Use DFMA Methodology To Analyze On Car Wiper System.
DECLARATION
I hereby, declared this Bachelor‟s Project entitled “Use DFMA Methodology to Analyze
on Car Wiper System” is the result of my own research except as cited in references.
Signature
:
Author‟s Name
: Noorazmie Afzam b. Muhamad Zaki
Date
:
i
APPROVAL
This Bachelor‟s Project submitted to the senate of UTeM and has been accepted as
fulfillment of the requirement for the Degree of Bachelor of Manufacturing Engineering
(Design) with Honours. The member of the supervisory committee is as follow:
…………………………………………
En. Tajul Ariffin b. Abdullah
Project Supervisor
Faculty of Manufacturing Engineering
ii
ABSTRACT
A project titled „„Use DFMA Methodology to Analyze on Car Wiper System‟. The
objectives of this project are mainly to identify weakness of current design in market and
use DFMA methodology the design efficiency and use DFMA to improved current
design and proposed new design too. Through those questions was distributed to well off
public in Malacca Parade parking to detect main part which possess problem and
weakness. That study of member support in this study to seek best concept in design part
that. Which part need to be studied is wiper blade ask for a lot in upgrade. Through that
study, visit carried out to manufacture or wiper blade supplier car to vehicle factory in
Malaysia. The study will be done in Laboratory at Faculty Of Mechanical Engineering,
Technical University of Malaysia Melaka with Boothroyd And Dewhurst software to
identify part will redesign or improved. The problem that happens in the wiper blade can
be identifying by using the DFMA software with assembly cost. At the end of this
research, the several expected result are to provide better redesign wiper blade.
iii
ABSTRAK
Kajian ini adalah bertajuk „Use DFMA Methodology to Analyze on Car Wiper System‟ .
Objektif bagi pelaksanaan projek ini pada amnya adalah untuk mengkaji kelemahan
yang terdapat dalam rekabentuk biasa yang ada dipasaran serta menggunakan kaedah
DFMA untuk mengkaji kebolehan dalam rekabentuk produk tersebut. Juga
menggunakan DFMA untuk meningkatkan keberkesanan reka bentuk produk terbaru.
Melalui soalan-soalan yang diedar untuk khalayak ramai yang berada di tempat letak
kereta Melaka Parade bagi mengesan bahagian utama yang mempunyai masalah dan
kelemahan. Kajian tersebut bagi member sokongan dalam kajian ini untuk mendapatkan
konsep yang terbaik dalam rekaan part tersebut. Bahagian yang perlu dikaji adalah
pengelap cermin yang banyak meminta di tingkatkan. Melalui kajian tersebut, lawatan
dijalankan ke tempat pembuat atau pembekal pengelap kereta untuk kilang kenderaan di
Malaysia. Kajian tersebut dilakukan di dalam makmal Fakulti Kejuruteraan Mekanikal,
Universiti Teknikal Malaysia Melaka dengan mengunakan perisian Boothroyd DFMA
dimana ia akan mengesan bahagian yang perlu direka kembali atau dibuang untuk
mempertingkatkan lagi rebentuk tersebut. Dimana bahagian pengelap cermin dikanlpasti
permasalah dan diselsesaikan dengan menggunakan perisian DFMA untuk permasalahan
cost pemasangan. Di akhir kajian ini juga keputusan yang diduga adalah, dapat
menyediakan satu reka bentuk baru yang lebih baik dari yang asal.
iv
DEDICATION
For my beloved family:
Muhamad Zaki bin Saleh
Ruhani binti Zakaria
Noorazrin Azafri bin Muhamad Zaki
Noorazlie Syazrin bin Muhamad Zaki
Nizartul Athirah binti Muhamad Zaki
Nur Farahana binti Muhama Zaki
To my lovely fiancé
Noor Juliana binti Jaa’far
To all my beloved and cherish friends
v
ACKNOWLEDGEMENTS
Alhamdulillah and Thank to Allah S.W.T. with all His Gracious and His Merciful for
giving me strength and ability to accomplish this project research successfully. I would
like to take the utmost opportunity to express my sincere and gratitude to my supervisor,
En Tajul Ariffin bin Abdullah who is always giving me supports and guidance in
completing this Final Year Project 1 & 2 until up to this stage in victory.
Also with the greatest thanks to my beloved parents En Muhamad Zaki Bin Saleh and
Ruhani Binti Zakaria and family who always pray and give the encouragement while
pursuing my research and project. Their sacrifices are never being forgotten and will be
remembered forever.
Besides, thanks a lot to Dr. Mohd Rizal Bin Salleh, Dean of Manufacturing Engineering,
Malaysia Technical University of Malacca and also to all lecturers of Faculty of
Manufacturing Engineering.
I also would like to convey my appreciation to all the staff in Wiper car manufacture for
supporting me in accomplishes my Final Year Project without hesitation. All knowledge
and experience I gained would not be forgotten.
And last but not least, to all my fellow friends who involves direct or indirectly that
always stand strong beside me in giving opinions and supports throughout our
relationship, I really thankful and appreciate it. All yours are the most valuable things
for the rest of my life.
vi
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
vi
Table of Content
vii
List of Figure
xi
List of Table
xiv
List of Abbreviations
xv
1.0
CHAPTER 1: INTRODUCTION
1.1
Introduction
1
1.2
Objective
3
1.3
Problem Statement
4
1.4
Scope
4
2.0
CHAPTER 2: LITERATURE REVIEW
2.1
Introduction
6
2.2
Traditional Design Methods
7
2.2.1
Differences DFMA with Traditional Methods
10
2.3
Design for Manufacture (DFM)
12
2.3.1
DFM Principle
14
2.3.2
Benefit of DFM
15
vii
2.4
Design for Assembly
16
2.4.1
Base Component
17
2.4.2
Number of Part
18
2.4.3
Fastener
18
2.4.4
Design of Part
19
2.4.5
Redesign
19
2.5
Design For Manufacture And Assembly (DFMA)
20
2.5.1
DFMA with Concurrent Engineering
20
2.5.1
DFMA is Combination With Two Methods DFA & DFM
21
2.5.3
Design For Manufacture And Assembly Process
23
2.5.4
Benefit Design Manufacture And Assembly
24
3.0
CHAPTER 3: CAR WIPER
3.1
Introduction
28
3.2
The Car Wiper Uses
29
3.3
History of Car Wiper
30
3.4
Raw Material
31
3.5
The Type of Car Wiper
32
3.6
The Working Principle of Car Wiper
34
3.6.1
Motor and Gear Reduction
35
3.6.2
Linkage
35
3.7
Wiper Blade
36
3.7.1
The slope and area of the windshield
36
3.7.2
The amount of spring tension on the wiper arm
37
3.7.3
The number of pressure points or claws holding the blade
37
3.7.4
The material used in the blade itself
38
3,8
Wiper Control
38
3.9
The Manufacturing Process
39
viii
4.0
CHAPTER 4: RESEARCH METHODOLOGY
4.1
Introduction
42
4.2
Methodology
42
4.3
Questionnaire Outline / Survey Instrument.
43
4.4
The Advantages and limitations of Questionnaire Survey
44
4.5
Analysis of the Survey Data.
44
5.0
CHAPTER 5: RESULT FROM SURVEY AND DFMA ANALYSIS
5.1
Introduction
46
5.2
Questionnaire Survey Result
46
5.3
Scenario Simulation
53
5.4
DFA
59
5.4.1
Current design
59
5.4.2
Redesign
62
5.5
DFM
65
6.0
CHAPTER 6: DISCUSSION
6.1
Introduction
68
5.2
Data from Questionnaire
68
6.3
Analysis from DFMA
72
7.0
CHAPTER 7: CONCLUSION
7.1
Introduction
73
7.2
Conclusion
74
8.0
CHAPTER 5: SUGGESTION AND RECOMMENDATION
8.1
Introduction
76
8.2
Suggestion and Recommendation
76
ix
9.0
REFERENCES
79
10.0
APPENDICES
81
x
LIST OF FIGURE
2.1
Sequential Design Approach
8
2.2
Traditional Manufacturing Process
9
2.3
Model of generic process or productive system
11
2.4
Typical DFM flowchart (Martin O‟Driscoll, 2001).
14
2.5
Type for Considered About DFA
17
2.6
Typical stages in a DFMA procedure
24
3.1
Windshield wiper car
29
3.2
Picture Inventor Mary Anderson
30
3.3
Tandem System
33
3.4
Some of the different wiper blade schemes used by various cars
34
4.1
Framework of an Implementation Model for Research
45
5.1
Show Pie Chart List of Part.
48
5.2
Show Pie Chart for a Weakness for Wiper Blade
49
5.3
Pie Chart for Time Change Their Wiper Blade.
50
5.4
Show Pie Chart for Criteria.
51
xi
5.5
Concept design process flowchart
53
5.6
Use diagram
5.7
show about concept 1, have 4 claws and rivet each other
57
5.8
Show about concept 2, which reduce 2 claw a improve the bushing
57
5.9
show about concept 3
57
5.10
List assembly the wiper blade
5.11
New Wiper Blade
5.12
Table and the chart show a breakdown of time per
.
.
54
58
.
58
59
product for current design
5.13
Table and the chart show a breakdown of cost per
60
product for current design
5.14
Table show a DFA index for current design
61
5.15
Table and the chart show a breakdown of time
62
per product for redesign
5.16
Table and the chart show a breakdown of cost
63
per product for redesign
5.17
Table show a DFA index for redesign
5.18
Show Graph the Total Cost $ vs Life Volume for
.
64
65
Superstructure Part
5.19
Show Graph the Total Cost $ vs Life Volume for
65
Element Part
5.20
Show Graph the Total Cost $ vs Life Volume for Claw Part
66
5.21
Show Graph the Total Cost $ vs Life Volume for
66
Bushing Part
xii
5.22
Show graph The Total Cost $ vs Life Volume for Adapter Part
xiii
67
LIST OF TABLE
5.1
List Manufacture and Car Used.
47
5.2
List of Part.
48
5.3
List the Weakness
49
5.4
Show Time Change Their Wiper Blade
50
5.5
The Criteria from Correspondent Thinking
51
5.6
Show calculation pointer for questionnaire as use in Pugh‟s matrix
52
5.7
Pugh‟s Matrix for concept collection
55
5.8
List Part Material and Process (Champion Motor Sdn. Bhd.)
57
6.1
Show calculate negative, neutral and positive
71
xiv
LIST OF ABBREVIATIONS
DFA
-
Design for Assembly
DFM
-
Design for Manufacture
DFMA
-
Design for Manufacture and assembly
SPC
-
Statically Process Control
CAE
-
Computer-Aided Engineering
xv
CHAPTER 1
INTRODUCTION
1.1
Introduction
Manufacturing industry era is beginning of the year 1960‘s, at this time
manufacturing industry walk with such great. A lot of competition and new
inventions producing products that give competition in world economy. At
that time, it has been used tradition system, each division or sector part to the
someone‘s expertise in undergoes his task only. While somebody only have
the expertise in his field but will in stationed in stated sector. No deep
unanimity does something decision. This matter will give some problem to
those areas that further. For example, designer will design only product that
he think well founded because every each design it only guided to data are
acquired. The real problem that will happen when the designer creates their
design make would be brought to department process. So here will happen
the differences of opinion because possibility design make unable meet
machine utilization or process would be made. If their making also, it will go
to be on expansion cost. The cost will be rising because a part that the
arduous make. In tradition practice, industries practices ―wall approach".
Wall approach is a barrier happens inside the area of manufacturing. Term
"we design it, you build it" of course deep synonym in tradition system. Here
no discussion will make, only waited what designer should do is more
1
enough. This matter, if continuously will make one company pay for higher
whereas stated cost can be reduced. Apart from that, part also actually could
be reduced.
By year end 1970, this problem realized by a person whose named Geoffrey
Boothroyd in University of Massachusetts. With the case study which is
done by Geoffrey Boothroyd has made it with one method whose can solve
the problem with producing his Design for Assembly and Design for
Manufacture (DFA and DFM). Design for Assembly (DFA) is a method or
system to facilitate a deep product installation. This matter, emphasize with
some procedure that need followed and am being cared deep assembly
method. It can be reduce cost bear by the company. Apart from that, can
reduce part unconnected sense in the products can be chased away. With that
system, installation time could be reduced hereby get increase productivity
quoted company. Whereas Design for Manufacture (DFM) is a system or
method that concerned to the components something easy of use in the
products process and cost. Process driving at is deep machine utilization
make stated product could be reduced. Hereby, designer necessary drop
heavy process that have and the process that would face. Each part necessary
have the process or machine that there on the company because it will reduce
manufacturing cost. Through DFM and DFA, wall approach get be torn and
are eliminated in a sector. Through to the DFM and DFA, to will start of
something product will happen a discussion through the chief of each
department.
They will jointly discuss deep tackle will happen and can
produce one product with good. Hence, the process dialogue is this in that
process paramount is very importance. Dialogue is important to encouraged
between designs and manufacturing engineers that will giving the team an
attitude necessary to concurrent engineering.
In 1983, through to the Dr. Geoffrey Boothroyd and Dr. Peter Dewhurst have
introduced DFMA (Design for Manufacture and Assembly).
With this
method, exist deeply union DFA's method and DFM previously. DFMA's
purpose introduced was to facilitate more of something products are studied
in installation aspects and his manufacturing.
2
If second this aspect
emphasized, product one make will reduce in the use cost to make and
through data are obtainable get also that person, redesign something product
until producing a good product.
This motivated author, to use the method DFMA for his bachelor's for the
project. A product wiper seated study deep product wiper now much
difference car among one product wiper with one product another. Whereas
function to wiper car is the same, namely wiping things that there were to car
mirror and also help driver give the view best-of in his driving. In study
weakness have the product will be identify, by using DFMA methodology,
design that there were this, Get our particle suffixed to the emphatic word in
sentence pores to quantify design efficiency.
Apart from that, increase
goodness to current design and new design and comparing them.
In conclusion is the method use this can be help a tackle will arise after this.
It is the method for sense get helps the research. Our one box know, DFMA's
method can help in settling minimize part that there to each product. Apart
from that, through no DFMA work that postpone too long as time can be
shortened.
1.2
Objective
There were 3 objectives would be made:
To identify weaknesses of current design of car wiper system.
Use DFMA methodology to quantify the design efficiency.
Use DFMA to improve current design and proposed new design.
3
1.3
Problem Statement
In recognition process to use DFMA method, a product would be identified.
Through stated product, with necessary study in the use and function product
stated. Current product will be undertaken via the market that there were in
passed market study material and difference design that there were in
circulation in the market. Current product that there were to market have
difference each design and each product different form and unequal follow
the price to market. Proven each product have cost in whose bear different.
Through DFMA, will approach current design with comparing all products to
market and find best-of to approach current product stated become primary
current product. Later, to current design stated redesign back to gain product
a more favorable go comparing it to section evaluate the effectiveness
software DFMA stated in tackle stated. Whether software DFMA can solve
this problem and enhance product stated to best from the aspect benefit to
manufacture and assembly process.
1.4
Scope
The aim for this project is to use the DFMA method on this project. Research
for weakness in the current design and approach that to make redesign that.
Use the methodology of DFMA software. By using software Boothroyd and
Dewhurst software can solve and increase product stated. Purpose a study the
effectiveness software stated in tackle to current product. Weakness that can
to current product could be overcome nicely. Apart from increase another to
product with new emphasizes manufacture and assembly process.
This
matter, there were to Boothroyd and Dewhurst software because in software
4
stated there were DFA and DFM. With this method, the extra time spent in
the early design stage is much less the time that ill be spent in the repeatedly
redesign. And meanwhile, the cost will be reduced. A design team was
founded and the goal of the team was to finish the design with a concept that
would meet the product requirement and meanwhile, improve the
manufacturability of the product. They used Boothroyd – Dewhurst DFMA as
the framework during the whole design process.
When the concept design finished the designer will met the supplier at this
time, reviewed the part design and developed a better one. The results of this
effort are that the new product is greatly simplified, the improvement of
assembly and assembly cost. DFMA shorten the manufacturing time,
decrease the cycle time and keep the high quality of the product, and
meanwhile make the design more creative. The author was focused the efforts
on the analysis material selection, assembly process and the sheet metal
working of the parts. Have a five parts were redesigned from a manufacture
point of view which reduce time and cost. An added bonus to those changes
was a time and cost saving at the assembly stage.
In conclusion, DFMA is a good method to increase the productiveness,
decrease the cycle time and cost of manufacture and assembly. Meanwhile,
the DFMA software is helpful to finish these products faster and easier.
DFMA software combines the knowledge of product design, assembly
process, material selection and manufacturing technology.
5
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
Design for Manufacture and Assembly (DFMA) as it has become to known
and is now a widely accepted technique. Design for Manufactured and
Assembly (DFMA) technique has been utilized extensively in industry field
these days. If its trace the history of DFMA its can even find it before the
Second World Warford and Chryler use the DFM philosophy in their design
and manufacturing process of the weapons, tanks, and other military
products. Dr. Geoffrey Boothroyd and Dr. Dewhurts
who founded the
Boothroyd Dewhurts. Inc (BDI) in 1982 is the first persons doing the research
job in this new technology in the early 1970‘s. Currently these programs are
used to help the design in almost all the industrial fields including circuit
boards with manual assembly, with robotic assembly and with machining. It
also does a lot of work examining the economic justification of each design
revision. It has been practiced in many manufacturing industry around the
world, among other seek to reduce development time, lower costs, increase
productivity and improve product quality.
DFMA is to maximize the use of manufacturing processes and minimize the
number of components in and assemble or product (K.L. Edwards, 2002).
6
I hereby, declared this Bachelor‟s Project entitled “Use DFMA Methodology to Analyze
on Car Wiper System” is the result of my own research except as cited in references.
Signature
:
Author‟s Name
: Noorazmie Afzam b. Muhamad Zaki
Date
:
i
APPROVAL
This Bachelor‟s Project submitted to the senate of UTeM and has been accepted as
fulfillment of the requirement for the Degree of Bachelor of Manufacturing Engineering
(Design) with Honours. The member of the supervisory committee is as follow:
…………………………………………
En. Tajul Ariffin b. Abdullah
Project Supervisor
Faculty of Manufacturing Engineering
ii
ABSTRACT
A project titled „„Use DFMA Methodology to Analyze on Car Wiper System‟. The
objectives of this project are mainly to identify weakness of current design in market and
use DFMA methodology the design efficiency and use DFMA to improved current
design and proposed new design too. Through those questions was distributed to well off
public in Malacca Parade parking to detect main part which possess problem and
weakness. That study of member support in this study to seek best concept in design part
that. Which part need to be studied is wiper blade ask for a lot in upgrade. Through that
study, visit carried out to manufacture or wiper blade supplier car to vehicle factory in
Malaysia. The study will be done in Laboratory at Faculty Of Mechanical Engineering,
Technical University of Malaysia Melaka with Boothroyd And Dewhurst software to
identify part will redesign or improved. The problem that happens in the wiper blade can
be identifying by using the DFMA software with assembly cost. At the end of this
research, the several expected result are to provide better redesign wiper blade.
iii
ABSTRAK
Kajian ini adalah bertajuk „Use DFMA Methodology to Analyze on Car Wiper System‟ .
Objektif bagi pelaksanaan projek ini pada amnya adalah untuk mengkaji kelemahan
yang terdapat dalam rekabentuk biasa yang ada dipasaran serta menggunakan kaedah
DFMA untuk mengkaji kebolehan dalam rekabentuk produk tersebut. Juga
menggunakan DFMA untuk meningkatkan keberkesanan reka bentuk produk terbaru.
Melalui soalan-soalan yang diedar untuk khalayak ramai yang berada di tempat letak
kereta Melaka Parade bagi mengesan bahagian utama yang mempunyai masalah dan
kelemahan. Kajian tersebut bagi member sokongan dalam kajian ini untuk mendapatkan
konsep yang terbaik dalam rekaan part tersebut. Bahagian yang perlu dikaji adalah
pengelap cermin yang banyak meminta di tingkatkan. Melalui kajian tersebut, lawatan
dijalankan ke tempat pembuat atau pembekal pengelap kereta untuk kilang kenderaan di
Malaysia. Kajian tersebut dilakukan di dalam makmal Fakulti Kejuruteraan Mekanikal,
Universiti Teknikal Malaysia Melaka dengan mengunakan perisian Boothroyd DFMA
dimana ia akan mengesan bahagian yang perlu direka kembali atau dibuang untuk
mempertingkatkan lagi rebentuk tersebut. Dimana bahagian pengelap cermin dikanlpasti
permasalah dan diselsesaikan dengan menggunakan perisian DFMA untuk permasalahan
cost pemasangan. Di akhir kajian ini juga keputusan yang diduga adalah, dapat
menyediakan satu reka bentuk baru yang lebih baik dari yang asal.
iv
DEDICATION
For my beloved family:
Muhamad Zaki bin Saleh
Ruhani binti Zakaria
Noorazrin Azafri bin Muhamad Zaki
Noorazlie Syazrin bin Muhamad Zaki
Nizartul Athirah binti Muhamad Zaki
Nur Farahana binti Muhama Zaki
To my lovely fiancé
Noor Juliana binti Jaa’far
To all my beloved and cherish friends
v
ACKNOWLEDGEMENTS
Alhamdulillah and Thank to Allah S.W.T. with all His Gracious and His Merciful for
giving me strength and ability to accomplish this project research successfully. I would
like to take the utmost opportunity to express my sincere and gratitude to my supervisor,
En Tajul Ariffin bin Abdullah who is always giving me supports and guidance in
completing this Final Year Project 1 & 2 until up to this stage in victory.
Also with the greatest thanks to my beloved parents En Muhamad Zaki Bin Saleh and
Ruhani Binti Zakaria and family who always pray and give the encouragement while
pursuing my research and project. Their sacrifices are never being forgotten and will be
remembered forever.
Besides, thanks a lot to Dr. Mohd Rizal Bin Salleh, Dean of Manufacturing Engineering,
Malaysia Technical University of Malacca and also to all lecturers of Faculty of
Manufacturing Engineering.
I also would like to convey my appreciation to all the staff in Wiper car manufacture for
supporting me in accomplishes my Final Year Project without hesitation. All knowledge
and experience I gained would not be forgotten.
And last but not least, to all my fellow friends who involves direct or indirectly that
always stand strong beside me in giving opinions and supports throughout our
relationship, I really thankful and appreciate it. All yours are the most valuable things
for the rest of my life.
vi
TABLE OF CONTENTS
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
vi
Table of Content
vii
List of Figure
xi
List of Table
xiv
List of Abbreviations
xv
1.0
CHAPTER 1: INTRODUCTION
1.1
Introduction
1
1.2
Objective
3
1.3
Problem Statement
4
1.4
Scope
4
2.0
CHAPTER 2: LITERATURE REVIEW
2.1
Introduction
6
2.2
Traditional Design Methods
7
2.2.1
Differences DFMA with Traditional Methods
10
2.3
Design for Manufacture (DFM)
12
2.3.1
DFM Principle
14
2.3.2
Benefit of DFM
15
vii
2.4
Design for Assembly
16
2.4.1
Base Component
17
2.4.2
Number of Part
18
2.4.3
Fastener
18
2.4.4
Design of Part
19
2.4.5
Redesign
19
2.5
Design For Manufacture And Assembly (DFMA)
20
2.5.1
DFMA with Concurrent Engineering
20
2.5.1
DFMA is Combination With Two Methods DFA & DFM
21
2.5.3
Design For Manufacture And Assembly Process
23
2.5.4
Benefit Design Manufacture And Assembly
24
3.0
CHAPTER 3: CAR WIPER
3.1
Introduction
28
3.2
The Car Wiper Uses
29
3.3
History of Car Wiper
30
3.4
Raw Material
31
3.5
The Type of Car Wiper
32
3.6
The Working Principle of Car Wiper
34
3.6.1
Motor and Gear Reduction
35
3.6.2
Linkage
35
3.7
Wiper Blade
36
3.7.1
The slope and area of the windshield
36
3.7.2
The amount of spring tension on the wiper arm
37
3.7.3
The number of pressure points or claws holding the blade
37
3.7.4
The material used in the blade itself
38
3,8
Wiper Control
38
3.9
The Manufacturing Process
39
viii
4.0
CHAPTER 4: RESEARCH METHODOLOGY
4.1
Introduction
42
4.2
Methodology
42
4.3
Questionnaire Outline / Survey Instrument.
43
4.4
The Advantages and limitations of Questionnaire Survey
44
4.5
Analysis of the Survey Data.
44
5.0
CHAPTER 5: RESULT FROM SURVEY AND DFMA ANALYSIS
5.1
Introduction
46
5.2
Questionnaire Survey Result
46
5.3
Scenario Simulation
53
5.4
DFA
59
5.4.1
Current design
59
5.4.2
Redesign
62
5.5
DFM
65
6.0
CHAPTER 6: DISCUSSION
6.1
Introduction
68
5.2
Data from Questionnaire
68
6.3
Analysis from DFMA
72
7.0
CHAPTER 7: CONCLUSION
7.1
Introduction
73
7.2
Conclusion
74
8.0
CHAPTER 5: SUGGESTION AND RECOMMENDATION
8.1
Introduction
76
8.2
Suggestion and Recommendation
76
ix
9.0
REFERENCES
79
10.0
APPENDICES
81
x
LIST OF FIGURE
2.1
Sequential Design Approach
8
2.2
Traditional Manufacturing Process
9
2.3
Model of generic process or productive system
11
2.4
Typical DFM flowchart (Martin O‟Driscoll, 2001).
14
2.5
Type for Considered About DFA
17
2.6
Typical stages in a DFMA procedure
24
3.1
Windshield wiper car
29
3.2
Picture Inventor Mary Anderson
30
3.3
Tandem System
33
3.4
Some of the different wiper blade schemes used by various cars
34
4.1
Framework of an Implementation Model for Research
45
5.1
Show Pie Chart List of Part.
48
5.2
Show Pie Chart for a Weakness for Wiper Blade
49
5.3
Pie Chart for Time Change Their Wiper Blade.
50
5.4
Show Pie Chart for Criteria.
51
xi
5.5
Concept design process flowchart
53
5.6
Use diagram
5.7
show about concept 1, have 4 claws and rivet each other
57
5.8
Show about concept 2, which reduce 2 claw a improve the bushing
57
5.9
show about concept 3
57
5.10
List assembly the wiper blade
5.11
New Wiper Blade
5.12
Table and the chart show a breakdown of time per
.
.
54
58
.
58
59
product for current design
5.13
Table and the chart show a breakdown of cost per
60
product for current design
5.14
Table show a DFA index for current design
61
5.15
Table and the chart show a breakdown of time
62
per product for redesign
5.16
Table and the chart show a breakdown of cost
63
per product for redesign
5.17
Table show a DFA index for redesign
5.18
Show Graph the Total Cost $ vs Life Volume for
.
64
65
Superstructure Part
5.19
Show Graph the Total Cost $ vs Life Volume for
65
Element Part
5.20
Show Graph the Total Cost $ vs Life Volume for Claw Part
66
5.21
Show Graph the Total Cost $ vs Life Volume for
66
Bushing Part
xii
5.22
Show graph The Total Cost $ vs Life Volume for Adapter Part
xiii
67
LIST OF TABLE
5.1
List Manufacture and Car Used.
47
5.2
List of Part.
48
5.3
List the Weakness
49
5.4
Show Time Change Their Wiper Blade
50
5.5
The Criteria from Correspondent Thinking
51
5.6
Show calculation pointer for questionnaire as use in Pugh‟s matrix
52
5.7
Pugh‟s Matrix for concept collection
55
5.8
List Part Material and Process (Champion Motor Sdn. Bhd.)
57
6.1
Show calculate negative, neutral and positive
71
xiv
LIST OF ABBREVIATIONS
DFA
-
Design for Assembly
DFM
-
Design for Manufacture
DFMA
-
Design for Manufacture and assembly
SPC
-
Statically Process Control
CAE
-
Computer-Aided Engineering
xv
CHAPTER 1
INTRODUCTION
1.1
Introduction
Manufacturing industry era is beginning of the year 1960‘s, at this time
manufacturing industry walk with such great. A lot of competition and new
inventions producing products that give competition in world economy. At
that time, it has been used tradition system, each division or sector part to the
someone‘s expertise in undergoes his task only. While somebody only have
the expertise in his field but will in stationed in stated sector. No deep
unanimity does something decision. This matter will give some problem to
those areas that further. For example, designer will design only product that
he think well founded because every each design it only guided to data are
acquired. The real problem that will happen when the designer creates their
design make would be brought to department process. So here will happen
the differences of opinion because possibility design make unable meet
machine utilization or process would be made. If their making also, it will go
to be on expansion cost. The cost will be rising because a part that the
arduous make. In tradition practice, industries practices ―wall approach".
Wall approach is a barrier happens inside the area of manufacturing. Term
"we design it, you build it" of course deep synonym in tradition system. Here
no discussion will make, only waited what designer should do is more
1
enough. This matter, if continuously will make one company pay for higher
whereas stated cost can be reduced. Apart from that, part also actually could
be reduced.
By year end 1970, this problem realized by a person whose named Geoffrey
Boothroyd in University of Massachusetts. With the case study which is
done by Geoffrey Boothroyd has made it with one method whose can solve
the problem with producing his Design for Assembly and Design for
Manufacture (DFA and DFM). Design for Assembly (DFA) is a method or
system to facilitate a deep product installation. This matter, emphasize with
some procedure that need followed and am being cared deep assembly
method. It can be reduce cost bear by the company. Apart from that, can
reduce part unconnected sense in the products can be chased away. With that
system, installation time could be reduced hereby get increase productivity
quoted company. Whereas Design for Manufacture (DFM) is a system or
method that concerned to the components something easy of use in the
products process and cost. Process driving at is deep machine utilization
make stated product could be reduced. Hereby, designer necessary drop
heavy process that have and the process that would face. Each part necessary
have the process or machine that there on the company because it will reduce
manufacturing cost. Through DFM and DFA, wall approach get be torn and
are eliminated in a sector. Through to the DFM and DFA, to will start of
something product will happen a discussion through the chief of each
department.
They will jointly discuss deep tackle will happen and can
produce one product with good. Hence, the process dialogue is this in that
process paramount is very importance. Dialogue is important to encouraged
between designs and manufacturing engineers that will giving the team an
attitude necessary to concurrent engineering.
In 1983, through to the Dr. Geoffrey Boothroyd and Dr. Peter Dewhurst have
introduced DFMA (Design for Manufacture and Assembly).
With this
method, exist deeply union DFA's method and DFM previously. DFMA's
purpose introduced was to facilitate more of something products are studied
in installation aspects and his manufacturing.
2
If second this aspect
emphasized, product one make will reduce in the use cost to make and
through data are obtainable get also that person, redesign something product
until producing a good product.
This motivated author, to use the method DFMA for his bachelor's for the
project. A product wiper seated study deep product wiper now much
difference car among one product wiper with one product another. Whereas
function to wiper car is the same, namely wiping things that there were to car
mirror and also help driver give the view best-of in his driving. In study
weakness have the product will be identify, by using DFMA methodology,
design that there were this, Get our particle suffixed to the emphatic word in
sentence pores to quantify design efficiency.
Apart from that, increase
goodness to current design and new design and comparing them.
In conclusion is the method use this can be help a tackle will arise after this.
It is the method for sense get helps the research. Our one box know, DFMA's
method can help in settling minimize part that there to each product. Apart
from that, through no DFMA work that postpone too long as time can be
shortened.
1.2
Objective
There were 3 objectives would be made:
To identify weaknesses of current design of car wiper system.
Use DFMA methodology to quantify the design efficiency.
Use DFMA to improve current design and proposed new design.
3
1.3
Problem Statement
In recognition process to use DFMA method, a product would be identified.
Through stated product, with necessary study in the use and function product
stated. Current product will be undertaken via the market that there were in
passed market study material and difference design that there were in
circulation in the market. Current product that there were to market have
difference each design and each product different form and unequal follow
the price to market. Proven each product have cost in whose bear different.
Through DFMA, will approach current design with comparing all products to
market and find best-of to approach current product stated become primary
current product. Later, to current design stated redesign back to gain product
a more favorable go comparing it to section evaluate the effectiveness
software DFMA stated in tackle stated. Whether software DFMA can solve
this problem and enhance product stated to best from the aspect benefit to
manufacture and assembly process.
1.4
Scope
The aim for this project is to use the DFMA method on this project. Research
for weakness in the current design and approach that to make redesign that.
Use the methodology of DFMA software. By using software Boothroyd and
Dewhurst software can solve and increase product stated. Purpose a study the
effectiveness software stated in tackle to current product. Weakness that can
to current product could be overcome nicely. Apart from increase another to
product with new emphasizes manufacture and assembly process.
This
matter, there were to Boothroyd and Dewhurst software because in software
4
stated there were DFA and DFM. With this method, the extra time spent in
the early design stage is much less the time that ill be spent in the repeatedly
redesign. And meanwhile, the cost will be reduced. A design team was
founded and the goal of the team was to finish the design with a concept that
would meet the product requirement and meanwhile, improve the
manufacturability of the product. They used Boothroyd – Dewhurst DFMA as
the framework during the whole design process.
When the concept design finished the designer will met the supplier at this
time, reviewed the part design and developed a better one. The results of this
effort are that the new product is greatly simplified, the improvement of
assembly and assembly cost. DFMA shorten the manufacturing time,
decrease the cycle time and keep the high quality of the product, and
meanwhile make the design more creative. The author was focused the efforts
on the analysis material selection, assembly process and the sheet metal
working of the parts. Have a five parts were redesigned from a manufacture
point of view which reduce time and cost. An added bonus to those changes
was a time and cost saving at the assembly stage.
In conclusion, DFMA is a good method to increase the productiveness,
decrease the cycle time and cost of manufacture and assembly. Meanwhile,
the DFMA software is helpful to finish these products faster and easier.
DFMA software combines the knowledge of product design, assembly
process, material selection and manufacturing technology.
5
CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
Design for Manufacture and Assembly (DFMA) as it has become to known
and is now a widely accepted technique. Design for Manufactured and
Assembly (DFMA) technique has been utilized extensively in industry field
these days. If its trace the history of DFMA its can even find it before the
Second World Warford and Chryler use the DFM philosophy in their design
and manufacturing process of the weapons, tanks, and other military
products. Dr. Geoffrey Boothroyd and Dr. Dewhurts
who founded the
Boothroyd Dewhurts. Inc (BDI) in 1982 is the first persons doing the research
job in this new technology in the early 1970‘s. Currently these programs are
used to help the design in almost all the industrial fields including circuit
boards with manual assembly, with robotic assembly and with machining. It
also does a lot of work examining the economic justification of each design
revision. It has been practiced in many manufacturing industry around the
world, among other seek to reduce development time, lower costs, increase
productivity and improve product quality.
DFMA is to maximize the use of manufacturing processes and minimize the
number of components in and assemble or product (K.L. Edwards, 2002).
6