Professional Documents
Culture Documents
Que: 02 Which Factor determine the choice of Material? Explain Any Two in Brief? (GTU-IMP)
→ Appropriate selection of material is significant for the safe and reliable functioning of a
part or component.
→ Engineering materials can be broadly classified as “metals such as” iron, copper,
aluminum, and their alloys etc., and “non-metals such as” ceramics , polymers ,
natural materials (e.g. wood, cotton, flax, etc.), composites (e.g. carbon fibers) etc.
→ Each of these materials is characterized by a unique set of physical, mechanical and
chemical properties, which can be treated as attributes of a specific material.
→ In particular, the selection of a specific engineering material for a part or
component is guided by the function it should perform and the constraints imposed
by the properties the material.
→ The problem of selection of an engineering material for a component usually
begins with setting up the target Function, Objective, Constraints, and Free
Variables.
→ Following Factors which would be consider during Materials selections:
1. Function of Component
2. Objective of component manufacturing
3. Free Variables of materials
4. Materials Index
5. Performance Of Equations
6. Properties of Materials
7. Cost of Materials etc.
8. Machinability Of Materials:
9. Availability of Materials:
10. Interchangeability of Materials
1. Function of Component:
→ The Function refers to the task that the component is primarily expected to
perform in service – for example, support load, sustain pressure, transmit heat,
etc.
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→ Development of a Material Index (M) for an intended service includes the following
steps.
1. Initial Screening of Engineering Materials.
2. Identification of Functions, Constrains, Objectives and Free Variables.
3. Development of a Performance Equation.
4. Use constraints to eliminate the free variable(s) from the performance
equation and develop the material index.
5. Rank a suitable set of materials based on the material index.
4. Cost of Materials:
5. Machinability Of Materials:
6. Availability of Materials:
7. Interchangeability of Materials
→ Market Share and profitability are the Major determinants of the success of any
organization.
→ The Factors that influence and improve the competitive edge of company are Unit
cost of product, quality, and Lead time.
→ Concurrent engineering (CE) has emerged as discipline to help achieve the
objectives of reduced cost, batter quality, and Improve delivery performance.
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→ CE means that the design and development of the product, the associated
manufacturing equipment and processes, and repair tools and process are handled
concurrently.
→ Concurrent engineering also known as “Simultaneous engineering, is a method of
designing and developing products, in which the different stages run
simultaneously, rather than consecutively.
→ It decrease product development time and also the time to market, leading to
improve productivity and reduced cost.
1. Tools for concurrent Engineering:
2. DFM
3. DFA
4. Teguchi method for robust design
5. Group Technology
6. FMEA
7. Value Engineering etc…
→ Initially two of those can be outlined here;
(a) DFM
(b) DFA
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4. Reduced Mass
5. Improve serviceability
6. Batter quality
7. Reduced logistic time
8. Reduced time to market launching
9. Less production problem etc..
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Conclusion:
→ Using DFMA tool in concurrent engineering has benefits of :
1. Reduce time to market
2. Reduced Press shop machinery and die stamping investments
3. Reduced indirect cost
4. Improve rack logistics
5. Reduced setup and increase productivity
→ Implementation of concurrent engineering in design and product development
should be done for the benefit of industries.
Que: 03 What is Poka-yoke? Write status and functions of Poka-yoke? Also write seven steps
(OR) What is meaning of Poka-Yoke? Which are seven steps to be followed by Poka-Yoke
Attainments? (GTU-IPM)
Definition:
Objective:
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Why Poka-Yoke:
→ Poka-Yoke was developed from Toyota Motors as a tool to achieve Zero Defects.
→ The process of Zero Defects is known as “Mistake Proofing” or “Fail-Safe”
→ By taking over repetitive tasks or actions that depend on vigilance or memory,
Poka-Yoke can free workers time and mind to pursue more value added
activities.
Purpose of Poka-Yoke:
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Eliminate of Waste:
→ The 5’S system eliminates Waste in the workplace making it easy to identify
abnormal conditions.
→ CAP Do approach also used to Eliminate the waste
Check ►Act► Plan ►Do ►Check
Check: What is the waste?
Act: Find root causes?
Plane: Poka-Yoke, Kaizen, Continuous Improvements.
Do: Implement Poka-Yoke & Measure Result.
→ Lean practice does not allow extra inventory to compensate for scrap.
→ Lean ideology focuses on speed…&…Speed cannot exist when defects and rework
prevail.
→ Cost pressure don’t tolerate continued mistakes :- Scrap, Rework, lateness
At Most Importantly:
→ Our Customers rightfully expect “Defect free product” and “Tradition won’t
provide 100% defect-free products.
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Steps of Poka-Yoke:
Step: 04 observed the process and detail the steps that differ from from the
standard.
Step: 06 Identify the mist ake-proof device necessary to prevent the defect.
Show the team the poka-yoke hints and examples of poka-yoke devices.
Que: 04 What are the advantages of applying Design for Manufacture and Assembly (DFMA)
(OR) What is DFMA? State its tangible and intangible benefits. Also write DFMA principles.
(OR) What is design for manufacture and assembly? Write three main activities of DFMA.
Definition:
→ The term “design for manufacture”(or DFM) means_____ the design for the ease
of manufacture of the collection of parts that form the product after assembly
→ “Design for assembly” (or DFA) means the design of the product for the ease of
assembly
→ Design for manufacture and assembly (DFMA) is a combination of DFA and DFM..
→ It is concurrent engineering team approach
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→ The best result occur, when DFMA used in the product conceptual stage
DFMA provides a systematic procedure for analyzing a proposed design from the
point of view of assembly and manufacture.
This procedure results in simpler and more reliable products that are less
expensive to assemble and manufacture.
In addition, any
Reduction in the number of parts in an assembly produces a snowball effect
on cost reduction because of the drawings and specifications that are no longer
needed the vendors that are no longer needed, and the inventory that is eliminated.
DFMA is used for three main activities:
1. 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 the improvements.
2. As a benchmarking tool to study competitors’ products and quantify
manufacturing and assembly difficulties.
3. As a should-cost tool to help control costs and to help negotiate suppliers
contracts.
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There is a much better opportunity to meet predicted cost schedule and quality
targets, When the manufacturing process data is captured early.
1. Reduced –
- Production Cost
- Defects
- Reworks
- Assembly time
2. Improve Reliability
3. Shorter development schedules and reduce cycle times
4. Batter Quality
5. Development of robust product design
6. Batter supplier product integrations
7. More effective risk managements
DFMA Principal:
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Que: 05 What is six sigma? Explain two key methodologies of six sigma. (GTU)
1. DMAIC :
→ DMAIC is used for projects aimed at improving an existing business
process.
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DMAIC Methodology:
1) Define:
2) Measure :
→ Measure key aspects of the current process and collect relevant data.
3) Analyze:
→ Analyze the data to investigate and verify cause and effect relationship
→ Determine what the relationship are and attempt to ensure that all
factors have been considered.
→ Analyze and determine root cause of the defect under
investigation.
4) Improve:
5) Control:
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2. DMADV:
→ DMADV is used for projects aimed at creating new product or process
design.
DMAIC Methodology:
1) Define:
→ Define design goals that are consistent with customer demands and the
enterprise strategy.
2) Measure :
3) Analyze:
4) Design:
5) Verify:
→ Verify the design, set up pilot run, implement the production process
and hand it over to the process owner(s).
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Que: 06 What is lean? List any five lean principles. State the benefits of using lean
Manufacturing. (GTU)
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