DFMA - Serviceability.pptx

Service is defined as:
occupation or function of serving;
to perform services for:
to repair or provide maintenance for,
to perform any of the business functions auxiliary
to production or distribution.
Design for Serviceability (DFS)

To stay competitive, a company
must look at all elements of
customer satisfaction
To be profitable, a company
must consider the total product
life cycle costs
accomplish
these goals by
serviceability
Why

Incorporate serviceability
early in their designs to
deliver a product that is
efficiently serviceable.
By the time of concept formulation, 70% of the
life cycle costs of a product are committed
Product is efficiently serviceable
When

How
A step-by-step methodology
Analyze opportunities and
best design directions
using simple checklists,
incorporate basic design features.
more serviceable designs

• Location
• Simplification
• Standardization
• Design for Repair
• Life Factors
• Diagnostics
Design Elements

Review the Design’s Serviceability
• Location - Accessibility, Obstructions, Orientation, Visibility
• Simplification - Minimization, Clustering, Labeling, Intuitive
• Standardization - Components and Sub-components, Fasteners and
Connectors, Tools
• Design for Repair - Ergonomics, Service Aids, Obvious Operation, Safety
• Life Factors - Reaction, Mechanical Stress, Environment, Location,
Component Retirement
• Diagnostics - Indicators, Accessibility, Procedures

Location Checklist
Obstructions
– Do other components have to be removed for visibility, service, or removal?
– Is there potential for damage of nearby components in the service process?
– Can you offer more space by moving, hiding, or shrinking the component or
adjacent component?

Oil Fill Cap/Tube
LOCATION CHECKLIST
•Accessibility, obstruction – Cap and
tube access is blocked on three
sides.

Oil Filler Tube
LOCATION CHECKLIST
•Accessibility, obstruction – Cap
and tube access is blocked on
three sides.

LOCATION CHECKLIST
•Visibility – visibility is
poor because the tube
opening is the same color
as the surrounding area
when the cap is removed.
Oil Filler Tube

Oil Stick
LOCATION CHECKLIST
•Accessibility, obstruction – Dip
stick access is blocked on three
sides.

LOCATION CHECKLIST
•Visibility – visibility is poor
because the tube opening is
the same color as the
surrounding area when the
dip stick is removed.
Oil Stick

LOCATION CHECKLIST
• Accessibility – Oil filter is not easily
accessed for replacement.
• Obstruction – Oil filter is accessed only
through a narrow slot and degree of
rotation with a tool is restricted.
• Orientation – Oil filter is oriented for
oil drainage but not for the safety of the
operator.
• Visibility – Engine side threads for the
oil filter are not visible.
Oil Filter

Power Steering Pump Reservoir
LOCATION CHECKLIST
• Accessibility, obstruction – Power
Steering reservoir is easily accessed.
Removal is open for about 360 degrees of
turn.
• Visibility – Power Steering reservoir is
clear and obvious.

LOCATION CHECKLIST
• Obstruction – The reservoirs have
obstructions around them that interfere
with fluid pour. They are also located
towards the center of the vehicle.
Coolant & Washer Fluids

LOCATION CHECKLIST
•Obstruction – The reservoirs
have obstructions around them
that interfere with fluid pour.
They are also located towards
the center of the vehicle.
•Visibility – The labeling and
color of the reservoirs make
them distinctive given the color
of the surrounding parts.

Orientation
– Do the service steps require multiple re-orientations?
– Can any fluids be retained in the process?
– Will Service expose other parts to contamination?
Visibility
– Can the component be clearly seen for diagnosis
and/or removal/installation?
– Does the layout look BIC (Best in Class)?
Location Checklist

Minimization
– Have you reduced part count with DFA (Design for Assembly)?
– Have you reduced or eliminated user adjustments?
Clustering
– Is the component located where expected?
– Is the component grouped with like functions?
Simplification Checklist

Simplification Checklist
Labeling
–Does the component have clear instructions?
–Is the component color coded?
Intuitive
–Is the disassembly obvious?

Oil Fill Cap/Tube
SIMPLIFICATION CHECKLIST
•Labeling – cap does have clear
labeling

Oil Stick
•Clustering – the oil filling tube is not
local to this dip stick.

Oil Stick
•Labeling – handle has clear
labeling

• Clustering – The reservoir is
located near the master
cylinder
• Labeling – The labeling on
the cap should be painted.
Also, there are too many
letters so the character size is
quite small making the text
hard to read.
Master Cylinder

Master Cylinder
• Labeling – The reservoir has no
labeling to tell its function when
the cap is removed.

Labeling – The reservoir cap has clear,
colored labeling.
Labeling – There is no label on the
reservoir itself. Also, there seems to be no
indication as to the correct fluid level, only
a warning not to go past it.

• Labeling – The labeling of the reservoir
caps are clear and colored.

•Clustering – The two reservoirs
are located next to each other,
have a similar appearance but
contain incompatible fluids.
•Labeling – The color and shape
similarity of the reservoirs make
them indistinctive with the caps
removed. The bottles should have
labels.
Coolant & Washer
Fluids

•Labeling – The labeling of the
reservoir caps are clear and
colored.

•Clustering – The two reservoirs
are located next to each other,
have a similar appearance but
contain incompatible fluids.
•Labeling – The color and shape
similarity of the reservoirs make
them indistinctive with the caps
removed. The bottles should have
labels.

Oil Filler Tube
DESIGN FOR REPAIR CHECKLIST
•Ergonomics – Cap rotation and oil
pour is not easily accomplished.

Ergonomics – Cap rotation and oil pour is not easily accomplished.
Two of three possible positions for oil refill demand an incorrect bottle position.
Oil Filler Tube

Oil Filler Tube
Oil refill in correct bottle position but there are no directions on
the bottle or on the vehicle to demonstrate this.

Oil Stick
•Ergonomics – Dip stick reinsertion is
not easily accomplished.

•Ergonomics – Dip stick
reinsertion is not easily
accomplished.
Oil Stick

• Ergonomics – Surrounding obstructions
make filter replacement difficult.
• Safety – Oil flow during removal and
when the filter is removed is not
controllable.
Oil Filter

Service aids – The cap is tethered to the
bottle.

Oil Fill Cap/Tube
•Ergonomics – Cap rotation and
oil pour is not easily
accomplished.

This brake fluid reservoir will look
different in each car, but the premise is
still the same. The line level will show you
if you’re needing to add more fluid, or if
you’re fluid is the wrong color.

This is just an example of a coolant reservoir. You can see the two
notches on the side as indicators of your coolant level. If your engine is
hot, you won’t get an accurate reading- and you’ll probably burn your
face or hands off. (okay, not completely off, but it will hurt!)

This is an example of a
power steering reservoir,
and while most cars won’t
look exactly like this- you
can still see the min and
max line indicators. You
should rarely need to
replace/fill your power
steering fluid. Even some
car manuals say you never
have to replace it- but a
good judge is the fluid’s
color!

What do you notice
in this LOGO?

Materials Extraction
Guideline
Avoid or minimise use of hazardous, toxic or in
any other way environmentally unfriendly
materials.
Toxic and reactive highly hazardous chemicals
which present a potential for a catastrophic
event at or above the threshold quantity

Reason
Guideline Materials Extraction
Avoid or minimise use of hazardous, toxic or
in any other way environmentally unfriendly
materials.
Decrease toxic and/or
hazardous emissions in
later life stages and/or
decrease harmful
emissions during
production

Guideline
Avoid materials with a high
energy content (Aluminium)

Guideline
Avoid materials with a high
energy content (Aluminium)
Reason
Decrease the amount of energy used
during extraction and/or production

Guideline
Use materials which are renewable,
recyclable and/or recycled, minimise
use of thermosets or mixed polymers

Guideline
Reason
Use materials which are renewable,
recyclable and/or recycled, minimise
use of thermosets or mixed polymers
Decrease the amount of non-renewable materials to
be extracted from the earth

Guideline
Design products in a way that reduces
material use, use better design
instead of over- dimensioning

Guideline
Reason
Design products in a way that reduces
material use, use better design
instead of over- dimensioning
Decrease the amount of materials to be extracted from
the earth

Guideline
Reason
Design for minimum waste production
during production
Decrease amount of material wasted during
production

Guideline
Minimise number of
materials used

Minimise number of
materials used
Increase recyclability and ease the
sorting process
Guideline
Reason

Guideline
Reason
Production
Decrease amount
of harmful
gaseous, liquid or
solid emissions
during production

Guideline
Reason
Production
Decrease amount of raw material
required and the amount of waste
created by production processes

Lithium-ion and Lithium polymer batteries are generally found in
mobile telephones, laptop computers, E bikes etc
Lithium metal batteries
Are these
Recyclable ?

Guideline
Transport, distribution and packaging
Optimise efficiency transport modes following these rules:
transport by container ship or train is preferable over
transport by lorry transport by air is to be avoided

Guideline
Reason
Decrease energy use and emissions
from transport and avoid
environmentally harmful ways of
transport (such as flight)

Guideline
Minimise long distance transport by maximising
work with local suppliers and markets

Guideline
Reason
Increase efficiency of transport

Guideline
Minimise amount of packaging material and the
number of (virgin) materials in the packaging.
A single strawberry in
a plastic lidded cup?
Display fruit and
vegetables

Guideline
Reason
Decrease amount of material needed for packaging
reduce contamnalia to aid the recycling of materials
Pears in protective nets
Several in a clear bag, then carry them home in
yet another plastic bag

Guideline
Maximise use of refillable or reusable
containers where appropriate
Over-wrapped snacks
The outer box, plastic wrap,
plastic tray, inner box, inner
plastic wrap and paper
covering.

Guideline
Reason
Decrease amount of material needed for packaging by
re-use of containers
Plastic-sealed magazines ?

Guideline
Avoid use of non-appropriate
materials for packaging such as,
PVC and Aluminium
Toothpicks sheathed in plastic
How about toothpicks in a jar?

Guideline
Reason
Use
Decrease the amount consumables used by a product
during its life

Guideline Use
Design for easier maintenance and repair by: indicate opening
instructions for cleaning and/or repair indicate parts for maintaining
by colour codes make location of wear detectable on parts make
vulnerable parts easy to dismantle and replace

Guideline
Reason
Upgrade
o Strive to increase reparability and upgrading if it is economically feasible
o Make sure that parts that need to be upgraded are easily identified, separated
and repaired or replaced e.g. in easily accessible modules
o Use a modularized design to allow for upgrading
o Try to incorporate in the module design instructions for replacement or
upgrading

DFMA - Serviceability.pptx

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