel system, ignition system, clutch, and rewind starter. Technical details are given for various components, along with potential problems, causes, and remedies. Tightening torques are specified for many fasteners.
This document provides specifications and repair instructions for STIHL trimmers models TS 410 and TS 420. It includes sections on safety, specifications, troubleshooting, repair of major components, specifications, and tightening torques. The document contains detailed instructions on inspecting and repairing the shortblock, fuel system, ignition system, rewind starter, anti-vibration system, actuating levers, and other components. Tables provide specifications for the engines, fuel system tests, and recommended tightening torques.
Stihl ms 192 t chainsaw service repair manualfjjskekkmemm
This document provides specifications and troubleshooting information for the STIHL MS 192 T chainsaw. It includes specifications for the engine, fuel system, ignition system, and chain lubrication system. It also lists tightening torques for various fasteners. The bulk of the document discusses troubleshooting various problems that could occur with the clutch, chain drive, chain brake, rewind starter, ignition system, carburetor, engine, and chain lubrication system. It provides causes and remedies for common issues.
Stihl ms 192 t chainsaw service repair manualufjjdfjkskekme
This document provides specifications and troubleshooting information for the STIHL MS 192 T chainsaw. It includes specifications for the engine, fuel system, ignition system, and chain lubrication system. The majority of the document discusses troubleshooting various systems, including the clutch, chain drive, ignition system, carburetor, and rewind starter. It provides potential causes and remedies for common problems with each system.
Stihl ms 192 t chainsaw service repair manualfusjejfjskekemm
This document provides specifications and troubleshooting information for the STIHL MS 192 T chainsaw. It includes specifications for the engine, fuel system, ignition system, and chain lubrication system. The document also lists typical tightening torques for various fasteners. Additionally, it provides potential causes and remedies for common problems with the clutch, chain drive, chain brake, chain tensioner, chain lubrication, rewind starter, ignition system, carburetor, and engine.
Stihl ms 192 t chainsaw service repair manualfujjdjjkskemme
This document provides specifications and troubleshooting information for the STIHL MS 192 T chainsaw. It includes specifications for the engine, fuel system, ignition system, and chain lubrication system. The document also lists typical tightening torques for various fasteners. Additionally, it provides potential causes and remedies for common problems with the clutch, chain drive, chain brake, chain tensioner, chain lubrication, rewind starter, ignition system, carburetor, and engine.
Jcb sd70 pt axles service repair manualifkskjdksmem
This document is the service manual for JCB Drivetrain Systems Ltd's SD 70/PT axles. It provides general information, safety guidelines, routine maintenance procedures, and technical specifications. The manual is organized into sections covering hydraulics, axles, brakes, and other components. It aims to guide service engineers through maintenance, repair, and overhaul of axle systems and includes part numbers, torque specifications, and a list of recommended service tools. Replacement parts should match original specifications and all seals and gaskets must be renewed during reassembly.
This document is the service manual for JCB Drivetrain Systems Ltd's SD 70/PT axles. It provides general information, safety guidelines, routine maintenance procedures, and technical specifications. The manual is organized into sections covering hydraulics, axles, brakes, and other components. It includes lists of torque specifications and recommended service tools. Updates to the manual are documented, with changes noted for each issue.
JCB SD70 PT Axles Service Repair Manual.pdff8usejkdmde3
This document is the service manual for JCB Drivetrain Systems Ltd SD 70/PT axles. It provides general information on unit identification, replacement parts, torque settings, and service tools. The manual is organized into sections covering general information, care and safety, routine maintenance, and procedures for specific components like hydraulics, axles, and brakes. It includes records of changes made between issues.
JCB SD70 PT Axles Service Repair Manual.pdfdjkkskmmmdm
This document is the service manual for JCB Drivetrain Systems Ltd's SD 70/PT axles. It provides general information, safety guidelines, routine maintenance procedures, and technical specifications. The manual is organized into sections covering hydraulics, axles, brakes, and other components. It includes lists of torque specifications and recommended service tools. Updates to the manual are documented, with changes noted for each issue.
Jcb sd70 pt axles service repair manualfjskekfsmem
This document is the service manual for JCB Drivetrain Systems Ltd SD 70/PT axles. It provides general information on unit identification, replacement parts, torque settings, and service tools. The manual is organized into sections covering general information, care and safety, routine maintenance, and procedures for specific components like hydraulics, axles, and brakes. It includes records of changes made between issues.
JCB SD70 PT Axles Service Repair Manual.pdff8uejdkdmdm3e
This document is the service manual for JCB Drivetrain Systems Ltd SD 70/PT axles. It provides general information on unit identification, replacement parts, torque settings, and service tools. The manual is organized into sections covering general information, care and safety, routine maintenance, and procedures for specific components like hydraulics, axles, and brakes. It includes records of changes made between issues.
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2. DFMA
DFMA stands on Design for Manufacture and Assembly. DFMA is
the combination of two methodologies; Design For Manufacturing,
which means the design for ease of manufacture of the parts that will
form a product, and Design For Assembly, which means the design
of the product for ease of assembly.
DFMA is used as the basis for concurrent engineering studies to
provide guidance to the design team in simplifying the product
structure, to reduce manufacturing and assembly costs, and to
quantify improvements. The practice of applying DFMA is to
identify, quantify and eliminate waste or inefficiency in a product
design. DFMA is also used as a benchmarking tool to study
competitors’products, and as a should cost tool to assist in supplier
negotiations.
2
3. Introduction
The aim of this project is to identify unnecessary parts in
an assembly and to Specify assembly time and costs.
Reduction and redesign the parts is one task that is
useful to decrease the costs and time of assembling . In
this project, new design and old design have been
compared and the results of development has been
included.
3
4. Objective
-Numbering of parts in the original design
- Redesign of the product (Description, Justification and Sketches)
- Classification of each part for the new design
- Estimated Assembly time for new design
- Design efficiency of new product
- Discussion/Comparison of new with the old design
4
5. Product to be Studied
Toaster
The toaster is typically a small Mechanic-
electric kitchen appliance designed to toast
multiple types of Bread products. A typical
modern two-slice toaster draws from 600 to
1200 Watts and makes toast in 1 to 3 minutes.
There are also non-electrical toasters that can
be used to toast bread products over an open
fire or flame.
5
6. Numbering of parts in the original design
According to the Charts below the number of total parts in original design is : 82
6
Name of assembly:
TOASTER
1 2
The names of parts
PartI.D.number
Numberoftimesthe
operationiscarriedout
consecutively
Front plate 1 1
Small L plate (nut) 2 1
rivet 3 5
L Plate A 4 1
Small Fire proof plate 5 7
Medium Fire proof plate 6 1
Holder of moving system
guide
7 1
Guide 8 1
Spring 9 1
Main plate of moving
system
10 1
Handling plate 11 1
Holder of U shape plate 12 1
U shape 13 1
Plastic part of U plate female 14 1
Plastic part of U plate male 15 1
Name of assembly:
TOASTER
1 2
The names of parts
PartI.D.number
Numberoftimesthe
operationiscarriedout
consecutively
Name of assembly:
TOASTER
1 2
The names of parts
PartI.D.number
Numberoftimesthe
operationiscarriedout
consecutively
Name of assembly:
TOASTER
1 2
The names of parts
PartI.D.number
Numberoftimesthe
operationiscarriedout
consecutively
Heater board left 16 1
Heater board middle 17 1
Heater board right 18 1
Bread holder 19 2
Back plate 20 1
Upper cover 21 1
Wire connector 22 2
welding 23 4
Electrical kit 24 1
soldering 25 2
Timer regulator 26 1
Front cover 27 1
Snap fit 28 4
Stopper switch 29 1
Holder of stopper switch 30 1
Screw M3*6 31 5
Switch 32 1
Nut M3 33 1
Screw M3*20 34 1
connector plate 35 1
Washer 36 2
wire of plug 37 3
screw M3*6 small pitch 38 3
Holder of wire 39 1
Cover of wire 40 1
Screw M3*12 ,different
shape
41 2
Back cover 42 1
Side cover 43 2
Screw M3*12 large pitch 44 4
Screw M3*12 small pitch 45 1
Bottom cover 46 1
Holder of bottom
cover
47 1
Screw M4*6 48 1
Handling plastic part 49 1
0.179 82
Design Efficiency
total
part
7. Eliminated/Changed parts in the NEW design
7
Name of
assembly:
TOASTER
Mustthepartmoverelative
toallotherparts?
Mustthepartbemadeofa
differentmaterials?
Mustthepartbeseparateto
allowaccesstootherpartsit
encloses?
The names of
parts
Name of
assembly:
TOASTER
Mustthepartmoverelative
toallotherparts?
Mustthepartbemadeofa
differentmaterials?
Mustthepartbeseparateto
allowaccesstootherpartsit
encloses?
The names of
parts
Name of
assembly:
TOASTER
Mustthepartmoverelative
toallotherparts?
Mustthepartbemadeofa
differentmaterials?
Mustthepartbeseparatetoallow
accesstootherpartsitencloses?
The names of
parts
1 no yes yes Front plate
0 no no no Small L plate (nut)
0 no no no rivet
0 no no no L Plate A
1 no yes no
Small Fire proof
plate
1 no yes no
Medium Fire proof
plate
0 no no no
Holder of moving
system guide
1 no yes yes Guide
1 yes no yes Spring
1 no no yes
Main plate of moving
system
0 no no no Handling plate
0 no no no
Holder of U shape
plate
1 no yes yes U shape
1 no yes yes
Plastic part of U plate
female
1 no yes no
Plastic part of U plate
male
1 no yes yes Heater board left
1 no yes yes Heater board middle
1 no yes no Heater board right
1 yes no yes Bread holder
1 no yes yes Back plate
1 no yes yes Upper cover
1 no no yes Wire connector
1 no yes yes Electrical kit
1 no no yes brazing
1 yes no yes Timer regulator
1 no yes yes Front cover
0 no no no Snap fit
1 no no yes Stopper switch
0 no no no
Holder of stopper
switch
0 no no no
Screw M3*6
,Large pitch
1 no yes yes Switch
0 no no no Nut M3
0 no no no Screw M3*20
1 no yes no connector plate
0 no no no Washer
1 no yes yes wire of plug
1 no no yes
screw M3*6 small
pitch
1 no no yes Holder of wire
0 no no no Cover of wire
0 no no no
Screw M3*12 ,
shape
0 no no no Back cover
0 no no no Side cover
0 no no no
Screw M3*12
large pitch
1 no no yes
Screw M3*12
small pitch
1 no no yes Bottom cover
0 no no no
Holder of bottom
cover
0 no no no Screw M4*6
1 no yes yes
Handling plastic
part
Orange Color shows Eliminated parts
Green Color shows Changed parts
8. Introduction of Eliminated/Changed parts in the NEW design
8
OLD (Original) Design NEW Design
Front Plate
Small L plate
(nut)
Rivet
L Plate
A
Holder of moving
system guide
Large
fire
proof
Small fire
proof
Small fire
proof
Description:
New Front Plate has changed in the shown position. The Holder of moving system has been removed and replaced with
the folded part as you can see.
The other change is about the fireproof hole, it has standardized with same size according to the other holes.
Due to use just one shape of fire proof (Small size) .
NEW Front Plate
Eliminated Parts
9. Introduction of Eliminated/Changed parts in the NEW design
9
OLD (Original) Design NEW Design
Main plate of
moving system
Description:
New moving system has produced with one sheet and using of folding the sheet instead of attaching the parts by rivet.
NEW Moving System
Eliminated Parts
Handling plate
Holder of U shape
plate
Breads Holder
Rivet
10. Introduction of Eliminated/Changed parts in the NEW design
10
OLD (Original) Design NEW Design
Upper Cover
Description:
New Cover will cover all the parts easily . Also, the assembly time will reduce much.
Stopper switch will assemble in the electrical kit such as regulator and there is no need to any holder or fastener.
NEW Main
Cover
Eliminated Parts
Front Cover
Snap fit Stopper
switch
Holder of
stopper
switch
Stopper
holder
Fastener
Back Cover
Side Covers
NEW Stopper
Switch
11. Introduction of Eliminated/Changed parts in the NEW design
11
OLD (Original) Design NEW Design
Description:
Fastening method for new switch has been changed from Nut and bolt to snap fit.
Switch
Eliminated Parts
Switch
Nut Bolt
Washer
12. Introduction of Eliminated/Changed parts in the NEW design
12
OLD (Original) Design
NEW Design
Description:
The fastening method of Bottom Cover has been changed from old method to 4 screw and 4 snap fit which is fastened
to the main body and the main cover will assemble via Screw M3X12 Large pitch.
Bottom Cover
Eliminated Parts
Bottom Cover
Screw M3*12
small pitch
Holder of bottom
cover
Screw M4*6
Screw M3*12
large pitch
13. Introduction of Eliminated/Changed parts in the NEW design
13
OLD (Original) Design
NEW Design
Description:
The previous design for connector needs 8 welding and 2 connector. However, in the new design it is reduced to 4 welding.
Connector s
Eliminated Parts
NEW
Connectors
Welding
14. Description of each New Designed Parts of Toaster
Acc. To DFA Methods
14
picture
Nameofpart
PartIDNO.
No.ofpart
α
β
Two-digitmanual
handlingcode
Manualhandling
timeperpart
Two-digitmanual
insertioncode
Manualinsertion
timeperpart
Function
Front plate 1 1 360 360 30 1.95 00 1.5
Main role of front plate
is Holding the heater
board and moving
system
Small Fire
proof plate
2 5 180 180 13 2.06 32 4
To avoid connection
between wire and body
15. Description of each New Designed Parts of Toaster
Acc. To DFA Methods
15
picture
Nameofpart
PartIDNO.
No.ofpart
α
β
Two-digitmanual
handlingcode
Manualhandling
timeperpart
Two-digitmanual
insertioncode
Manualinsertion
timeperpart
Function
Cylindrical
Guide
3 1 360 0 11 1.5 32 4
To Control the sliding
movement of moving
system.
Spring 4 1 360 180 20 1.8 34 6
To Return the moving
system in its position
(Returning The breads)
27. 27
Product tree structure for new design
Toaster
1-Main Body 2-Top Cover 3- Bottom Cover 4- Handling Plastic
Part
3- Holder of wire1-Electrical kit
2-Time Regulator 3- Stopper switch
2- Switch
Sub assembly is in
the next page
1- Screw M3*6
1- Screw M3*12
large pitch
28. 28
Product tree structure for new design
Toaster
1-Main Body
2- Cylindrical Guide1- Front plate 3- Spring 4- moving system 5- Heater board left 6- Heater board middle 7- Heater board right 8-Back plate
9- connector10- wire of plug
1- Small Fire
proof plate
1- U shape
Plate
2- Plastic part
of U plate female
3- Plastic part
of U plate male
1- screw M3*6
small pitch
2-Top Cover 3- Bottom Cover 4- Handling Plastic
Part
33. 33
Classification and analysis for each part of the new
design
Name of assembly: TOASTER 1 2 3 4 5 6 7 8 9
The names of parts
PartI.D.number
Numberoftimesthe
operationiscarried
outconsecutively
Two-digitmanual
handlingcode
Manualhandlingtime
perpart
Two-digitmanual
insertioncode
Manualinsertiontime
perpart
Operationtime(sec)
2*[4+6]
Operationcost
(RM)
Figuresfortheoretical
minimumparts
estimation
wire of plug 19 3 20 1.13 92 5 18.39 0.023907 3
screw M3*6 small pitch 20 3 11 1.8 38 6 23.4 0.03042 3
Holder of wire 21 1 31 2.25 0 0 1.5 3.75 0.004875 1
Screw M3*12 long pitch 22 4 11 1.8 38 6 7.8 0.01014 4
Bottom cover 23 1 20 1.8 30 2 3.8 0.00494 1
Top Cover 24 1 30 1.95 0 0 1.5 3.45 0.004485 1
Handling plastic part 25 1 30 1.95 0 1 2.5 4.45 0.005785 1
25
Total
different
part
0.4851
Design Efficiency
38
Total part
235.02 0.305526 38
TM CM NM
34. 34
Discussion – Comparison between New design and Old design
New Design
The formula to calculate the design efficiency :
Design efficiency =(3*NM)/TM
* NM = Theoretical minimum number of parts
According to DFA worksheet, NM= 38
*TM = Total manual assembly time
According to DFA worksheet, TM= 235.02
*CM = Total Cost of Manual assembly
According to DFA worksheet, CM= 0.305
Design Efficiency = (3*38)/235.02 = 0.485
Old Design
The formula to calculate the design efficiency :
Design efficiency =(3*NM)/TM
* NM = Theoretical minimum number of parts
According to DFA worksheet, NM= 38
*TM = Total manual assembly time
According to DFA worksheet, TM= 641.24
*CM = Total Cost of Manual assembly
According to DFA worksheet, CM= 0.833
Design Efficiency = (3*38)/641.24 = 0.178
35. 35
Discussion – Comparison between New design and Old design
No. Criteria Old Design New Design Improvement Percentage
1 Design Efficiency (%) 17.8 % 48.5 % 30.7 % 30.7%
2 Assembly Time (sec) 641.24 sec 235.02 sec 249.62 sec 36.65%
3
Total Assembly Cost
(RM)
0.833 RM 0.305 RM 0.528 RM 36.6%
4
Total Number Of Different
Parts
49 25 24 51%
5 Fasteners 32 12 20 37.5%
36. 36
Conclusion
Based On Design For Assembly (DFA) Guideline, The aims of this method
have been satisfied by:
- Simplifying the assembly sequences, component handling and insertion.
- Standardize the materials , components and subassemblies to increase
economics of scale and reduce tooling costs.
- Reduction of mass production of many parts.
- Taking the advantage of process capability to reduce unnecessary
components of additional processing.
In addition, the new design outcome is available in below.
* Design efficiency has been improved 30.7 %
* Assembly time has been reduced 249.62 sec
* Manual assembly cost has been reduced 0.528 RM
* Total Eliminated different part is 24
39. 39
References
1- Boothroyd, G., Dewhurst, P. & Knight, W. (1994), “Production Design for
Manufacturing and Assembly”, New York: Marcel Dekker, Inc.
2- http://www.investinpahang.gov.my/index.php?rp=comptetitive_wages.pdf
3- Norcross, Eric (2006). "The Cyber Toaster Museum". Toaster.org. The Toaster
Museum Foundation. pp. section "1900–1920". http://www.toaster.org/museum.html.
Retrieved 2008-08-16.
4- http://en.wikipedia.org/wiki/Toaster
5- http://www.dfma.com/software/index.html