ED 302 Design for X. Overview. How can we emphasize manufacturing, performance issues throughout the development process?

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1 ED 302 for X Overview Dr. G Saravana Kumar gsaravana@iitm.ac.in (daytime) How can we emphasize manufacturing, performance issues throughout the development process? Planning Planning Concept Concept Development Development System-Level System-Level Detail Detail Testing Testing and and Refinement Refinement Production Production Ramp-Up Ramp-Up 1

2 Checklist for Embodiment and Detail Checklist for Embodiment and Detail 2

3 Checklist for Embodiment and Detail Phase 2 -, Engineering and Product Validation Itterative approach separated with prototyping and testing Generate the Identify performance specifications Create Subsystem Solutions Alpha Prototype Test and evaluate Develop the Develop the design based on Alpha testing Engineered improvements Beta Prototype Testing Refine the Refined Working Prototype Testing 3

4 Tools and Methodologies Computer Aided Solid Modeling Conventional Analysis and calculations Computer Aided Analysis Kinematic Analysis Finite Element Methods Methodologies: Failure Mode Effects Analysis for Manufacturing and Assembly Outputs Engineered design with specifications Validated product Validate through: Analysis Prototype Test 4

5 The IBM Proprinter A Case Study The Proprinter is a dot matrix printer designed and manufactured by IBM in the 1980's. The Proprinter was designed to be a low cost printer for use with the IBM personal computer (IBM PC) Why Build Proprinters in the U.S.? IBM: Leader in PC market Least expensive IBM printer cost 5000$ Low cost printer market was completely controlled by Japan A manufacturing analysis has shown that IBM could not build a competitive low cost printer IBM Decides to Build the Proprinter Existing low-cost printers consisted of 150 to 200 parts. Only about 50 of these were working parts. Rest were rivets, screws, fasteners, cables, belts, pulleys, and springs. These parts are impossible to assemble in an automated lane, so they had to be put together manually. This high labor content made assembly possible only overseas were labor rates are low. ing for Automated Assembly (DFAA) was the only option available. Because robots cannot handle screws, parts should snap together. Parts should be eliminated when possible and carry multiple functions to reduce assembly time and complication. 5

6 Other design objectives Speed: designers set a target of 200 characters per second for the Proprinter( 3 times the existing speed). Near-letter quality printing, Front-feed single sheet paper handling, Automatic pin feed paper handling. Reliable printer without need for maintenance. Cost constraint of $500 per printer. The product vision follows simple DFAA ( for Automated Assembly) rules ( for Assembly and for Manufacturing) and encouraged the design team to design a product that could be manufactured using robots. for X for Manufacturing for Assembly for Production for Maintenance for Environment (including Recycling/Disposal) for Quality FMEA Prototyping and of Experiments 6

7 for Manufacturing and Assembly DFM/A are descriptions for activities undertaken by the design team to improve the efficiency of the design with respect to manufacturability They run from: Generalized rules of thumb Software driven analytical tools DFM Estimate the manufacturing costs. Reduce the costs of components. Reduce the costs of assembly. Reduce the costs of supporting production. Consider the impact of DFM decisions on other factors. 7

8 Elements of the Manufacturing Cost of a Product Manufacturing Cost Components Assembly Overhead Standard Custom Labor Equipment and Tooling Support Indirect Allocation Raw Material Processing Tooling DFM Method Proposed Estimate the Manufacutring Costs Reduce the Costs of Components Reduce the Costs of Assembly Reduce the Costs of Supporting Production Consider the Impact of DFM Decisions on Other Factors Recompute the Manufacturing Costs N Good enough? Y Acceptable 8

9 DFA - Reduce the Costs of Assembly for Assembly (DFA) index Integrated Parts (Advantages and Disadvantages) Maximize Ease of Assembly Consider Customer Assembly for Production Some general guidelines Consider Available Facilities Consider Available Tools Consider Available Worker Skills Employ Simplicity Standardize 9

10 for Maintenance Some general operations Service, to maintain the intended condition Inspect, to monitor and assess the actual condition Repair, to recover the intended condition Failure repair Preventive repair Some general guidelines Prevent damage and increase reliability Avoid possibility of errors during assembly, disassembly and startup Simplify service procedure Make the results of servicing checkable Simplify inspection procedure Service, inspection and repair documents as well as labels Availability of components and spares 10

11 for Environment (including Recycling/Disposal) Some general guidelines Consider Energy Consumption Consider Restricted Materials Consider Material Minimization Acoustics Recycling Refurbished Sales DFE Solutions Throughout Product Life 11

12 DFE Solutions Throughout Product Life for Quality (Robust ) Planning Planning Concept Concept Development Development System-Level System-Level Detail Detail Testing Testing and and Refinement Refinement Production Production Ramp-Up Ramp-Up Robust Concept and System Robust Parameter Quality efforts are typically made here, when it is too late. 12

13 Failure Mode Effects Analysis Some errors have high probability but are easy to detect and guard against Some errors have low probability but are very hard to detect. A structured methodology for identifying and reducing failures. of Experiments Modeling Understanding relationships between design parameters and product performance Understanding effects of noise factors Optimizing Reducing product or process variations Optimizing nominal performance 13

14 Robust s A robust product or process performs correctly, even in the presence of noise factors. Noise factors may include: parameter variations environmental changes operating conditions manufacturing variations Who is the better target shooter? X Y 14

15 Who is the better target shooter? X X can simply adjust his sights. Y Y requires lengthy training. for X for Manufacturing for Assembly for Production Environment (including Recycling/Disposal) for Quality FMEA Prototyping and of Experiments for Cost for Durability for Corrosion for Aesthetics for Ergonomics for ****** 15