DESIGN FOR ASSEMBLY

PRESENTED BY,
V.GANESH
ME CIM
ROLL NO:200821524

DEFINITION
"a process for improving product design for

easy and low-cost assembly, focusing on

functionality and on assemblability
concurrently.
The aim of design for assembly (DFA) is to

simplify the product so that the cost of

assembly is reduced.
It improve quality and reliability, and a reduce

in production equipment and part inventory

DFA GUIDELINES
MINIMIZE THE NUMBER OF PARTS
STANDARDIZE AND USE COMMON PARTS AND

MATERIALS
DESIGN FOR EASE OF FABRICATION
DESIGN FOR PARTS ORIENTATION AND
HANDLING
MINIMIZE FLEXIBLE PARTS AND
INTERCONNECTIONS
DESIGN FOR EASE OF ASSEMBLY
DESIGN FOR EFFICIENT JOINING AND
FASTENING

MINIMIZE THE NUMBER OF

PARTS
Minimize the number of parts:
It reduce the number of assembly

operations.
-Each part should be examined to see if it
can be eliminated or combined with other
parts.
-Two parts need to be separate only if there is
relative motion between them

STANDARDIZE AND USE

COMMON PARTS AND
MATERIALS
Standardize: Standardize PCB

dimensions so that standard fixtures can

be used during wave soldering, cleaning,
etc.
Standardize the location of tooling holes
and board thickness.
When smaller boards suffice, design
them such that multiple quantities can
be cut from a larger standard board.

DESIGN FOR EASE OF

FABRICATION
Select processes compatible with the

materials and production volumes.

Select materials compatible with production

processes and that minimize processing

time while meeting functional requirements.
Avoid unnecessary part features because

they involve extra processing effort and/or

more complex tooling.

DESIGN FOR PARTS

ORIENTATION AND
HANDLING
To
minimize non-value-added manual effort and
ambiguity in orienting and merging parts.

Basic principles are:

-It is stable and self-aligning

-Parts easy to grasp and insert
-Avoid parts that are sticky or slippery
-Design the work station area to minimize the distance
to access and move a part.
-Parts presented in the right orientation
-Avoid parts that can be easily damaged or broken

MINIMIZE FLEXIBLE PARTS

AND
AvoidINTERCONNECTIONS
flexible and flimsy parts such as belts,
gaskets, tubing, cables and wire harnesses
Their flexibility makes material handling

and assembly more difficult and these parts

are more susceptible to damage.
Use plug-in boards and backplanes to

minimize wire harnesses

DESIGN FOR EASE OF

ASSEMBLY
By utilizing simple patterns of movement

and minimizing the axes of assembly

Complex orientation and assembly

movements in various directions should

be avoided
Assembly should proceed vertically with

other parts added on top and positioned

with the aid of gravity

DESIGN FOR EFFICIENT JOINING

AND FASTENING
Threaded fasteners (screws, bolts, nuts and

washers) are time-consuming to assemble

and difficult to automate.
Where they must be used, standardize to

minimize variety and use fasteners such as

self threading screws and captured washers
Use integral attachment methods (snap-fit)

DESIGN PRINTED CIRCUIT

BOARDS FOR ASSEMBLY
Minimizing component variety
Standardizing component packaging
Using auto-insertable or placeable components
Using a common component orientation
Component placement to minimize soldering

"shadows
Selecting component and trace width that is within
the process capability
Using appropriate pad and trace configuration and
spacing to assure good solder joints and avoid
bridging
Using standard board and panel sizes
Using tooling holes
Establishing minimum borders, and avoiding or
minimizing adjustments.

PCB DESIGN PROCESS

DESIGN PROCESS FLOW

1.Requirements allocation and

functional partitioning

It defining the configuration of a new PCA are

taken long before detailed circuit design and

layout activities begin.
Performance requirements are based on what

the end product , how it is to do it, and under

what conditions it will be expected to fulfill its
intent.

Allocation of functional elements

of a system/product.

PCA PARTITIONING
Constraints for partitioning:
1. Circuit performance
considerations may involve
- Length of signal connections
-Segregation of digital and analog
circuitry
-Power distribution
-Component power dissipation

3. Producibility and testability

needs may include
- Circuit density (components and
interconnections)
- Ability to identify and isolate circuit
faults
- Component packaging and mounting
- Characteristic tolerances (circuit
parameters and physical features)

2. Physical constraints may include

- Size and shape of the space
allocated for PCAs
-Area needed for components and
interconnections
- Quantity of inputs and outputs
required
- Environmental conditions
- Heat removal

4. Maintainability requirements may

have to be
-accommodate
- Ease of PCA removal and
replacement
- Access for adjustment and test (in
place and out of the product)
-Provision of features for repair and
modification

2.CIRCUIT DESIGN
First identify the inter operability of the

functions
Determine how signals are to flow between

them and functions external to the PCA.

The next step is to define how these functions

are to be physically accomplished by selecting

part types, logic families, and use of customdesigned

Functional flow diagram

A functional flow diagram shows the

relationships of critical hardware and

software entities on the PCA.
It describes the internal interfaces that are
required for system operation.
An example of a functional flow diagram.

LAYOUT DESIGN RULES

General rules and guidelines to be used when designing a family or

group of similar PCAs for a system . they are

Component types and logic families (specific part numbers, values,
tolerances)
Circuit design rules (loads, terminations, drivers, power distribution,
clock signal distribution, grounding, EMI protection, part derating)
Placement of parts and circuitry (proximity, signal coupling, orientation)
Interconnection layout (min/max trace dimensions, parallel conductors,
stubbing, impedance, order of signal and ground/power layers)
Mechanical design (board dimensions, construction, material,mounting
hardware, thermal management, environmental protection,
identification marking)
Location of signal and test connectors and key connector pin
assignments (power/ground, clock lines)
Test and maintenance (fault isolation, test/adjustment accessibility)

Mechanical design
Mechanical design of a PCA defining its

physical form and structure.

This includes establishing the assembly

outline (i.e., length, width, height), circuit

board dimensions and how it is mounted, the
method of interfacing it to other circuitry,
access for removal/replacement, test and
adjustment, heat removal, and
environmental protection.

3.Mechanical Design
3.1 Board Configuration
3.2 Support Structure and Mounting

Hardware
3.3 Heat-Sink Design
3.4 Connectors and Test Points
3.5 Height Restrictions and Keep-Out
Areas

3.1 Board Configuration

The primary constraints are

-The size and shape of a circuit board

-Where the assembly is to be installed
-How it is to be mounted, and the amount
and type of circuitry it will contain
Board construction (i.e., material, number
of layers , stackup) is mainly influenced by
component and interconnection density
and circuit performance requirements.

3.2 Support Structure and

Mounting
Hardware
Support
Structure
It provide protection against
excessive vibration and shock inputs and
include adequate heat-removal capabilities.
Mounting Hardware
It perform the way the PCA is to be
mounted, the location of the I/O connectors,
alignment features, and the mechanical
extraction and replacement method

3.3 Heat-Sink Design

It provide internal cooling mechanisms
Three modes of heat removal from

components are conduction, convection, and

radiation
Heat sinks are available that use one, two,
or a combination of all three modes
The objective of designing a PCA for optimal
heat dissipation is to ensure that the
maximum allowable temperature of
components and board material is not
exceeded during operation.

Examples of heat sinks for improving thermal dissipation of PCA

3.4 Connectors and Test

Points
Connector selection is usually made based on the
following factors:
- The quantity and type of signal and power connections
required
(current, voltage, impedance controlled, shielded)
-The space available for these connections (density)
-How a PCA physically interfaces with the system (plug-in,
permanent mount)
-Circuit interfaces with the system (motherboard, hard wiring,
flex, directly to adjacent assembly)
-Board construction (single/double-sided, multilayer)
-Type of component mounting (through-hole, surface-mount)
-Environment (temperature, humidity)
-Reliability (number of insertions/withdrawals)
-Application (military, space, industrial, commercial

Test points
Test points are required to be accessible

while a PCA is mounted in the system, then

they are usually soldered to the boards
surface near its edge
It based on their location and purpose
If a small quantity is needed (8 to 10),
individual points can be soldered to the
board
Larger quantities can be obtained as
multipont units and soldered to the board in
a single operation

3.5 Height Restrictions and

Keep-Out Areas
Assemblies will restrict the height of

components or hardware mounted on a PCA

Even it prevent parts from being installed in
specific areas of the board.
These restrictions may be applied to either or

both sides of an assembly and must be

respected when laying out a board.
It providing clearance for insertion and

withdrawal of an assembly

4 .Board Layout
Layout Design Rule:
A designer should have a well-defined and documented

set of design rules and guidelines in hand before starting

the physical layout effort.
These rules generally are derived from a number of

preestablished requirements and conditions, including

-Circuit performance
- Types of components included in the circuit
- The system operating environment
- Manufacturing and test processes
- Reliability and maintainability
- The circuit board construction and materials
- Cost and schedule limitations

REFERENCE
PRINTED CIRCUIT ASSEMBLY DESIGN

LEONARD MARKS , JAMES A.

CATERINA
McGraw-Hill Publication