Maintenance Tips for Boom Placers : Maximizing Performance and Extending Lifespan
https://pinakins.in/maintenance-tips-for-boom-placers/
Saturday, November 30, 2024
Industrial Engineering ONLINE Course - PDF Files
Introduction to Modern Industrial Engineering - Blog Based Book by Narayana Rao K.V.S.S.
11130+ DOWNLOADS so far (from 3 locations).
Expect many faculty members to recommend the EBook for additional reading in the new academic year 2024-2025.
Industrial Engineering ONLINE Course - Main Index Page
Review of Module 1 - Introduction to Industrial Engineering - IE ONLINE Course - Download PDF from
https://www.academia.edu/43450192/Review_of_Introduction_to_Industrial_Engineering_Module_-_IE_Online_Course
Download Industrial Engineering Concepts - Industrial Engineering ONLINE Course Module 2 - Review from:
https://www.academia.edu/43449439/Industrial_Engineering_Concepts_-IE_Course_Module_2_-_Review
https://www.linkedin.com/posts/narayana-rao-kvss-b608007_industrial-engineering-concepts-module-activity-6682551995259248640-Rjte/
Ud. 30.11.2024
Pub. 27.6.2020
Monitor - Technology Monitoring - Applied Industrial Engineering
Process Step of Applied Industrial Engineering - Industrial Engineering 4.0
Monitor - Explore - Analyze - Develop - Optimize - Participate - Install - Improve
http://nraoiekc.blogspot.com/2018/05/applied-industrial-engineering-process.html
EIRMA (1999) working group report.
Technology monitoring is: “the identification and assessment of technological advances critical to the company’s competitive position and of detecting changes and discontinuities in existing technology; new emerging technologies with potentially significant impact on the company’s products and market and its production and business processes.”
To identify new technologies as they are ready for commercialization, industrial engineering, a discipline and profession connected to engineering processes and activities of the organization has to do technology monitoring to protect the productivity advantage of the organization.
New Technology Industrial Engineering
_____________________2024
McKinsey Technology Trends Outlook 2024
July 16, 2024 Report
30 Emerging Technologies - 2018
#1 Artificial Intelligence #AI /Machine Learning / Deep Learning
#2 Internet of Things #IOT / #IIOT & Sensors & Wearables
#3 Mobile & Social Internet — Advancements, Social Networks/Media, Search, Messenging and Livestreams
#4 Blockchain — Cryptocurrencies, Distributed Ledger Systems, DAOs, DApps
#5 Big Data — Apps, Infrastructure & Predictive Analytics
#6 Automation — Information, Task, Process, Machine, Decision & Action
#7 Robots incl. Drones & Autonomous Vehicles — Consumer/Commercial/Industrial Robots and Robotics
#8 Immersive Media — #VR/ #AR/ #MR/ 360°
#9 Mobile Technologies & Advancements — infrastructure, networks, standards, services & devices
#10 Cloud Computing — Software-as-Service (SaaS), Infrastructure-as-a-Servcie (IaaS), Platform-as-a-Service (PaaS) & MESH Apps
#11 3D Printing — Additive Manufacturing and Rapid Prototyping
#12 CX — Customer Journey, Experience, Personalization & Commerce Tools
#13 EnergyTech — Efficiency, Storage & Decentralized Grid
#14 Cybersecurity incl. Adaptive Security — Security, Intelligence Detection, Remediation & Adaptation
#15 Voice Assistants -Interfaces, Chatbots & Natural Language Processing
#16 Nanotechnology - Computing, Medicine, Machines + Smart Dust
#17 CollaborativeTech — Crowd, Sharing, Workplace & Open Source Platforms & Tools
#18 Health Tech — Advanced Genomics, Bionics & Health Care Tech.
#19 Human-Computer Interaction — Facial/Gesture Recognition, Biometrics, Gaze Tracking
#20 Geo-spatial Tech — GIS, GPS, Mapping & Remote Sensing, Scanning, Navigation
#21 Advanced Materials — Composites, Alloys, Polymers, Biomimicry, Nanomanufacturing
#22 New Touch Interfaces — Touch Screens, Haptics, 3D Touch, Paper, Feedback & Exoskeletons
#23 Wireless Power
#24 Clean Tech. — Bio-/Enviro-Materials + Solutions, Sustainability, Treatment & Efficiency
#25 Quantum Computing — + Exascale Computing
#26 Smart Cities — Infrastructure & Transport
#27 Edge/Fog Computing
#28 Faster, Better Internet — Broadband incl. Fiber, 5G, Li-Fi , LPN and LoRa
#29 Proximity Tech. — Beacons, .RFID, Wi-Fi, Near-Field Communications & Geofencing
#30 New Screens — next evolution TVs, Digital Signage, OOH, MicroLEDS & Projections
The list is prepared and published by Sean Moffitt in:
https://medium.com/@seanmoffitt/the-top-30-emerging-technologies-2018-2028-eca0dfb0f43c
What technologies are to be explored for further understanding by industrial engineers?
2020
Digital Twins
Digital twin technology is very important for industrial engineers. Process improvement can be done using digital twins.
Digital Twins - Blog Posts
Digital Twin - Bibliography
Digital Twins of CNC Machines - Bibliography
Process Digital Twin
Supply Chain Digital Twin - Introduction
Digital Twins of Machine Tools
Digital Twins for Machine Tools and Machine Tool Components and Accessories
SAP Digital Twin Software & Technology - Introduction
Updated on 30.11.2024, 26.11.2021, 19.12.2020, 8 July 2018, 16 June 2018
Design for Manufacturing and Assembly for Product Industrial Engineering (DFMA): Concepts and Case Studies
2023 BEST E-Book on #IndustrialEngineering.
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING.PRODUCT INDUSTRIAL ENGINEERING - FACILITIES INDUSTRIAL ENGINEERING - PROCESS INDUSTRIAL ENGINEERING. Free Download.
https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0
DFMA is an Industrial Engineering Innovation.
G. Boothroyd, ‘Design for Producibility—The Road to Higher Productivity’,Assembly Engineering, March 1982.
G. Boothroyd, Department of Industrial & Manufacturing Engineering, University of Rhode Island, 02881-0805, Kingston, RI, USA
Peter Dewhurst, Professor Emeritus
Recent from LinkedIn AI
Prefabricated Buildings Related
Lesson 246 of IEKC Industrial Engineering ONLINE Course Notes.
My advocacy now is IEs must first concentrate on improving engineering elements and then move into productivity managerial elements and non-engineering areas. Machine work study or machine effort improvement, value engineering and design for manufacturing and assembly are major engineering based IE methods. All are available as existing methods.
Product Design for Manufacture and Assembly, Third Edition
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
CRC Press, 08-Dec-2010 - Technology & Engineering - 712 pages
https://books.google.co.in/books/about/Product_Design_for_Manufacture_and_Assem.html?id=W2FDCcVPBcAC
Note: It is important to read the books by Boothroyd to understand the full method of DFMA. The DFMA method is to be combined with Value Analysis and Engineering to do product industrial engineering. In the note only attempt is made to make readers aware of issues raised and solutions proposed by DFMA method.
Design for Manufacturing: A Structured Approach
Corrado Poli
Mechanical Industrial Engineering Department
University of Massachusetts Amherst
Elsevier, 29-Nov-2001 - Technology & Engineering - 424 pages
Design for Manufacturing assists anyone not familiar with various manufacturing processes in better visualizing and understanding the relationship between part design and the ease or difficulty of producing the part.
Decisions made during the early conceptual stages of design have a great effect on subsequent stages. In fact, quite often more than 70% of the manufacturing cost of a product is determined at this conceptual stage, yet manufacturing is not involved. Through this book, designers will gain insight that will allow them to assess the impact of their proposed design on manufacturing difficulty.
The vast majority of components found in commercial batch-manufactured products, such as appliances, computers and office automation equipment are either injection molded, stamped, die cast, or (occasionally) forged. This book emphasizes these particular, most commonly implemented processes.
In addition to chapters on these processes, the book touches upon material process selection, general guidelines for determining whether several components should be combined into a single component or not, communications, the physical and mechanical properties of materials, tolerances, and inspection and quality control.
In developing the DFM methods presented in this book, he has worked with over 30 firms specializing in injection molding, die-casting, forging and stamping.
Implements a philosophy which allows for easier and more economic production of designs
Educates designers about manufacturing
Emphasizes the four major manufacturing processes
WHAT IS DESIGN FOR MANUFACTURE AND ASSEMBLY?
"To manufacture" refers to the manufacturing of the individual component parts of a product or assembly
"To assemble" refers to the addition or joining of parts to form the completed product.
The term "design for manufacture" (or DFM) means the design for ease of manufacture of the collection of parts that will form the product after assembly.
"Design for assembly" (or DFA) means the design of the product for ease of assembly.
Thus, "design for manufacture and assembly" (DFMA) is a combination of DFA and DFM.
DFMA process is used for three main activities:
1. As the basis for providing guidance to the design team in simplifying the product structure, to reduce manufacturing and assembly costs.
2. As a tool to study competitors' products and quantify manufacturing and assembly difficulties.
3. To support should-cost models.
Once methods for analyzing assembly difficulties were developed in the 1970s, it was found that the simplification of products by reducing the number of separate parts through DFA—on the order of 50% on average—could easily achieve substantial reductions in assembly costs. Much more important, however, was the fact that even greater savings could be achieved in the cost of the parts. The ability to estimate both assembly and part manufacturing costs at the earliest stages of product design is the essence of DFMA.
Much of the DFMA methodology involves analytical tools that allow designers and manufacturing engineers to estimate the manufacturing and assembly costs of a proposed product before detailed design has taken place. The text book by Boothroyd et al. provides the basic equations and data that allow manufacturing and assembly cost estimates to be made. Thus, for a limited range of materials and processes the engineer or student (reader) can make cost estimates for real parts and assemblies and, therefore, become familiar with the details of the methods employed and the assumptions made.
The ability to estimate both assembly and part manufacturing costs at the earliest stages of product design is the essence of DFMA. A primary objective of DFMA development has been to develop economic models of manufacturing processes, based on product design information, and which require a minimum of manufacturing knowledge.
Reported Benefits of DFMA
In 1988 Ford Motor Company reported that Boothroyd DFA software had helped them save billions of
dollars on their Taurus line of automobiles. Later, General Motors (GM) made comparisons between its assembly plant at Fairfax, Kansas, which made the Pontiac Grand Prix, and Ford's Atlanta assembly plant for its Taurus and Mercury Sable models. GM found a large productivity gap and concluded that 41% of the gap could be traced to the manufacturability of the two designs. For example, the Ford car had fewer parts—10 in its front bumper compared with 100 in the GM Pontiac—and the Ford parts fit together more easily.
Subsequently , GM has become one of the leading users of DFMA. It became a driver of quality and cost improvement through technical improvements to both product and process. It was made an integral part of engineering and manufacturing employee training.
Ingersoll-Rand Company reported that the use of DFMA software from Boothroyd Dewhurst, Inc., slashed product development time from two years to one. Examples of benefits: The number of parts in a portable compressor radiator and oil-cooler assembly from 80 to 29, decreased the number of fasteners from 38 to 20, trimmed the number of assembly operations from 159 to 40 and reduced assembly time from 18.5 to 6.5min. The new design went into full production in February, 1990.
DFMA efforts at Hewlett Packard Loveland started in the mid-1980s with redesign of existing products and continued with application to new product design. During these studies, one to three manufacturing engineers interacted frequently with the R&D team members and gave their suggestions and opinion. The studies proved the benefits of DFMA and eventually, by 1992, HP Loveland had incorporated DFMA into a formal concurrent engineering approach. There was significant improvement in their product manufacturing and assembly costs.
DFMA and Value Analysis
DFMA can be compared with Value Analysis. The objectives of DFMA and value analysis are the same. If some think that value analysis is more comprehensive, they have to realize that 13 value analysis techniques of L.D. Miles does not include the steps advocated in DFMA. DFMA is a more technically intensive method. DFMA is meant to be applied early in the design cycle and value analysis does not have any techniques or tools to give proper attention to the structure of the product and its possible simplification. Hence value engineering has to include DFMA in its techniques appropriately. DFMA is a systematic step-by-step procedure that can be applied at all stages of design and that challenges the designer or design team to justify the existence of all the parts and to consider alternative designs. Experience has shown that DFMA still makes significant improvements of existing products even after value analysis has been carried out.
*Design for Manufacture and Rapid Prototyping Both Seek the Same Size Prize: A Better Product Made Faster.
Mechanical Engineering. Sep 1999, 121(09): 72-74 (3 pages)
DFMA One Among Many Techniques
Since the introduction of DFMA, many more design based techniques have been proposed, for example, design for quality (DFQ), design for competitiveness (DFC), design for reliability, and many more. Design for performance is also specially advocated now whereas Miles argued that in his time design for performance is getting all the attention and design for value is not getting attention. Boothroyd remarks that DFMA is the subject that has been neglected over the years, while adequate consideration has always been given to the design of products for performance, appearance, etc. DFMA tools also encourage dialogue between designers and the manufacturing engineers and any other individuals who play a part in determining final product costs during the early stages of design. This means that teamwork is encouraged and the benefits of simultaneous or concurrent engineering can be achieved.
DFMA is an important technique to be used in product industrial engineering.
Further Articles on DFMA
DFMA - Case Studies
DFMA Software Company
When manufacturers need to reduce costs, they call Boothroyd Dewhurst. The company’s innovative software lets manufacturers estimate the cost of components and recommends efficient designs that save time and money. It was founded by two University of Rhode Island engineering faculty and now in the hands of URI alumni. Launched in 1983 by then URI engineering Professors Geoff Boothroyd and Peter Dewhurst, the company now counts more than 800 clients with names like General Electric, Boeing, Whirlpool, Motorola and John Deere. President H.W. Bush awarded the professors the National Medal of Technology for their work.
Brian Rapoza and Nicholas Dewhurst, URI engineering alumni are research and development manager and vice president, respectively, at Boothroyd Dewhurst in Rhode Island. It’s a place where innovation flourishes and a passion for encouraging U.S. manufacturing runs deep. Peter Dewhurst’s son, mechanical engineering undergraduate alumnus Nicholas Dewhurst (’93), is executive vice president on the frontlines of exchanges between client engineers and his company.
COMBINED APPLICATION OF CAXX AND DFMA TECHNIQUES IN THE DESIGN PROCESS
2012
Tamás KULCSÁR, Imre TIMÁR
APPLYING DFMA TECHNIQUES IN THE DESING IN THE DESIGN AND MANUFACTURE OF WIND TUNNEL MODELS
June 2017International Journal Advanced Quality 45(1):35
DOI:10.25137/IJAQ.n1.v45.y2017. p35-40
Authors: Srdjan Živković, Military Technical Institute, Belgrade, Serbia & Dušan Ćurčić
Metal Air Battery Shell Unit Redesign with DFMA Aspect
Design for Manufacturing Analysis on the front wheel hubs
by AACY Yu · 2008
Integration and Application of TRIZ and DFMA: Two case studies; one a simple
system and the other a more complex aerospace system.
Redesigns get radical improvements using DFMA: Precision engineering slices 500 parts off plasma cutter design
Case Study: DFMA guidelines used to compare the three VR controllers, the PlayStation Move controller to design new simpler controller. - Detailed Report
Design for manufacturing and assembly (DFMA) in ABB
Tomasz Nowak, Marcin Chromniak, Robert Sekula, Lucas-Lu Gao
ABB Review 2006.
Small Satellite - DFMA Case Study - Raytheon - 2007
Redesigning of Shopping Cart for Cost Reduction Using DFMA
C. D. Naiju, Pranav. V. Warrier and V. Jayakrishnan
School of Mechanical Engineering, VIT University, Vellore, India
MATEC Web of Conferences 95 matecconf/201
ICMME 2016
DFMA ASPECTS OF THE SHEET METAL PARTS IN A POWER ELECTRONIC
SYSTEM CABINET
Bachelor’s thesis of Jarkko Matikka
2018
39 pages
Application of Design for Manufacturing and Assembly: Development of a Multifeedstock Biodiesel Processor
By Ilesanmi Afolabi Daniyan and Khumbulani Mpofu
Published: November 5th 2018
DOI: 10.5772/intechopen.80085
DFMA helps medical OEM save plenty.
Don’t just demand lower prices from your suppliers; A mechanical engineer at a veterinary device manufacturer used DFMA software and worked with his injection molding supplier, PTA Corp., to turn 43 parts into a single injection molding, and consolidated 30 other parts into just four plastic ones, all courtesy of a mammoth metal-to-plastic conversion.
Matt Defosse | Jan 13, 2011
DFMA for Early Cost Estimation of Pedestal Fan - A Case Study
C. D. Naiju, V. Jayakrishnan and Pranav. V. Warrier
SMEC, VIT University, Vellore, India
Journal of Industrial and Intelligent Information Vol. 5, No. 1, June 2017
Hinge Assembly DfMA Design and Implementation
January 7, 2020
Akshay Harlalka, C. D. Naiju, Mukund Nilakantan Janardhanan & Izabela
Nielsen (2016) Redesign of an in-market food processor for manufacturing cost reduction
using DFMA methodology, Production & Manufacturing Research, 4:1, 209-227, DOI:
10.1080/21693277.2016.1261052
To link to this article: https://doi.org/
Redesigning of Agarwood Extracting Machine Applying DFMA Principle
M S Salim1, M A Lajis1, Z C Ros2, A Nawawi3, S Shamsudin1 and N K Yusuf1
Published under licence by IOP Publishing Ltd
IOP Conference Series: Materials Science and Engineering, Volume 637, The 3rd International Conference on Robotics and Mechantronics (ICRoM 2019) 9–11 August 2019, Sabah, Malaysia
Citation M S Salim et al 2019 IOP Conf. Ser.: Mater. Sci. Eng. 637 012006
DFMA APPLIED in LONGBOW APACHE HELICOPTER .
Design for Manufacturing and Assembly Application on the design of the AH64D Helicopter.
Consultants - DFMA
Consultant for DFMA Software in India - https://despat.com/
https://concept274.com/
What is DFMA®? - Video by Boothroyd Dewhurst, Inc.
Design for Manufacture and Assembly (DFMA®) is a powerful cost reduction strategy employed by hundreds of global manufacturers.
DFMA Research Papers
Redesign methodology for mechanical assembly
AbdulRahman El-Nounu, Atanas Popov, and Svetan Ratchev
Res Eng Des. 2018; 29(1): 107–122.
(Interesting developments in DFMA methods mentioned in the paper.
Book
Product Design for Manufacture and Assembly, Second Edition - Contents
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
Table of Contents
1.1 What Is Design for Manufacture and Assembly? 1
1.2 How Does DFMA Work? 8
1.3 Reasons for Not Implementing DFMA 16
1.4 What Are the Advantages of Applying DFMA During
Product Design? 21
1.5 Typical DFMA Case Studies 22
1.6 Overall Impact of DFMA on U.S. Industry 34
1.7 Conclusions 39
References 40
2. Selection of Materials and Processes 43
2.1 Introduction 43
2.2 General Requirements for Early Materials and Process Selection 45
2.3 Selection of Manufacturing Processes 46
2.4 Process Capabilities 48
2.5 Selection of Materials 55
2.6 Primary Process/Material Selection 65
2.7 Systematic Selection of Processes and Materials 71
References 83
3. Product Design for Manual Assembly 85
3.1 Introduction 85
3.2 General Design Guidelines for Manual Assembly 86
3.3 Development of the Systematic DFA Methodology 93
3.4 Assembly Efficiency 93
3.5 Classification Systems 96
3.6 Effect of Part Symmetry on Handling Time 96
3.7 Effect of Part Thickness and Size on Handling Time 101
3.8 Effect of Weight on Handling Time 103
3.9 Parts Requiring Two Hands for Manipulation 104
3.10 Effects of Combinations of Factors 104
3.11 Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation 104
3.12 Effect of Chamfer Design on Insertion Operations 105
3.13 Estimation of Insertion Time 108
3.14 Avoiding Jams During Assembly 109
3.15 Reducing Disc-Assembly Problems 111
3.16 Effects of Obstructed Access and Restricted Vision on
Insertion of Threaded Fasteners of Various Designs 112
3.17 Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations 115
3.18 Effects of Holding Down 115
3.19 Manual Assembly Database and Design Data Sheets 118
3.20 Application of the DFA Methodology 119
3.21 Further Design Guidelines 125
3.22 Large Assemblies 128
3.23 Types of Manual Assembly Methods 130
3.24 Effect of Assembly Layout on Acquisition Times 133
3.25 Assembly Quality 137
3.26 Applying Learning Curves to the DFA Times 141
References 143
4. Electrical Connections and Wire Harness Assembly 147
4.1 Introduction 147
4.2 Wire or Cable Harness Assembly 149
4.3 Types of Electrical Connections 152
4.4 Types of Wires and Cables 159
4.5 Preparation and Assembly Times 160
4.6 Analysis Method 182
References 190
5. Design for High-Speed Automatic Assembly and Robot Assembly 191
5.1 Introduction 191
5.2 Design of Parts for High-Speed Feeding and Orienting 192
5.3 Example 196
5.4 Additional Feeding Difficulties 199
5.5 High-Speed Automatic Insertion 199
5.6 Example 201
5.7 Analysis of an Assembly 202
5.8 General Rules for Product Design for Automation 203
5.9 Design of Parts for Feeding and Orienting 208
5.10 Summary of Design Rules for High-Speed Automatic Assembly 210
5.11 Product Design for Robot Assembly 211
References 217
6. Printed Circuit Board Design for Manufacture and Assembly 219
6.1 Introduction 219
6.2 Design Sequence for Printed Circuit Boards 220
6.3 Types of Printed Circuit Boards 220
6.4 Terminology 222
6.5 Assembly of Printed Circuit Boards 223
6.6 Estimation of PCB Assembly Costs 238
6.7 Case Studies in PCB Assembly 244
6.8 PCB Manufacturability 249
6.9 Design Considerations 252
6.10 Glossary of Terms 263
References 266
7. Design for Machining 267
7.1 Introduction 267
7.2 Machining Using Single-Point Cutting Tools 267
7.3 Machining Using Multipoint Tools 275
7.4 Machining Using Abrasive Wheels 284
7.5 Standardization 290
7.6 Choice of Work Material 291
7.7 Shape of Work Material 293
7.8 Machining Basic Component Shapes 294
7.9 Assembly of Components 307
7.10 Accuracy and Surface Finish 308
7.11 Summary of Design Guidelines 311
7.12 Cost Estimating for Machined Components 313
References 337
8. Design for Injection Molding 339
8.1 Introduction 339
8.2 Injection Molding Materials 340
8.3 The Molding Cycle 342
8.4 Injection Molding Systems 344
8.5 Injection Molds 346
8.6 Molding Machine Size 351
8.7 Molding Cycle Time 353
8.8 Mold Cost Estimation 359
8.9 Mold Cost Point System 367
8.10 Estimation of the Optimum Number of Cavities 369
8.11 Design Example 372
8.12 Insert Molding 374
8.13 Design Guidelines 375
8.14 Assembly Techniques 376
References 379
9. Design for Sheet Metalworking 381
9.1 Introduction 381
9.2 Dedicated Dies and Press-working 383
9.3 Press Selection 403
9.4 Turret Pressworking 409
9.5 Press Brake Operations 413
9.6 Design Rules 416
References 422
10. Design for Die Casting 423
10.1 Introduction 423
10.2 Die Casting Alloys 423
10.3 The Die Casting Cycle 425
10.4 Die Casting Machines 426
10.5 Die Casting Dies 429
10.6 Finishing 430
10.7 Auxiliary Equipment for Automation 432
10.8 Determination of the Optimum Number of Cavities 433
10.9 Determination of Appropriate Machine Size 439
10.10 Die Casting Cycle Time Estimation 443
10.11 Die Cost Estimation 453
10.12 Assembly Techniques 457
10.13 Design Principles 458
References 459
11. Design for Powder Metal Processing 461
11.1 Introduction 461
11.2 Main Stages in the Powder Metallurgy Process 463
11.3 Secondary Manufacturing Stages 464
11.4 Compaction Characteristics of Powders 468
11.5 Tooling for Powder Compaction 475
11.6 Presses for Powder Compaction 478
11.7 Form of Powder Metal Parts 481
11.8 Sintering Equipment Characteristics 484
11.9 Materials for Powder Metal Processing 489
11.10 Contributions to Basic Powder Metallurgy Manufacturing
Costs 492
11.11 Modifications for Infiltrated Materials 511
11.12 Impregnation, Heat Treatment, Tumbling, Steam Treatment,
and Other Surface Treatments 512
11.13 Some Design Guidelines for Powder Metal Parts 514
References 515
12. Design for Sand Casting 517
12.1 Introduction 517
12.2 Sand Casting Alloys 519
12.3 Basic Characteristics and Mold Preparation 519
12.4 Sand Cores 524
12.5 Melting and Pouring of Metal 525
12.6 Cleaning of Castings 526
12.7 Cost Estimating 527
12.8 Design Rules for Sand Castings 537
12.9 Example Calculations 542
References 546
13. Design for Investment Casting 549
13.1 Introduction 549
13.2 Process Overview 549
13.3 Pattern Materials 552
13.4 Pattern Injection Machines 552
13.5 Pattern Molds 554
13.6 Pattern and Cluster Assembly 554
13.7 The Ceramic Shell-Mold 555
13.8 Ceramic Cores 556
13.9 Pattern Meltout 556
13.10 Pattern Burnout and Mold Firing 557
13.11 Knockout and Cleaning 557
13.12 Cutoff and Finishing 557
13.13 Pattern and Core Material Cost 557
13.14 Wax Pattern Injection Cost 561
13.15 Fill Time 562
13.16 Cooling Time 562
13.17 Ejection and Reset Time 564
13.18 Process Cost per Pattern or Core 566
13.19 Estimating Core Injection Cost 567
13.20 Pattern and Core Mold Cost 567
13.21 Core Mold Cost 572
13.22 Pattern and Cluster Assembly Cost 572
13.23 Number of Parts per Cluster 574
13.24 Pattern Piece Cost 575
13.25 Cleaning and Etching 576
13.26 Shell Mold Material Cost 576
13.27 Investing the Pattern Cluster 577
13.28 Pattern Meltout 578
13.29 Burnout, Sinter, and Preheat 578
13.30 Total Shell Mold Cost 579
13.31 Cost to Melt Metal 579
13.32 Raw Base Metal Cost 583
13.33 Ready-to-Pour Liquid Metal Cost 584
13.34 Pouring Cost 584
13.35 Final Material Cost 584
13.36 Breakout 586
13.37 Cleaning 587
13.38 Cutoff 587
13.39 Design Guidelines 590
References 591
14. Design for Hot Forging 593
14.1 Introduction 593
14.2 Characteristics of the Forging Process 593
14.3 The Role of Flash in Forging 595
14.4 Forging Allowances 600
14.5 Preforming During Forging 603
14.6 Flash Removal 609
14.7 Classification of Forgings 610
14.8 Forging Equipment 613
14.9 Classification of Materials 622
14.10 Forging Costs 622
14.11 Forging Die Costs 631
14.12 Die Life and Tool Replacement Costs 636
14.13 Costs of Flash Removal 637
14.14 Other Forging Costs 640
References 641
15. Design for Manufacture and Computer-Aided Design 643
15.1 Introduction 643
15.2 General Considerations for Linking CAD and DFMA
Analysis 643
15.3 Geometric Representation Schemes in CAD Systems 645
15.4 Design Process in a Linked CAD/DFMA Environment 660
15.5 Extraction of DFMA Data from CAD System Database 663
15.6 Expert Design and Cost Estimating Procedures 665
References 668
Nomenclature 669
Index 683
Product Design for Manufacture and Assembly, 3rd Edition
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
CRC Press, Dec 8, 2010 - Science - 712 pages
DFMA - More Articles, Books and Papers
2018 DFMA Forum
DfAM meets DFMA at upcoming International Forum in Rhode Island
Photo of Victor Anusci Victor AnusciJune 29, 2018
Chinese automotive company BAIC (Beijing Automotive Industry Holding Co., Ltd.) will discuss using DFMA to control whole vehicle costs and Goldense Group will address the maturing face of globalization, as countries and states increasingly focus policies and resources on becoming centers of excellence for selected industries and technologies—specifically those with high DFMA requirements.
A Distinguished DFMA Supporter of the Year winner, Bill Devenish, will deliver four Kohler group papers on subjects ranging from early, data-driven product development to using DFMA very late in “the ship has already sailed” phase of production.
Additional presenters include Nick Dewhurst of Boothroyd Dewhurst, Inc., (Opening Address and DFMA Overview), Swiss-based Endress & Hauser (The Million Dollar Story of DFMA at E&H), Starkey Hearing Technologies (The Positive Impacts of DFMA for Hearing Aid Development), and Dynisco (DFMA and Systems Engineering Approaches), among others.
2019 DFMA Forum Explores Innovative Strategies for Product Simplification and Early Cost Estimating in Manufacturing
Boothroyd Dewhurst to host 2019 International Forum on Design for Manufacture and Assembly October 1-2 in Providence, RI, USA
Presenters this year represent a cross-section of the industry’s leading DFMA experts. Topics to be presented include:
Conducting a Step-by-Step DFMA Analysis, by Bill Devenish of L3 Technologies. With global revenues in excess of $10 billion, L3 develops advanced defense technologies and commercial solutions for a variety of highly complex industries.
DFMA: An Enabler of a Lean Enterprise, by Charlie Hackett of Hypertherm, a company that produces leading industrial plasma cutting and gouging solutions.
Study Results for Overcoming Barriers to Implementing and Sustaining Product Development Tools, by Matt Miles of Dynisco, a provider of sensing and polymer test equipment.
DFMA Case Studies in Supplier Costing for Low Volume Medical Devices, by Fred Johnson and Brian Rapoza of Ortho Clinical Diagnostics and Boothroyd Dewhurst, respectively. Ortho Clinical Diagnostics is a leading provider of in vitro diagnostics for hospitals and other medical facilities around the world.
Designing and Implementing an Innovative Workshop Oriented DFMA Process, by Rashmeet Sangari and Joe Budzinski of Johnson and Johnson. Founded in 1886, Johnson and Johnson researches, develops and manufactures a variety of consumer, medical and pharmaceutical products for the global healthcare industry.
Other distinguished presenters include: Aaron Ulmer of L3 Technologies; Nicholas Dewhurst and Chris Tai, both of Boothroyd Dewhurst, Inc; Ryan John, of Kohler; Volker Frey, of Endress & Hauser; and Keith Brady of Renishaw.
2020 Virtual DFMA Forum
_________________
https://www.youtube.com/watch?v=00dEjmZlIDY
_________________
Product Design For Engineers
Devdas Shetty
Cengage Learning, 09-Apr-2015 - Technology & Engineering - 538 pages
Intended to serve as a primary text for Product Design, Capstone Design, or Design for Manufacturing, PRODUCT DESIGN FOR ENGINEERS explores techniques for managing innovation, entrepreneurship, and design. Students are introduced to the creative problem-solving method for product success through case studies that explore issues of design for assembly, disassembly, reliability, maintainability, and sustainability. The book's interdisciplinary approach, step-by-step coverage, and helpful illustrations and charts provide mechanical, industrial, aerospace, manufacturing, and automotive engineering students with everything they need to design cost-effective, innovative products that meet customer needs.
https://books.google.co.in/books?id=u5uaBAAAQBAJ&printsec=frontcover#v=onepage&q&f=false
Design for Manufacturing and Assembly: Concepts, architectures and implementation
O. Molloy, E.A. Warman, S. Tilley
Springer Science & Business Media, Dec 6, 2012 - 205 pages
https://books.google.co.in/books?id=8T3UBwAAQBAJ
O. Molloy,
https://scholar.google.co.uk/citations?user=TBH2_0cAAAAJ&hl=th
Integrated Design of a Product Family and Its Assembly System
Pierre De Lit, Alain Delchambre
Springer Science & Business Media, 28-Jun-2011 - Science - 281 pages
https://books.google.co.in/books?id=rZzzBwAAQBAJ
Casting Design Issues and Practices
H.W. Stoll
https://books.google.co.in/books?id=vQAj5iB4KY4C&pg=PA1#v=onepage&q&f=false
O. Molloy, E.A. Warman, S. Tilley
Springer Science & Business Media, Dec 6, 2012 - 205 pages
In order to compete in the current commercial environment companies must produce greater product variety, at lower cost, all within a reduced product life cycle. To achieve this, a concurrent engineering philosophy is often adopted. In many cases the main realization of this is Design for Manufacture and Assembly (DFM/A). There is a need for in-depth study of the architectures for DFM/A systems in order that the latest software and knowledge-based techniques may be used to deliver the DFM/A systems of tomorrow. This architecture must be based upon complete understanding of the issues involved in integrating the design and manufacturing domains. This book provides a comprehensive view of the capabilities of advanced DFM/A systems based on a common architecture.
https://books.google.co.in/books?id=8T3UBwAAQBAJ
O. Molloy,
https://scholar.google.co.uk/citations?user=TBH2_0cAAAAJ&hl=th
Integrated Design of a Product Family and Its Assembly System
Pierre De Lit, Alain Delchambre
Springer Science & Business Media, 28-Jun-2011 - Science - 281 pages
The last two decades have witnessed important shifts in customers' behaviour. Companies now need to integrate customers in their strategies and manufacturers have to propose a large variety of products to meet the market's demand. Increasing the range of PVs attracts and retains customers, yet it dramatically augments the cost and complexity of the manufacturing systems. As many decisions taken at the design stage of the product are decisive for its entire life, it is crucial to integrate the process and the assembly system when designing the product.
Integrated Design of a Product Family and Its Assembly System presents an integrated approach for the design of a product family and its assembly system, whose main principles consider the product family as a fictitious unique product for which the assembly system is to be devised. It imposes assembly and operation constraints as late as possible in the design process to get liberties in the system design, and adapts the product family at each design stage to integrate the new constraints related to the successive design choices.
Integrated Design of a Product Family and Its Assembly System is an important, must-have book for researchers and Ph.D. students in Computer-Integrated Manufacturing, Mechanical Engineering, and Manufacturing, as well as practitioners in the Design, Planning and Production departments in the manufacturing industry. Integrated Design of a Product Family and Its Assembly System is also suitable for use as a textbook in courses such as Computer-Aided Design, Concurrent Engineering, Design for Assembly, Process Planning, and Integrated Design.
https://books.google.co.in/books?id=rZzzBwAAQBAJ
Casting Design Issues and Practices
H.W. Stoll
https://books.google.co.in/books?id=vQAj5iB4KY4C&pg=PA1#v=onepage&q&f=false
Search "Design for Manufacture" in archive.org, More than 2000 results come and many are design and manufacture descriptions - books and reports.
Practical Design for Manufacturability and Assembly
A deep dive into product development, manufacturing and assembly cost reduction focusing on first principles and design best practices. _ - Interesting Explanation
William Burke
15 MAY 2020 • 13 MIN READ
DFMA - Concepts, Benefits and Applications
Bayoumi, A.M.E.
University of South Carolina
DFMA for Mechanical Items in Electronics Products
2019
Mechanical design for electronics product-DFMA and failure analysis
Jerry Wang, 26-Oct-2019 - Technology & Engineering - 14 pages
General DFMA principles, considerations. Failure analysis method and possible cause frequent problems.
DFMA: A Method for Rules Classification - Computer Aided DFMA
Design For Manufacturability And Assemblability Of Printed Circuit Board
Development and utilization of a DFMA-evaluation matrix for comparing the level of modularity and standardization in clamping systems
V. Leminen*, H. Eskelinen**, S. Matthews***, J. Varis****
http://dx.doi.org/10.5755/j01.mech.19.6.5999
ISSN 1392 - 1207. MECHANIKA. 2013 Volume 19(6): 711-715
Application of a Design Method for Manufacture and Assembly: Flexible Assembly Methods and their Evaluation for the Construction of Bridges
Master of Science Thesis in the Master’s Programme Design and Construction Project Management
MICHEL KALYUN, TEZERA WODAJO
Department of Civil and Environmental Engineering, Division of Structural Engineering
Steel and Timber Structures
CHALMERS UNIVERSITY OF TECHNOLOGY
Göteborg, Sweden 2012
Development of Microwave Ridged Horn Antenna using DFMA Approach
Dr. Lachiram, ES Suraj.
Defence Electronics Research Laboratory (DLRL), Hyderabad
Dr Soni, JS
Bharat Institute of Engineering and Technology, Hyderabad, India
International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181 http://www.ijert.org
IJERTV5IS100022
Vol. 5 Issue 10, October-2016
Integration of DFMA and DFE for Development of a Product Concept: A Case Study
Boppana V. Chowdary & Azizi Harris
The University of the West Indies, St Augustine, Trinidad,
Seventh LACCEI Latin American and Caribbean Conference for Engineering and Technology (LACCEI’2009)
“Energy and Technology for the Americas: Education, Innovation, Technology and Practice”
June 2-5, 2009, San Cristóbal, Venezuela.
Application of DFE and DFMA for enabling sustainable development: Exclusively for automotive sectors Paperback – January 23, 2019
by Suresh Periyasamy (Author)
LAP LAMBERT Academic Publishing (January 23, 2019)
Language : English
Paperback : 188 pages
DfMA House Panel Production
The consortium has designed an efficient production line for DfMA houses under factory conditions (Figure 1). The aim is to address low productivity by reducing variability in work processes and utilising lean principles to ensure a continuous system flow of DfMA houses.
DFMA = Design for Assembly + Manufacturing by Bob Warfield
DFMA Videos
MFET 460 Integrated Design for Manufacture & Assembly: DFMA Videos
Ud 30.11.2024, 2.12.2023, 27.11.2021
Pub 15.12.2019
Taylor - Narayana Rao Principles of Industrial Engineering
Industrial Engineering for Society Prosperity through Productivity Improvement satisfying all constraints and limits.
New. Popular E-Book on IE,
Introduction to Modern Industrial Engineering. #FREE #Download.
In 1% on Academia.edu. 12,000+ Downloads so far.
https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0
Online Free Access Handbook of Industrial Engineering includes all modules of IE Online Course Notes.
Industrial Engineering for Society Prosperity through Productivity Improvement satisfying all constraints and limits.
New. Popular E-Book on IE,
Introduction to Modern Industrial Engineering. #FREE #Download.
In 1% on Academia.edu. 12,000+ Downloads so far.
https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0
Industrial Engineers, Display Industrial Engineering Principles in Your Department.
Practice them and Provide Value to the organization.
Taylor - Narayana Rao Principles of Industrial Engineering were developed Prof. Narayana Rao K.V.S.S. in two stages. In the first Stage, Taylor's principles of scientific management were converted into basic principles of industrial engineering.
Principles of Scientific Management - Taylor
The managers following scientific management thought do the following things.
First. They develop a science for each element of a man's work, which replaces the old rule-of.-thumb method.
Second. They scientifically select and then train, teach, and develop the workman, whereas in the past he chose his own work and trained himself as best he could.
Third. They heartily cooperate with the men so as to insure all of the work being done in accordance with the principles of the science which has been developed.
Fourth. There is an almost equal division of the work and the responsibility between the management and the workmen. The management take over all work for which they are better fitted than the workmen, while in the past almost all of the work and the greater part of the responsibility were thrown upon the men.
The principles explain the question what is industrial engineering (IE)?
Basic Principles of Industrial Engineering - Narayana Rao
1. Develop science for each element of a man - machine system's work related to efficiency and productivity.
2. Engineer methods, processes and operations to use the laws related to the work of machines, man, materials and other resources.
3. Select or assign workmen based on predefined aptitudes for various types of man - machine work.
4. Train workmen, supervisors, and engineers in the new methods, install various modifications related to the machines that include productivity improvement devices and ensure that the expected productivity is realized.
5. Incorporate suggestions of operators, supervisors and engineers in the methods redesign on a continuous basis.
6. Plan and manage productivity at system level.
(The principles were developed on 4 June 2016 (During Birthday break of 2016 - 30 June 2016 to 7 July 2016).
The principles were developed by Narayana Rao based on principles of scientific management by F.W. Taylor)
Principles of Industrial Engineering - Narayana Rao - Detailed List
Clicking on the link will take you to more detailed content on the principle
9. Principles of motion economy to be used in all IE studies in the area of human effort engineering
11. Work measurement
21. Cost measurement
The full paper on the principles by Prof. K.V.S.S. Narayana Rao is now available for downloading from IISE 2017 Annual Conference Proceedings in Proquest Journal Base.
Presentation on Principles of Industrial Engineering First made by Dr. Narayana Rao on 23 May 2017 in IISE Annual Conference, Pittsburgh, USA.
_________________
_________________
John Heap
Managing Director at Institute of ProductivityPrinciples of Productivity Science
Stimulated by recent exchanges in this group, on behalf of the World Confederation of Productivity Science, I have drafted the following principles of productivity science .... the principles that productivity leaders and practitioners should adopt to ensure their work is technically and ethically valid. Comments welcome!Undertake a structured and systematic review of the social, environmental and economic value created by human endeavour;
Measure, at macro and micro levels, the value created - and the resources consumed to produce it;
Design products in ways which facilitate efficient manufacturing, distribution and subsequent disposal; Design services that are user-focused and scalable whilst remaining efficient in terms of their requirements for physical infrastructure and administrative support.
Strive to identify and eliminate or minimize waste across the lifecycle of services and products (including throughout manufacturing and delivery processes);
Ensure all working environments and working practices are designed to ensure the safety and well-being of the workforce;
Minimise the consumption of energy and natural resources;
Minimise harmful effects on the natural environment;
Establish working systems, processes and methods that reduce inherent variability;
Treat all members of the workforce with respect and, wherever possible, engage them in decision-making processes that affect their work roles or working conditions;
Ensure that all staff have the tools, equipment and skills necessary to maximize their performance;
Engage individuals and teams in productivity and performance enhancing reviews and investigations.
Posted on linked on 27 June 2018
https://www.linkedin.com/groups/2587524/2587524-6417631280732651523
Industrial Engineers, Display Industrial Engineering Principles
in Your Department.
Practice them and Provide Value to the organization.
Principles of Industrial Engineering
1. Productivity Science Principle of Industrial Engineering.
2. Productivity Engineering Principle of Industrial Engineering.
3. Ubiquity of Industrial Engineering Principle.
4. Machine Utilization Economy Principle of Industrial Engineering.
5. Optimization Principle of Industrial Engineering.
6. Return on Investment Principle of Industrial Engineering.
7. Implementation Principle of Industrial Engineering.
8. Human Effort Engineering Principle of Industrial Engineering.
9. Motion Economy Principle of Industrial Engineering.
10. Operator Comfort and Health Principle of Industrial Engineering.
11. Work Measurement Principle of Industrial Engineering
12. Operator Selection Principle of Industrial Engineering
13. Process Training Principle of Industrial Engineering
14. Productivity training Principle of Industrial Engineering
15. Employee Involvement Principle of Industrial Engineering
16. Productivity Incentives Principle of Industrial Engineering
17. Hearty Cooperation Principle of Industrial Engineering
18. Productivity Management Principle of Industrial Engineering
19. System Level Focus Principle of Industrial Engineering
20. Productivity Measurement Principle of Industrial Engineering
21. Cost Measurement Principle of Industrial Engineering
Industrial Engineering - More Principles
Industrial Engineering Principle of Respect for People.
Taylor wrote, "The writer has a profound respect for the working men of this country. "
https://nraoiekc.blogspot.com/2013/08/personal-relations-between-employers.html
Quality Principle of Industrial Engineering
Effectiveness First - Efficiency Next Principle of Industrial Engineering.
Updated on 4.8.2024, 29.6.2024, 13.10.2023, 6.4.2023, 27.1.2023, 13 Jan 2023, 4 August 2021, 29 June 2021, 5 July 2017, 28 June 2017
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