PRODUCT

LIFECYCLE
MANAGEMENT
P R E S E N T ATI O N
D AT E : M A R C H 0 9 , 2 0 1 6

DESIGN FOR
ASSEMBLY (DFA)
OMKAR PRADEEP KHANVILKAR (ME-231)

BRIEF
Introduction
Definition
Comparison of Assembly Methods
Benefits of DFA

Methods of DFA Analysis

Case Study

INTRODUCTION
Definition
Ease of Assembly

Assembly Methods
Manual Assembly
Fixed or Hard Automation
Soft Automation or Robotic Assembly

Benefits
Fewer Parts
Reduction in Assembly Time & Cost
Reduction in Total Product Cost

METHODS OF DFA ANALYSIS

Hitachi Method: The Hitachi Assembly Evaluation Method (AEM);
Boothroyd & Dewhurst Method: The B&D - DFA Evaluation Method;
Lucas DFA Method: The Lucas DFA Evaluation Method.

C A S E S T U DY

Lucas Method to design

Automotive Fuel Intake
Cover

CASE STUDY
1.

Rivet: allows the rotation of the fuel cover, before the

DFA analysis union of 4, 5, 6 e 7 parts with part 3.

2.

Double action torsion spring, keeps the fuels cover

open during the feeding procedure, and facilitates its
closure.

3.

Fixed hinge, fixes the fuel cover to the car body.

4.

Movable hinge, allows connection between 5, 6 and 7

parts with 1;

5.

External cover

6.

Internal cover allows plastic lock attachment and

increases fuel intake cover stiffness.

7.

Plastic lock, allows electrical or manual locking of the

fuel cover, depending on the car version.

CASE STUDY

Assembly Functional Analysis before DFA of part

4

Feeding analysis for part 4 before DFA

CASE STUDY

Fitting analysis for part 4

CASE STUDY
The mobile interface increases in order to allow
the direct union with the external cover.
The external cover thickness was increased to
support the new structural requirement.
The flange at the external cover was changed to
allow electrical resistance spot weld.
The plastic lock was changed for a new metal
one assembled also by spot weld.
The hemming process was replaced with a spot
weld.
The riveting force over the rivet was changed to
increase the friction between the mobile and
fixed interfaces.

CASE STUDY

CASE STUDY
Performance indexes for the fuel intake cover

Before

After

CASE STUDY

Performance indexes for all parts of the fuel intake cover after DFA
application

SUMMARY
DFA is a powerful tool for product development, since the conceptual phase
of the product development.
An efficient application of its statements allow gains in terms of reduction in
the number of parts necessary, without compromising the functionality of
the product, and also allows a cost reduction, and in many cases an
improvement in the product quality.

REFERENCES
Websites:
http://deed.ryerson.ca/~fil/t/dfmdfa.html
https://en.wikipedia.org/wiki/Design_for_assembly
https://
www.academia.edu/3734072/Product_Design_Improvement_by_Design_for_Assembly_DFA_Method_A_Ca
se_Study_on_Steam_Iron

Notes:
Design for assembly case: automotive fuel intake cover, Open Access Library, Volume 6 (12) 2012
me349_dfa_lecture_notes.pdf, Wise
Design for assembly : a critical methodology for product reengineering and new product development,
Mohan V . Tatikonda, CFPIM

THANK YOU