v
TABLE OF CONTENT
Declaration i
Approval ii
Abstract iii
Abstrak iv
Dedication v
Acknowledgement vi
Table of Content vii
List of Tables xi
List of Figures xii
List Abbreviations xiv
1. INTRODUCTION
1
1.1 Background of the Project
1 1.2
Objectives 3
1.3 Scopes
3 1.4
Problem Statement 4
1.5 Significant of study
5
2. LITERATURE REVIEW
6
2.0 Introduction
6 2.1
Comparison on DFA method 6
2.2 Nail Clipper
9 2.3
Nail Anatomy 10
2.4 The Microstructure and Mechanical properties of
Human fingernail 11
2.5 Design
13 2.5.1 What is Design
13 2.6
Redesign 15
vi 2.7
Definition of Assembly 16
2.7.1 Objective of Assembly 17
2.8. Product Structure
17 2.9
Product Assortment 19
2.10 Design for Assembly
25 2.10.1 What is DFA
25 2.10.2 Benefit of DFA
25 2.10.3 Principle of DFA
26 2.10.3.1 Reduce the total number of parts
28 2.10.3.2 Estimate Handling and Assembly Cost
28 2.11
Manual Assembly Efficiency 29
2.12 General Characteristic of DFA Methodology
31 2.13
Design for Assembly Guideline 32
2.13.1 Simplify the Design 32
2.13.2 Standardize the Parts 32
2.13.3 Ease of Connection 33
2.13.4 Design for Ease Assembly 33
2.14.5 Design for Efficient Joining and Fastening 34
2.15 Boothroyd Dewhurst Method
34 2.14.1 Boothroyd - Dewhurst procedure
36 2.15
Example of DFA Boothroyd Dewhurst Method Handling Analysis
37 2.16
Ease of Handling 40
2.17 Evaluation of Original Product DFA Worksheet
41 2.18
Past case study on Design for Assembly 41
2.18.1 Fire Hose Reel 41
2.18.1.1 Problem Definition 42
2.18.1.2 Solution 42
2.18.1.3 Conclusion 45
2.18.2 Post-design heavy-duty stapler DFA analysis 45
2.18.2.1 Conceptual DFA analysis 47
vii 2.18.2.2 Summary
50 2.18.3 Post-design electric wok DFA analysis
51 2.18.3.1 Conceptual DFA analysis
52 2.18.3.2 Summary
55 2.19
3D Solid Modeling 57
3. METHODOLOGY
58
3.1 Introduction
58 3.2
Gantt chart 59
3.3 Process Flow Chart
61 3.4
Define Problem 61
3.5 Information Search
62 3.6
Internal Information Search 62
3.7 External Information Search
63 3.8
Research Planning 64
3.9 Benchmarking on existing product
64 3.10
Data acquisition for analysis 67
3.11 Boothroyd-Dewhurst DFA Method
69 3.12
Manual assembly efficiency 69
3.13 The classification system
70 3.14
Redesign and Improvement 70
4. RESULT DISCUSSION
