EVALUATION OF PRODUCT ASSEMBLABILITY USING LUCAS HULL METHOD

Transcription

1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA EVALUATION OF PRODUCT ASSEMBLABILITY USING LUCAS HULL METHOD Thesis submitted in accordance with the requirements of Universiti Teknikal Malaysia Melaka for the Bachelor Degree of Manufacturing Engineering in Manufacturing Management By NURAZHANI BIN ABAS Faculty of Manufacturing Engineering May 2008

2 UTeM Library (Pind.1/2007) UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS TESIS* JUDUL: EVALUATION OF PRODUCT ASSEMBLABILITY USING LUCAS HULL METHOD SESI PENGAJIAN : 2007/2008 Saya NURAZHANI BIN ABAS mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syaratsyarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: (TANDATANGAN PENULIS) Alamat Tetap: LOT 1635 LRG. JUARA 1D TAMAN SUKMA, PETRA JAYA KUCHING SARAWAK. Cop Rasmi: (TANDATANGAN PENYELIA) Tarikh: 02 MEI 2008 Tarikh: * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

3 DECLARATION I hereby, declared this thesis entitled Evaluation of product assemblability using Lucas Hull method is the results of my own research except as cited in the references. Signature Author s Name Date : : :.. Nurazhani bin Abas 2nd May 2008

4 APPROVAL This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Management). The members of the supervisory committee are as follow: Mr. Nik Mohd Farid Che Zainal Abidin (PSM Supervisor) Official stamp:.. Date :..

5 ABSTRACT This report was provided to explain the result of study on the evaluation of product assemblability using Lucas Hull method. The focused on Lucas Hull Design for Assembly (DFA) method that used as a guideline for design assembly product. This study covers the importance, benefits, limitations and any related issues that occurred in Lucas Hull DFA method. The data was obtained from several techniques and methodologies such as further study on DFA tool, analysis product and implemented evaluation using TeamSet software. The TeamSet software provides result of product assemblability. In addition, based on result, several components of product was redesign to improve the product assemblability. i

6 ABSTRAK Laporan ini disediakan bagi menerangkan keputusan berkenaan kajian penilaian keupayaan cantuman produk berdasarkan teknik Lucas Hull. Tumpuan terhadap teknik rekabentuk untuk cantuman Lucas Hull yang digunakan sebagai tatacara untuk rekabentuk produk cantuman. Kajian ini meliputi kepentingan, kelebihan, had dan berkenaan isu yang terdapat pada teknik rekabentuk untuk cantuman Lucas Hull. Data diperolehi dari teknik dan tatacara seperti belajar dengan lebih lanjut mengenai rekabentuk untuk camtuman, produk analisis dan mengaplikasikan penilaian menggunakan perisian TeamSet. Keputusan penilaian keupayaan cantuman produk diperolehi dari perisian ini. Tambahan pula, berdasarkan keputusan, beberapa komponen dari produk akan direka semula untuk menaiktarafkan keupayaan cantuman produk tersebut. ii

7 DEDICATION Firstly, thank to Allah S.W.T for the opportunity to finish this project. I owe this project and my true happiness to my beloved parent. Since the day I started joining this University until today, they are very caring and supporting for me. For my adored parents: Abas bin Tomik Temah binti Abang And for my respected sisters: Nurazah Aishah binti Abas Nurazierah Athirah binti Abas iii

8 ACKNOWLEDGEMENT Assalamualaikum warahmatullahi wabarakatuh. First and foremost, Alhamdulillah, thank God for giving me a chance to complete my Final Year Project. I would also like to thank my beloved parents Abas bin Tomik and Temah binti Abang, my siblings and my friends especially Nurul Anis Nadia bt Zahar for giving me their support and motivation during my good and hard times. Thank you to all UTeM lecturers and staffs involved in this project especially my supervisor, En. Nik Mohd Farid Che Zainal Abidin. Not forgetting all technicians at UTeM that had been helpful in providing information needed to make this project a success. Without all of you, I could not have achieved what I have today. Last but not least, my special thanks to all of my colleagues that always giving assist for me to finish this research. Without all of you, I would not be where I m today. Thank you again. Thank you. Wassalam. Nurazhani bin Abas iv

9 TABLE OF CONTENTS Abstract... i Abstrak... ii Dedication... iii Acknowledgement... iv Table of Contents... v List of Figure... ix List of Table... xi List of Abbreviations... xii 1. INTRODUCTION Background Introduction Problem Statement Objectives Scope of Study Benefit of Study Report Outline LITERATURE REVIEW Introduction History Assembly Assembly Method Manual Assembly Hard Automation Assembly v

10 Robotic Assembly Design for Manufacture and Assembly (DFMA Guideline of DMFA Simplify and Reduce Number of Parts Standardize and Use Common Parts and Material Design for Fabrication Process Capability Mistakeproof product design assembly Orientation and Handling Interconnections and Flexible Parts Design for Ease Assembly Joining and Fastening Modular Product Automated Production Design for Assembly (DFA Methodology of DFA Design for Manufacture Methodology of DFM Boothroyd Method Hitachi Method Lucas Hull Method Theory of Lucas Hull Method Evaluation Procedure Assemblability Analysis Assemblability Factor TeamSet Software Design for Assembly DFA Methodology Functional Analysis Handling Analysis vi

11 Assembly Sequence Flowchart (ASF) Manufacturing Analysis Design to Target Cost (DTC Failure Mode Effect Analysis (FMEA) Quality Function Deployment (QFD) Concept Convergence METHODOLOGY Introduction Methodology Flowchart of Project Analysis Product Evaluation Assemblability Procedure of DFA Design Improvement Evaluation of Design Improvement RESULT AND DISCUSSION Introduction Analysis of product Assembling feature Result Assembly Sequence Flowchart Evaluation Result Result Analysis Analysis Summary Design Improvement Redesign Snap fit Eliminate Parts Evaluation Result analysis vii

12 4.5.4 DFA Analysis Summary Result Comparison Discussion Initial Design Analysis on Assembly Product Design Efficiency Factor Manual Insertion and Fastening Fastening Choice CONCLUSION Introduction Result Recommendation Product Design Teamset Software Further Study REFERENCES APPENDICES A B Gantt Chart for PSM I Gantt Chart for PSM II viii

13 LIST OF FIGURE Main schema of OPM Entities in CPM Geometrical features in part handling Other features affecting parts handling Incorrect geometry can allow part to jam during insertion Relative costs of different assembly method Production ranges for each type of assembly method Examples of design features affecting assembly DFA flowchart Example of PBS Part Assembly Window Functional analysis window Handling analysis window Primary process in manufacturing analysis Materials selection for manufacturing analysis a 3.1b Methodology flowchart for PSM I Methodology flowchart for PSM II Example of product assembly Liaison diagram TeamSet window; DFA icon choose Product structure Screw fastening area ix

14 a 4.5b a 4.7b a 4.9b a 4.11b Snap fit area Self locating area Design for assembly flowchart for initial iron dry design Design for assembly flowchart for initial iron dry design Analysis result for initial design of iron dry Potential improve area Potential improve area Potential eliminate part Design for assembly flowchart for new design of iron dry Design for assembly flowchart for new design of iron dry Analysis result for new design of iron dry Effect of part thickness on handling time Effect of part size on handling time Rearrangement of connected items to improve assembly efficiency and reduce costs Holding down and combination factor Parts that thickness and small in size x

15 LIST OF TABLE Lucas DFA method Manual Handling Analysis Lucas DFA method Manual Fitting Analysis Toolkits in TeamSet software Symbol in ASF Components of iron dry Group of components and fastening process Assembly problem Group of components and fastening process for new iron dry design Result comparison Design change Advantages and disadvantages of different kinds of fastening technique xi

16 LIST OF ABBREVIATIONS AEM ASF ConCon CPM CSM DFA DFM DFMA DTC FMEA MA OAM PBS PDM PSM QFD Assembly Evaluation Method Assembly Sequence Flowchart Controlled Concept Convergence Core Product Model Component Supplier Management Design for Assembly Design for Manufacture Design for Manufacture Assembly Design to Target Cost Failure Mode Effect Analysis Manufacturing Analysis Open Assembly Model Product Breakdown Structure Product Data Management Projek Sarjana Muda Quality Function Deployment xii

17 CHAPTER 1 INTRODUCTION 1.1 Background Introduction Manufacturing industry is one of the fields that play an important role in gaining a profit for country. It is also important in evolution of technology for human kind. Manufacturing is being studied hundred of years ago. Many achievements have been done regarding manufacturing field. In manufacturing, there were many processes that involved. One of the process was assembling. Assembly was an old process that does manually by human at ancient time. Time by time, assembly process evolved so more efficient and reducing time of production. Nowadays, assembly is done manually by human and automatically by robot. Assembling part is one of important process in manufacturing. Final assembly is the moment of truth (Charles H. Fine, MIT) (Whitney, 2004). Although this process is infamous but it is process that human always do. Assembling part play a major role in manufacturing field. Assembly is to bring or come together or to fit or put together. In manufacturing, assemble means putting two or more parts together to make one product. The product must be functioning to use by human. Assembling parts also involved efficiency and time. The part that easily to assembled can reduce time and may lead to make mass production. This easily assemble also can reduce assemble cost. 1

18 A method that known as Design for Assembly (DFA) was proposed to help designers considered assembly problem. Design for assembly is a process by which products are designed with ease of assembly in mind. Most products are assembled manually and the DFA method for manual assembly is the most widely used. Each product has their own assembleability than to determine weather the product good in assembly or not. The development of DFA has lead to development of Design for Manufacture (DFM). DFM is design that considered for manufacture. The DFA and DFM have strong relationship that gives benefit to manufacturing field. The manufacturing field has faced many challenges and the survival in this field is by used effectives tools and infrastructure. The uses of DFA and DFA have been made widely and these tools have lead to increasing in new design development. 1.2 Problem Statement Nowadays, one of the major processes in manufacturing field was assembling parts. Many companies that involved manufacturing want to reduce cost of their product make mass production and increase quality and reliability of the product. In assembling the product, there is opportunity for defective component and an assembly challenge. Delay in components assembly and miscommunication with manufacturers can lead to delays and cost overruns. Many ways to reduce the cost have taken such as reduce time assembling and simplified assembling process. Tolerance accumulation becomes more significant and may require additional design and manufacturing to produce an acceptable assembly. 2

19 1.3 Objectives 1. To identify improvements on product assemblability using LucasHull method 2. To evaluate product assemblability using LucasHull DFMA software. 3. To redesign the product and reevaluate its assemblability using LucasHull method. 4. To identify process in assembling parts of the product. 5. To compared product assemblability before and after improvement. 1.4 Scope In this project, parts of the product will be identified and analyzed. Assemblability of the product will be evaluated. Evaluation of the product is using LucasHull DFMA software. This evaluation is used to redesign and improved product structure. Redesign is on part of product and this will lead to redesign the product itself. It is also to compare product assemblability before and after improvement. All the process of assembling parts that regarding for this project is discuss in this project. 1.5 Benefit of study In this project, there are many benefit and advantages can get from this study. The knowledge that gains from this project is useful in manufacturing industry field. The benefits that get from this study are: a. Gain more and further knowledge about manufacturing process especially assembling process. b. Can enhance in using software that regarding assembling process. c. Able to generate idea and can solve problem that occur in the project. d. Enable to analyze product and may able to outcome new design of product. e. The result or finding from this study can be implementing by industry to improve manufacturing activities. f. As a reference for future study. 3

20 1.6 Report outline This report are consist five chapters. Chapter 1 generally about introduction of project which covers the assembly process and tools that used in this project. This chapter also includes problem statement, objectives, scope of study, benefits of study, report outline and report structure. Chapter 2 is discussing about literature review where theory and further knowledge are included in this chapter. Further about assembly process and tools that used is discuss in this chapter. Software used for this project will also be described in this chapter. Chapter 3 is about methodology in doing this project. The method that use is analysis, evaluating using software, improvement and outcome solution. In chapter 4, the data that collected are analyzed. The data will be evaluated and recorded. In this chapter also mentioned the result from analysis and evaluation result. This chapter also includes the proposing in improvement of product. The discussion about whole project is discussed in this chapter. Lastly in chapter 5, it is conclusion about project. This chapter will summarize all about this project and benefit that gain from the project. 4

21 Chapter 2 LITERATURE REVIEW 2.1 Introduction This chapter will discuss about assembly process, tools of assembly and TeamSet software that use in this project. Study and research has been done to gain better knowledge regarding to this project. Further knowledge that gets from study and research is used as guidance to enable proceeds with the project. The project is based on product assembly and features in the assembly to make the assembly process easy to handle. In assembly, the method of assembly and type of assembly are mention and analysis of assembly doing during early stages. This to ensure potential problem can identify that may affect product performance. Designer must know the difficulty of assemblability and know weather the part can be assembled or not. The assemblability and analysis can be made by evaluating assembly. Assembly evaluation is to recognize design quality for assemblability or feasibility. Assembly evaluation is very important to gather information regarding assemble and feature of assemble. The information is very important because it is can used as a key to improving design quality for better assemblability. The information also can use as a guide for further research in assembly process. There are many way for assembly evaluation. There are many model and tools that are used in making the evaluation. The model and tools are developing to make the application assembly process used to make manufacture product design for a better quality. One of the tools that used was Lucas Hull method. Teamset software that based on Lucas Hull method can used to evaluate product assemblability. 5

22 2.2 History The first guideline that widely used for assembly in manufacturing is Design for Assembly (DFA). Design for Assembly is develop by Boothroyd and Dewhurst in This guideline has resulted in several automated assembly evaluation and advisory system. The DFA is earlier tools that used regarding assemble product. Then this pioneer tool has encouraged to development of other tools and model. The other tools of DFA are Lucas Hull method. Nowadays many other tools and model had been develop as a feature to face nowadays challenge in manufacturing field especially assemble product. The developing of model is to unify and integrate product or assembly information. The new model that develops to support tools of assembly such as Core Product Model (CPM) and Open Assembly Model (OAM). The model overview all aspect in assembling from parts to process of assembled. This overview can help to analyzed product assemble more easy. To make the tools easy to used, software regarding tools are develop. Figure 2.1: Main schema of OPM Source: Zha, Foufou, Sudarsan and Sriram, (2004) 6

23 Figure 2.2: Entities in CPM Source: Zha, Foufou, Sudarsan and Sriram, (2004) The software will help the designer to applied tools of assembly easier and more effective. In this project, the software that used is TeamSet software that based on Lucas Hull method. The software is used to evaluate product assemblability and measure the performance regarding assembling of product. TeamSet is a software package which helps designers produce better products at minimum cost and in shorter time. This software has been used widely to applied DFA tool. Toolkits that include in this software are Quality Function Deployment (QFD), Manufacturing Analysis (MA), Failure Mode Effects Analysis (FMEA), Design to Target Cost (DTC) and Controlled Concept Convergence (ConCon). 2.3 Assembly Assembly is process that combine one or more parts to other parts to make product. Process of assembly is old process that used by manufacturer to make product. Assembly is an important process because it is last process to make functional product. Beside that, assembly can influence cost to manufacture of product. Many guideline about assemble have been develop to ensure quality of product and at the same time can reduce cost to 7

24 manufacture the product. Process of assembly involved many method and process capability. At ancient time, human used this process manually and supported by using tools. Nowadays, assembly can be doing using robot and it is do automatically Assembly method There are three major methods in the process of assembly. This method was widely applied in the industrial field. These three methods were effectively used and manufacturer usually used only one or two method at the same time. Each of the method has its own advantages and disadvantages. The major method was manual assembly, hard automation assembly and robotic assembly Manual assembly This is the old and ancient process of assembly. Although it was an old method, but it still widely used by certain manufacturer or company to assemble component. This manual assembly is handled manually by human. This kind of method based on human skill and human support by tool to manual assembly. Good assembly of product is because of skillful handling by human. Unskillful of this process can lead to low quality product. This method also usually takes more time. This manual assembly still chooses by manufacturer as a method to assembly because it is low cost. In manual assembly, there are many processes that involved making assemble to possible to maintain and good of assembling product can be made. The design product that to be assembled must be analyzed of it parts to detect the criteria of assembling. To joining two parts, there is many ways that can be made but the best ways must be choose to ensure the parts can be join easily and problem of joining can be avoid. The manual assembly can be dividing to two major processes which are handling the assembly and insertion and fastening of assembly. 8