viii 3.3.3.1.7 Action Taken
42 3.3.3.2 Discussion on FMEA solution
42 3.3.3.3 How to apply FMEA method
43 3.3.3.4 FMEA result
43 3.3.4 Design For Manufacturing Assembly DFMA flow chart
43 3.3.4.1 Functional analysis
43 3.3.4.2 Manufacturing analysis
44 3.3.4.3 Handling analysis
44 3.3.4.4 Assembly Analysis
44 3.3.4.5 Optimized analysis
44 3.5
Result Phase 45
3.5.1 Results and Discussion 45
3.5.2 Fabrication of product 45
3.6 Preparation Report Presentation
45 3.6.1 Preparation Report and Presentation Phase
45
CHAPTER 4: DEVELOPMENT OF SLITTING SHEET METAL MACHINE FOR WIRE MESH
4.0 Introduction 46
4.1 Market identification 47
4.2 Conceptual design stage 47
4.3 Concept evaluation or integrated the method of process design
48 4.3.1 Pugh Matrix Pugh’s Method
49
4.3.1.1 Proposed concept design of Slitting sheet metal machine 49 4.3.1.1.1 Datum Design
49 4.3.1.1.2 Product description of concept design A
50 4.3.1.1.3 Product description of concept design B
51 4.3.1.1.4 Product description of concept design C
52 4.3.1.2 Method of controlled convergence Pugh’s Method
53 4.3.2 Integration of Pugh’s Method and Failure Mode Effect and Analysis 56
FMEA
ix 4.3.2.1 Failure Mode Effect and Analysis FMEA
56 4.3.2.1.1 Suitability of design Ergonomic Design
57 4.3.2.1.2 Manufacturing consideration
57 Assembly operation
4.3.2.2 Recommended Action and RPN 59
4.3.2.2.1 Risk Priority Numbers RPN 59
4.3.2.3 Product Design Specification PDS for FMEA designs 59 4.3.2.4 Improvement of part design
60 4.3.2.5 Determine new RPN value
61 4.3.3 Design for Manufacturing Assembly DFMA
63 4.3.3.1 Proposed original design of Slitting sheet metal machine 63
4.3.3.1.1 Product description for original design 63
4.3.3.1.2 Product structure and part quantity for original 65 design
4.3.3.1.3 Bill of materials for original design 69
4.3.3.1.4 Part functions and critics for original design 70 4.3.3.1.5 Design for Manufacturing DFM analysis for 73
original design 4.3.3.1.6 Design for Assembly DFA analysis for original 75
design 4.3.3.2 Proposed redesign of Slitting sheet metal machine
76 4.3.3.2.1 Part eliminations from proposed design
76 4.3.3.2.2 Product description for proposed design
77 4.3.3.2.3 Product structure and part quantity for proposed 79
design 4.3.3.2.4 Bill of materials for proposed design
84 4.3.3.2.5 Part functions and critic for proposed design 85
4.3.3.2.6 Design for Manufacturing DFM analysis for 88
proposed design 4.3.3.2.7 Design for Assembly DFA Analysis for
89 proposed design
x 4.4
Concept development 91
4.5 Final design
93 4.6 Fabrication process
94 4.6.1 Flowchart of process fabrication
94 4.6.2 Fabrication process for Slitting sheet metal machine
95 4.7
Summary 103
CHAPTER 5: RESULT AND DISCUSSION 5.1 Introduction
104 5.2 Results
104 5.2.1 Pugh’s method result
104 5.2.1.1 Analysis on design concept C DC-C
105 5.2.1.2 Material selection for selection part
106 5.2.1.3 Finite Element Analysis FEA by using SolidWorks
107 Simulation
5.2.1.3.1 Load and Fixtures 107
5.2.1.3.2 Resultant Force 108
5.2.1.3.3 Stress 108
5.2.1.3.4 Resultant Displacement 109
5.2.1.3.5 Strain 110
5.2.1.4 Result of Pugh’s selection method 111
5.2.2 Failure Mode Effect Analysis FMEA Result 111
5.2.2.1 Result of FMEA for blade and shaft 111
5.2.2.2 Severity per Failure Mode SEV 112
5.2.2.3 Occurrence per Failure Mode OCC 113
5.2.2.4 Detection per Failure Mode DET 114
5.2.2.5 Risk Priority Numbers RPN 114
5.2.2.5.1 Reduction percentage 115
5.2.3 Design for Manufacturing Assembly DFMA result 117
5.2.3.1 Result for original design of Slitting sheet metal machine 117 5.2.3.1.1 Suggestion for redesign of original design
117
xi 5.2.3.2 Result for redesign of Slitting Sheet Metal Machine
120 5.2.3.3 Results comparison between original and redesigned
121 5.3 Discussion
122 5.3.1 The comparison between design concepts in Pugh’s method
123 Approach
5.3.2 Finite Element Analysis FEA for top layer shaft and blade 123
5.3.3 Failure Mode Effect Analysis FMEA design concept selection 124 5.3.4 Improvement of redesign concept in Design for Manufacturing 124
Assembly DFMA method 5.3.5 The comparison between existing slitting machine and redesign 125
slitting machine.
CHAPTER 6: CONCLUSION AND RECOMMENDATION
