This document shows how product complexity can be reduced by minimising number of parts with examples

1. 1. Identify and study five examples of product improvement by standardisation ?
•Example 1: SMART PLUG
SmartPlug saves you from using expensive timing elements or supplementary control elements
because SmartPlug makes the sensor smarter. Connected with SmartPlug, your sensor takes over
additional control functions. As a timer, counter or inverter, for monitoring frequency, or for on-delay.
Every variant of SmartPlug can be cascaded so that counters and timers, can be combined.
•Example 2: Packing of tobacco products
Plain standardised packaging means all cigarette packs will look the same. They are packaged
in a standard shape without branding, design or a logo:
 Health warnings will remain
 Brand names will be in standard type face, colour and size
 The shape, colour and method of opening the packet will be standardised
 The duty paid stamp will remain with covert markings that show the pack is not counterfeit
 Cigarette packs are also standardised in size and colour
Standardised packaging would apply to all tobacco products including rolling tobacco and cigars.
•Example 3: DVD PLAYER
They all use the same technology, just have different brand names on the final product and some
have better features
Example 4: Ford Motor Company (standardisation of workers)
Henry Ford, 20th-century mass production pioneer and founder of the Ford Motor Company, used
one worker to do one job in the assembly process in one way. Ford standardized workers’
methods so each could complete his step in the process quickly and efficiently. Ford's
standardized worker's methodology also made it possible to train replacement workers quickly. An
assembly line wouldn't shut down because a single worker was absent; a new one could be hired
and trained, avoiding interruptions in production.

2. 2. Identify five products and improve the ease of assembly
• Example 1: Motor Drive Assembly
Design Concept for Motor Drive Assembly
Modified Design for Assembly

3. ASSIGNMENT- 2
• Example 2: IRON BOX
Original Design Improved design
In improved design the three parts body filler, body holder and the support device are combined
to be new single part in order to reduce the part count and improve ease of assembly
•Example 3:
FIG 2: Proposed design of pressure recorder

4. Example 4:
After the design is modified and the number of parts to be assembled are reduced.This
helps to improve ease of assembly
Example 5:
Using snap fit instead of screw as fasteners reduces the number of parts to be assembled
Example 6:
Eliminating the need for fasteners on the left model, new model (right) in the assembly of
the adapter to the base part is redesigned

5. 3. Identify products and reduce the complexity of design
Example 1:
Fig.1 fig.2
•The linkages shown in fig.2 are too complicated, and will take a longer time to
be machined and Manufactured. Also, the two movable joints only provide
rotation about one axis
• The design shown in fig.1 replaces the conventional linkage design, and gives
it more flexibility, more degrees of freedom and hence close to ideal degrees of
rotation, thus increasing the utilization of the lamp as per user requirements
Example 2:
A conventional joint construction (left) has a very simple design. A monolithic solution (right) has a
more complex design
Example 3: Bottle cap opener