08 Design For Manual Assembly

PEMP
PDN 505
Session 8
Design for Manual Assembly
Lecture delivered by
Sudhindra MSRSAS
Prof. M. N. Sudhindra Kumar

Professor MSRSAS-Bangalore
M.S Ramaiah School of Advanced Studies - Bangalore
PEMP
PDN 505
Session Objectives
At the end of this session the delegate would have understood
The different methodology DFMA
Advantages of DFMA
Standardization of Parts
Effects of parts shape in the assembly
Guidelines of DFA
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Design guidelines of assembly
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Session Topics
Advantages of DFMA
Guidelines and Advantages
Standardization
Effect of parts on Handling Time
DFA Guidelines
Choice of Assembly Method
Design Analysis For Manual Assembly
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Design Guidelines for Insertion And Fastening
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Advantages of DFMA
1 . Systematic Approach
DFMA provides a systematic procedure to analyze a proposed
design from the point of view of a assembly and manufacture resulting in
simpler and more reliable products which are less expensive to
manufacture and assemble.
2 . Team Work
DFMA tool encourage dialogue between designers and
manufacturing engineers encouraging teamwork to get benefits of of
simultaneous or concurrent engineering.
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3 . Astounding Savings
Saving outweigh cost of effort and result in more reliable
products.
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Guide lines/Advantages:
1.2 Develop a Modular Design
A module is a self contained component with a standard
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interface to other components of a system.

Allows standardization of diversity.
Allows Customization by using different combinations of
standard components.
Resists obsolescence and shorter redesign cycle.
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1.3 Use Standard Components

Stock item is always less expensive than a custom made item.
Standard Items
Require less lead time.
More reliable because characteristics and
weaknesses are well known.
Order any quantity at any time.
Easier to repair and replacements are easier to
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find.
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1.4 Design Part to be Multifunctional
Combine functions wherever possible.
Example:
Spring and Structural member.
Electrical conductors and Structural member.
Chassis as an electrical ground.
Heat sink and a structural member.
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1.5 Design parts for multiple use.

Many parts can be designed for multi use,
Example:
A mounting plate can be used to mount a variety of
components.
Spacer can be used as an axle, lever, standoff etc.
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1.5.1 Sort all manufactured or purchased goods into two groups
a) Parts which are unique to a particular model (I.e. crank shafts,

housing etc)
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b) Parts which are generally needed in all products and /or models (Shafts,
flanges, bushings, spacers, gears etc)
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Standardization
Standardization lays down the definitive solution of a repetitive technical or
organizational problem with the best technical means available at the
time. It is therefore a form and economic optimization limited by the
time factors.
Standardization determines the best solution of recurring problems
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Standardization is the systematic unification by those concerned of

material and immaterial things for the benefit of the community. It
should not lead to the economic advantage of an individual case. It
stimulates rationalization and ensures quality in the business, technology,
science and administration. It serves the safety of people and things as
well as the improvement of quality in all of life. Furthermore it serves a
purposeful ordering of the information in the specific standardization
area. Standardization takes place on regional, national and international
levels.
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1.5.2 Divide each group into categories of similar parts (Part
families)
Create multiuse parts by standardizing similar parts.

To standardize, seek sequentially
1) To minimize the number of part categories.
2) To minimize the number of variation within each
categories.
3) To minimize the number of design features within each
variation.
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1.6 Design parts for ease of fabrication

Design using least costly materials that just satisfies functional
requirements (Including style and appearance) such that material
waste and cycle time are minimized.
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1.7 Avoid separate fasteners
In automation applications separate fasteners are difficult to feed,
tend to jam, require monitoring for presence and torque and require
costly fixturing, parts feeder and extra stations. In manual assembly
cost of driving a screw can be 6 to 10 times the cost of the screw.
Try to use tabs, snap fits.
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1.8 Maximise compliance

Non compliance (misalignment, tolerance stack up) can lead to use of
excessive assembly force, leading to sporadic automation failures and / or
product unreliability.
Factors affecting rigid part mating include part geometry (Accuracy,
consistency), stiffness of assembly tool, stiffness of jigs / fixtures holding
the parts, friction between parts.
Designed in compliance features include use of generous tapers /
chamfers for easy insertion, use of leads and other guiding features, use of
generous radii wherever possible.
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1.9 Minimise assembly directions
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All parts to be assembled in one direction. Extra

directions mean wasted time and motion, more transfer
stations, inspection stations and fixture nests.
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1.10 Minimize handling
Position is the sum of location (x,y,z) and orientation (,,).

Position costs money.
Parts to be designed to make position easy to achieve and the
production process should maintain the position once it is achieved.
Increased number of orientation increase equipment expense,
increase quality risk and slow feed rates and slow cycle times.
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To Assist easy orientation

- Parts to be symmetrical
- If polarity is important accentuate asymmetry, create obvious
asymmetry.
- Provide features to help guide and locate in proper position.
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1.10 Minimize handling
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To facilitate robotic part handling

- Provide large smooth top surface for vacuum pick-up.
- Provide inner hole for spring.
- Provide feature of sufficient length for a gripper pick-up.
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Effect of Symmetry on
the time required for
part handling
(grasp,move,orient and
place):
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Times are average for two

individuals and shaded areas
represent nonexistent values
of the total angle of symmetry
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Effect of part thickness on handling time:
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Effect of part size on handling time:
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Effect of symmetry on handling time when parts nest or tangle

severely(Disentangling time is not included)
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Effect of clearance on
insertion time:
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Effects of restricted
access and and
restricted vision on
initial engagement of
screws:
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Manual Assembly
Small parts all within easy

arm reach-workers sitting
Large parts require major

body motions for acquisition
mechanical assistance
may be required
1.very low volumeclean room or worker

at beginning of
learning curve
4.modular assembly center

largest part shorter then 35 in.
5. Custom assembly
layoutproducts assembled one-at-a-time
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2.bench assembly
repetitive work
3.multi station assembly
6.flexible assembly layoutproducts may be assembled

in batches
7.installation-assembly on site
8.multi-station assembly
Manual assembly methods

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Acquisition time for items not stored within easy reach of

the assembly worker:
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DFA Guidelines
Minimize part count by incorporating multiple functions into single parts. (Iredale
1964)
2.
Modularize multiple parts into single subassemblies (Crow 1988)
3.
Assemble in open space, not in confined spaces. Never bury important components
(Tipping 1965)
4.
Make parts to identify how to orient them for insertion. (tipping 1965)
5.
Standardize to reduce part variety (Tipping 1965)
6.
Maximize part symmetry. (Iredale 1964, Paterson 1965)
7.
Design in geometric or weight polar properties if non-symmetric (Tipping 1965)
8.
Eliminate tangly parts. (Iredale 1964, Tipping 1965)
9.
Color code parts that are different but similar in shape.
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1.
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DFA Guidelines
10. Prevent nesting of parts (Iredale 1964, Tipping 1965)
11. Provide orienting features on non symmetries (Iredale 1964, Tipping 1965)
12. Design the mating features for easy insertion ( Iredale 1964, Tipping 1965, Balswin 1966)
13. Provide alignment features (Baldwin 1966)
14. Insert new parts into an assembly from above (Tipping 1965)
15. Insert from the same direction or very few. Never require the assembly to be turned over.
(Tipping 1965)
16. Eliminate fasteners (Iredale 1964)
17. Place fasteners away from obstructions
18. Deep channels should be sufficiently wide to provide access to fastening tools. No channel
is best
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19. Providing flats for uniform fastening and fastening ease.

20. Proper spacing ensures allowance for a fastening tool.
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Make a choice between manual, special purpose automatic or
programmable automatic assembly based on good estimate of the most
economical assembly method.
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Information required:
Production volume per shift
Number of parts in assembly
Single product or a variety of products
Number of parts required for different styles of the product.
Number of major design changes excepted during the product life.
Investment policy regarding labor saving machinery.
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These questions, combined with several tables, are used to generate

recommendations for the general type of process to be used for
assembly, from the following categories:
Purely manual;
Manual with Mechanical assistance;
Dedicated automation on indexing machines;
Dedicated automation on station linked by free transfer device;
Flexible automation using programmable or selectable work heads (pick

& place units);
Flexible automation using programmable manipulators (Robots)
The outcome of this stage also includes an indication of the relative cost of
assembly, which can be used for comparisons between designs or
benchmarking across competitors.
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Design analysis for manual assembly

The key element here is the identification of ESSENTIAL parts. Essential
parts are those which;
Must have gross relative movement to all previously assembled parts

during product operation, OR
Must be made of a different material from all previously assembled

parts, OR
Must be separate for reasons of assembly or necessary disassembly.
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Agenda for redesign the number of non essential parts must be

minimized.
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Coding system and design data for handling and assembly

Parts, which survive the initial review, are now assessed for difficulty of handling and
presentation. Assessment areas are include:
Parts symmetry (About two orthogonal axes)
Parts feeding / presentation difficulty (weight, size, tangling, nesting, shingling)
Access to the site of assembly;
Direction of assembly;
Fitting and manipulation difficulty (skill levels, need for tools etc.; time
estimates are generated for standard operations);
Security of assembly (need for / presence of fasteners and inter stage transfer).
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This process produces cost estimates for the assembly process alone.
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Comparing an IDEAL assembly time with an estimated actual assembly time required
for a particular product design.
To calculate the IDEAL assembly time the theoretical minimum number of parts is
first determined by asking the following questions of each part in the assembly:
1.
Does the part move relative to all other parts already assembled?
2.
Must the part be of a different material than or isolated from all other parts already
assembled?
3.
Must the part be separate from all other parts already assembled because otherwise
necessary assembly and disassembly of other parts would impossible?
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If the answer to the part under consideration YES the number of parts is entered into
the calculation otherwise a zero is assigned.
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Theoretically minimum number of parts is the sum of the numbers assigned to each
parts in the assembly
IDEAL assembly time is calculated based on theoretical number of parts each of
which can be assembled in ideal time of 3 sec.
This ideal time assumed that each part is easy to handle and insert and that about one
third of the parts are secured immediately upon insertion with well designed snap
- fit elements.
To estimate ACTUAL assembly times, penalties in seconds are assigned for handling
difficulties, insertion difficulties associated with each part in the assembly
(standardized data based on time study are used)
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Actual assembly time is the sum of the handling and insertion times.
DESIGN EFFICIENCY =
Ideal Assembly time

Actual assembly time
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Design Guidelines for Part Handling

In general, for ease of part handling, a designer should attempt to:
Design a part that have end to end symmetry and rotational symmetry about the
axis of insertion. If this cannot be achieved try to design parts having the maximum
possible symmetry.
2.
Design part that, in those instances where the part cannot be made symmetric, are
obviously asymmetric.
3.
Provide features that will prevent jamming of parts that tend to nest or stack when
stored in bulk.
4.
Avoid features that will allow tangling of parts when stored in bulk.
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1.
5.
Avoid parts that stick together or are slippery, delicate, flexible, very small or very
large or that are hazardous to the handler (I.e. parts that are sharp, splinter easily,
etc)
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. We must consider the basic shape of the parts being assembled. Two
basic categories are prismatic and rotational.
. Rotational parts tend to roll when placed on a surface,suggestion that
they will need some sort
of holding fixture.This also means that during assembly,they must be
supported by hand if not in a stable position when working.
. Prismatic parts tend to have at least one stable orientation that allows
them to be rested on surfaces.Unlike rotational parts, if the prismatic parts
are made to be stable when put in their
final position, then they are much easier to fasten.
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The size of an object is generally the size of its largest major

dimension,and thickness is the smallest major diameter.
. There are a number of criteria that can be used to determine how

easily a part can be handled.
-a high size/thickness can be a measure of fragility.
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-large size values can indicate large weights.

-small size values can indicate the need for special tools.
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Design Guidelines for Insertion and Fastening

For ease of insertion a designer should attempt to:
Design so that there is little or no resistance to insertion & provide chamfers to
guide insertion of two mating parts. Generous clearance should be provided, but
care must be taken to avoid clearance that will result in a tendency for parts to jam
or hang up during insertion.
2.
Standardize by using common parts, processes, and methods across all models and
even across product lines to permit the use of higher volume processes that
normally result in lower product cost.
3.
Use pyramid assembly provide a progressive assembly about one axis of

reference. In general, it is best to assemble from above.
4.
Avoid, where possible, the necessity for holding parts down to maintain their
orientation during manipulation of the subassembly or during the placement of
another part. If holding down is required, then try to design so that the part is
secured as soon as possible after it has been inserted.
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1.
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Design Guidelines for Insertion and Fastening

For ease of insertion a designer should attempt to:
5. Design so that a part is located before it is released. A potential source of
problem arises from a part being placed where, due to design constraints, it
must be released before it is positively located in the assembly. Under these
circumstances, reliance is placed on the trajectory of the part being
sufficiently repeatable to locate it consistently.
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6. When common mechanical fasteners are used the following sequence

indicates the relative cost of different fastening processes, listed in order to
increasing manual assembly cost.
(a)Snap fitting, (b)Plastic
bending, (c)Riveting, (d)Screw fastening.
7. Avoid the need to reposition the partially completed assembly in fixture.
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Selected manual part handling time standards, seconds (Parts are within easy reach,
are not smaller than 6mm, do not stick together, and are not fragile or sharp).
For Parts that can be grasped and manipulated with one hand without the aid of grasping tools.
No Handling difficiencies
Thickness >2mm < 2mm
Size
6mm < Size
>15 mm
size
> 6mm
< 15mm
0
1
2
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Sym (deg) =
(Alpha + Beta)
Part nest or tangles

Thickness >2mm < 2mm
Size
6mm <
Size
>15 mm
size
> 6mm
< 15mm
3
4
5
Sym <360
1.13
1.43
1.69
1.84
2.17
2.45
360< = Sym
< 540
1.5
1.8
2.06
2.25
2.57
540 < = Sym

< 270
1.8
2.1
2.36
2.57
2.9
3.18
Sym = 270
1.95
2.25
2.51
2.73
3.06
3.34
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For parts that can be lifted with one hand but require wo hands because they severely nest or tangle,
are flexible or require forming etc
Alpha < = 180

Size
>15 mm
0
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4.1
Alpha = 360
6mm <
size
< 15mm
1
Alpha = 360
Size
> 6mm
4.5
5.6
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Parts inseted but not secured immediately or secured by snap fit
Secured by separate operation or part

No holding down
Holding down
Required
Easy to not easy
align
to
align
0
1
Required
Easy to
Not easy
align
to
align
2
3
Secured on insertion by snap fit

Easy to
Not easy
align
to
align
4
5
no access or
0
1.5
2.6
5.2
1.8
3.3
Obstructed access
or
ristricted vision
3.7
5.2
4.8
7.4
5.5
Obstructed access
and
ristricted vision
5.9
7.4
9.6
7.7
7.7
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vision difficulties
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Parts inserted and secured immediately by screw fastening with power tool
Not Easy to
Align
Easy to align
0
3.6
5.3
6.3
10.7
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No access or
Vision difficulty 3
Ristricted vision
only
4
Obstructed
access only
5
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Selected separate operation time, seconds
Screw tighten with
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power tool
0
5.2
Manipulation reorientation Addition of

or adjustment
1
4.5
non solids
2
7
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Coffee mill assembly tree
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DFA Analysis for the KRUPS COFFEE MILL
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Parts cost estimation and manufacturing process

optimization
As well as estimating the cost of assembly, the M of DFMA estimates
the basic cost of manufacturing the components, identifies suitable basic
manufacturing processes and then optimizes parts for the relevant
process.
The DFMA method is available on paper or in software. The software is

now available as part of a package of Design for --- products
marketed by Boothroyd Dewhurst Inc.
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Summary
Guidelines for assembly have been discussed like
- modular assemblies
- use of standard parts and assemblies
- multifunctional parts
- multiple use parts
- avoid separate fasteners
- maximise compliance
- minimise assembly directions
- minimise handling
Effect of part size, part geometry , assembly clearances and
part acquisition times on manual assembly time have been
tabulated
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08 Design For Manual Assembly

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08 Design For Manual Assembly

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PEMP

Prof. M. N. Sudhindra Kumar

M.S Ramaiah School of Advanced Studies - Bangalore

Design guidelines of assembly

M.S Ramaiah School of Advanced Studies - Bangalore

Design Guidelines for Insertion And Fastening

M.S Ramaiah School of Advanced Studies - Bangalore

interface to other components of a system.

M.S Ramaiah School of Advanced Studies - Bangalore

M.S Ramaiah School of Advanced Studies - Bangalore

1.3 Use Standard Components

M.S Ramaiah School of Advanced Studies - Bangalore

M.S Ramaiah School of Advanced Studies - Bangalore

1.5 Design parts for multiple use.

a) Parts which are unique to a particular model (I.e. crank shafts,

M.S Ramaiah School of Advanced Studies - Bangalore

Standardization is the systematic unification by those concerned of

Create multiuse parts by standardizing similar parts.

1.6 Design parts for ease of fabrication

1.8 Maximise compliance

1.9 Minimise assembly directions

All parts to be assembled in one direction. Extra

M.S Ramaiah School of Advanced Studies - Bangalore

Position is the sum of location (x,y,z) and orientation (,,).

To Assist easy orientation

1.10 Minimize handling

To facilitate robotic part handling

M.S Ramaiah School of Advanced Studies - Bangalore

Times are average for two

M.S Ramaiah School of Advanced Studies - Bangalore

Effect of part thickness on handling time:

M.S Ramaiah School of Advanced Studies - Bangalore

Effect of part size on handling time:

M.S Ramaiah School of Advanced Studies - Bangalore

Effect of symmetry on handling time when parts nest or tangle

M.S Ramaiah School of Advanced Studies - Bangalore

M.S Ramaiah School of Advanced Studies - Bangalore

Small parts all within easy

Large parts require major

1.very low volumeclean room or worker

4.modular assembly center

3.multi station assembly

6.flexible assembly layoutproducts may be assembled

Manual assembly methods

Acquisition time for items not stored within easy reach of

M.S Ramaiah School of Advanced Studies - Bangalore

Modularize multiple parts into single subassemblies (Crow 1988)

Standardize to reduce part variety (Tipping 1965)

Maximize part symmetry. (Iredale 1964, Paterson 1965)

Design in geometric or weight polar properties if non-symmetric (Tipping 1965)

Eliminate tangly parts. (Iredale 1964, Tipping 1965)

Color code parts that are different but similar in shape.

M.S Ramaiah School of Advanced Studies - Bangalore

19. Providing flats for uniform fastening and fastening ease.

M.S Ramaiah School of Advanced Studies - Bangalore

Choice of Assembly Method

Production volume per shift

Number of parts in assembly

Single product or a variety of products

Number of parts required for different styles of the product.

Number of major design changes excepted during the product life.

Investment policy regarding labor saving machinery.

M.S Ramaiah School of Advanced Studies - Bangalore