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Abstract
This report is to review the manufacturing & assembly of the car windshield wiper
blade and improve it or replace it with a new design. The old design is dismantled and
fully understands the manufacturing steps and assembly steps. The cost to
manufacture the wiper is briefly calculated. Improvement design and new design of
the wiper is made and following the Design for Manufacturing rules. The new design
is chosen by using the Weighted Objective Method and the critical review of the
redesign product is made.
Table of Contents
Abstract
1
Review of existing design
1.1
Design efficiency
1.2
Suitability for assembly
1.2.1
Exploded view of existing design
1.2.2
Sequence of assembly
1.2.3
Assembly process
1.2.4
Labor cost
1.2.5
Human error
1.2.6
The types of assembly process
1.2.7
Overview of current design
1.3
Breakdown of manufacturing and associated costs
1.3.1
All parts
1.3.2
Manufacturing process
1.3.3
Percentage of net shape manufacturing
1.3.4
Finishing process
2
Designs for manufacturing
3
Development of new design
3.1
Design efficiency
3.1.1
Problem of existing design in assembly
3.1.2
Problem of existing design in manufacturing
3.2
Gather information
3.3
Design for manufacture and associated costs
3.3.1
New Design
4
Critical review of new design
Superstructure
Big
Claw
Small
Claw
Pivot Pin
Rubber
element
Flexor
Figure 1
1.2.2 Sequence of assembly
1st step - 1 Rubber element + 2 Flexor
2nd step - 4 Small claw (left & right) + 2 big claw (left & right) + 4 pivot pin
3rd step - 1 Superstructure + 3 Pivot pin + 2 big claws
4th step - Pivot blocks + Latch release + all components
1.2.3 Assembly process
1st process - Slide in the 2 flexor to the element.
2nd process - Small claws combine with big claw by press in a pivot pin.
3rd process - Small claws and big claws clamped slide into the element.
4th process - Put in the superstructure with the claws by press in pivot pins.
5th process - Put a bigger pin at the middle of superstructure and assembly with
the latch release and pivot block.
2
Assembly process of current design is not suitable because many of this process
can use machine instead of human to reduce human error and cost of labour, can
produce more product in short period.
2.
3.
Comparisons with
Existing Design (b)
4.
5.
6.
7.
8.
No
No
Yes
No
Yes
9.
Yes
Comparison
Criteria
Score
Weight
Score
Design 2
Score
Weight
Score
Cost
DFM Rules
User Friendly
Environment
Appearance
Manufacturing
Assemble
Material
Total
DFM Rules
Design
Numbers of rules
Score
1
2
User Friendly
Design
HFE
Safety
Total
1
2
http://forum.autolanka.com/topic/14639-frameless-wiper-re-fill/
http://www.ecvv.com/product/2631869.html
10
http://www.agcoauto.com/content/news/p2_articleid/272
11