42629 lecture 3 pt3

Integrated Product Development

IPD - Concurrent engineeringThomas J. Howardhttps://sites.google.com/site/thomasjameshowardhomepage/[email protected]

Unless otherwise stated, this material is under a Creative Commons 3.0 Attribution–Share-Alike licence and can be freely modified, used and redistributed but only under the same licence and if including the following statement:

“Original material by Thomas J. Howard for course 42629 – Innovation and Product Development Department of Mechanical Engineering, The Technical University of Denmark”

Thanks to Thorkild Ahm, IPU for providing DfA samples

https://sites.google.com/site/thomasjameshowardhomepage/

mailto:[email protected]

2012Original material by Thomas J. Howard for course 42629 – Innovation and Product Development Department of Mechanical Engineering, The Technical University of Denmark

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Concurrent Engineering

Designing the Product and Production simultaneously

MarketProduct

Production

Business

2012Original material by Tim C. McAloone adapted for course 42629 – Innovation and Product Development Department of Mechanical Engineering, The Technical University of Denmark

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What are DFX methods?

DFX: Design For X• where ‘X’ is an important aspect related to the product lifecycle,• and ‘Design For’ means to design the product in order to improve

Important DFXs:DFE – Design for the EnvironmentDFM – Design for ManufacturabilityDFA – Design for AssemblyDFS – Design for ServiceabilityDFC – Design for ChangeoverDFD – Design for DisassemblyDFQ – Design for Quality (QFD method)


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Cost

Qu

alit

y

Flexib

ility

Ris

k

Tim

e

Effi

ciency

En

vir

onm

ent

Design for …

Df – CostDf – AssemblyDf – ManufacturingDf – UsabilityDf – QualityDf – ServiceabilityDf – EnvironmentPlatform development…

[Score model from Olesen, 1992]

DfX and Life Cycle


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Trade-offs… require knowledge of all DFX-areas

Petrol useage [km/L]

Acceleration ability 0-100km

[s]

Weight [g]

User-experienced Q

Amount of components [n]

Assembly speed [s]

Manufacturing costs [kr]

Running costs [kr]

[From McAloone,

Inspired by Allen Ward]

Design for Serviceability (DFS)“Don’t make ‘em start all over”


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DFS improvements...

Original Redesign


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Think about service in advance...Headlamp bulb replacement example

This side up

[Case from Winston Knight, Rhode Island]


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Here’s what it takes...Disassemble: Reassemble:

2 Screws (left side light)Cover (left side light)Cable connectorHousing (left side light)2 Screws (right side light)Cover (right side light)Cable connectorHousing (right side light)14 Screws (radiator panel)Radiator panel4 Screws (headlamp trim)Headlamp trimHeadlamp glassHeadlamp bulb

Headlamp bulbHeadlamp glassHeadlamp trim4 Screws (headlamp trim)Radiator panel14 Screws (radiator panel)Housing (right side light)Cable connectorCover (right side light)2 Screws (right side light)Housing (left side light)Cable connectorCover (left side light)2 Screws (left side light)

32 items 32 items


Design for Manufacture and Assembly (DFMA)“That’s all well and good but how are we gonna make it?”


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Boeing Helicopter(formerly McDonnell Douglas Helicopter Systems)

Apache Longbow Helicopter Redesign

Estimated savings

$1.3 billion over life of program

One aircraft per month

Increased to five per month



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Anti-Flair Bracket Assembly for the Boeing Longbow Apache Helicopter

Source: Alfredo Herrera,1998 International DFMA forum, Newport, RI

Before

5 sheet metal parts19 rivets20 tools needed32 hours manufacturing

After

1 high-speed machined part2 hours manufacturing10% less weight45% less costTooling cost virtually eliminated


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Jump Seat for Extended Cab Pick-up

Base line analysis105 separate parts

Total assembly time estimate 1440 s, excluding paint application

Many tubular parts and small tabs hand welded during assembly

Many reorientations of product during assembly



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Jump Seat for Extended Cab Pick-up

Phase 1 ProposalObjective to reduce parts and assembly time while maintaining essential functions

Most welding steps eliminated

Cams and rolling components replaced by slides guided in slots

Part count reduced to 19 , with 5 major subassemblies

Assembly time estimate reduced to 258 s

A more radical Phase 2 proposal that loses some functionality was also developed



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DfMA – Housing corner piece

[Andreasen, Kähler & Lund, 1988 – “Design for Assembly”]

Lønstrup


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DfA – Water sprinkler



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DfA – ‘Stacking’



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GNT Automatic


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DfA – Plastic integration


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DFMA exercise

motor

2 motor screws

sensor

2 standoffs -steel - machined

cover - sheetsteel - welded 4 small

screws

base - machinedaluminum

bushing -plastic

end plate -sheet steel

2 small screws

2 bushings -powder metal - brass

small screw



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DFA Analysis data sheet



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Re-designed solution

motor

2 motor screws

sensor

small screw

base - nylon

cover -injection molding



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Questions

?

42629 lecture 3 pt3

Technology