Optimization Design Of Slicing Machine Using Design Of Manufacturing And Assembly (DFMA) Method.

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OPTIMIZATION DESIGN OF SLICING MACHINE USING

DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

METHOD

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Design) (Hons.)

by

MUHAMAD DALEEL BIN MOHD IDROS B051010221

890808-07-5193

FACULTY OF MANUFACTURING ENGINEERING 2013


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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: OPTIMIZATION DESIGN USING DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA)

SESI PENGAJIAN: 2012/2013 SEMESTER 2

Saya MUHAMAD DALEEL BIN MOHD IDROS

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ()

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

Alamat Tetap:

NO 22,JLN BATU JAUHAR 6,TMN ROWTHER,68100 GOMBAK,SELANGOR Tarikh: _________________________

Disahkan oleh:

Cop Rasmi:

Tarikh: _______________________ ** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.


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DECLARATION

I hereby, declared this report entitled “Optimization Design of Slicing Machine using Design for Manufacturing and Assembly (DFMA) method” is the results of my own research except as cited in references.

Signature : ………

Author’s Name : MUHAMAD DALEEL BIN MOHD IDROS


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APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Design) (Hons.). The member of the supervisory is as follow:


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i

ABSTRAK

Projek ini adalah untuk menunjukkan penggunaan kaedah Rekabentuk Pembuatan dan Pemasangan (DFMA) dalam proses pembangunan produk. Di dalam projek ini, mesin pemotong di pilih sebagai produk di dalam proses Rekabentuk Pembuatan dan Pemasangan (DFMA). Objektif projek ini adalah untuk mengurangkan bahagian-bahagian komponen di dalam mesin pemotong di samping untuk menganalis bahan dan proses yang sesuai digunakan dalam penghasilan mesin pemotong. Di samping itu juga, kaedah Rekabentuk Pembuatan dan Pemasangan (DFMA) di pilih kerana kaedah ini dapat mengira kos tenaga kerja yang diperlukan dalam proses pembuatan. Bagi memudahkan proses analisis, perisian Boothroyd-Dewhurst DFMA digunakan. Perisian ini di pilih kerana ia terbukti berkesan untuk mengurangkan komponen-komponen dalam sesuatu produk dan mudah digunakan oleh pereka. Hasil kajian ini telah menunjukkan DFA indeks reka bentuk baru mesin pemotong meningkat 26% daripada reka bentuk asal dan kos reka bentuk baru adalah 45.27% lebih rendah dari RM9500.07 kepada RM5199.07. Kesimpulannya, DFMA digunakan sebagai asas untuk kajian kejuruteraan serentak untuk memberi panduan kepada perekabentuk dalam merekabentuk produk. Selain itu, Rekabentuk untuk Pembuatan (DFM) telah digunakan untuk memilih proses yang paling sesuai dan bahan-bahan dengan bimbingan sifat bentuk dalam carta keserasian. Tambahan pula, peringkat Rekabentuk untuk Pemasangan (DFA) adalah kaedah penting yang boleh digunakan untuk meningkatkan reka bentuk produk. Dalam usaha untuk meningkatkan projek ini, beberapa cadangan telah dirancang iaitu di harap kajian mengenai potensi bahagian geometri antaramuka atau data komponen yang dihubungkan dengan perisian dapat dilakukan. Projek ini diharap dapat diteruskan ke peringkat fabrikasi. Tambahan pula, pemilihan bahan mestilah memenuhi beberapa spesifikasi seperti dapat menahan daya tujah, suhu dan tekanan,.


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ii

ABSTRACT

This project is to demonstrate the use of Design Manufacture and Assembly (DFMA) in product development process. In this project, slicing machine is chosen as the product to use in the process of DFMA. The objective of this project is to reduce the number of component of the cutter as well as to analyse the materials and processes involved in the production of slicing machine. In addition, the method of DFMA is chosen due its ability to calculate the cost of labour required in the manufacturing process. To ease up the analysis, Boothroyd-Dewhurst DFMA software was used. This software is chosen due to its effectiveness in reducing the components in a product and which is convenient to be utilized by designers. The results of this study are the new design of slicing machine in which 26% improvement from original design in DFA index and the cost of the new design is 45.27% lower than the original design from RM9500.07 to RM5199.07. As for the conclusion, , DFMA is used as the basis for concurrent engineering studies to provide guidance to the designs in designing the product. Besides that, Design for Manufacturing (DFM) was applied to choose the most suitable process and material with the guidance of the shape attribute in the compatibility chart. Plus, Design for Assembly (DFA) stage is a vital tool that can be used to improve the product design. In order to improve the project, several recommendations has been planned which is a research on the potential of geometry interface part or components data to be linked to the software can be conducted. This project are recommended to be preceded into the fabrication stage. Plus, the material chosen must consists several specifications such as it can resist force, temperature and pressure.


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iii

DEDICATION

This report is dedicated to my parents, brothers and sisters for their endless love, support and encouragement. I also dedicate this work to my supervisor and friends

who have supported me throughout the process. I will always appreciate all they have done. Thank you.


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iv

ACKNOWLEDGEMENT

First of all, I would like to express my thankfulness to Allah S.W.T the Almighty because I manage to finish this Final Year Project on time. With full of His merciful, now I am writing this report of this project.

I also like to state my gratitude to my supervisor, Engr. Dr Hambali B. Ariff @ Arep for his assistance and guidance in producing this report and giving me his constructive comments, guidance, patience and encouragement until the completion of this report. Besides that, I would like to express my thankfulness to my parents and friends for their continuous supports and advices in complete the report.

I hope that this project report will fulfill the conditions as requested in Final Year Project in UTeM.


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v

TABLE OF CONTENTS

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Contents v

List of Tables ix

List of Figures xi

List of Abbreviations, Symbols and Nomenclatures xiv

CHAPTER 1: INTRODUCTION

1.1 Background of Project 1

1.2 Problem Statement 2

1.3 Objectives 3

1.4 Scope of Project 3

CHAPTER 2: LITERATURE REVIEW

2.1 Optimization Design (OD) 4

2.2 The Usage of Optimization Design in Improving Design 5 2.3 Design for Manufacturing and Assembly (DFMA) 6

2.3.1 History of DFMA 6

2.3.2 What is DFMA? 6

2.3.3 Advantages of applying DFMA 11 2.3.4 A Case Study from Previous Research 12

2.3.4.1 Texas Instruments 13

2.3.5 Design for Manufacturing (DFM) 15

2.3.6 Design for Assembly (DFA) 16

2.3.7 DFA Methodologies 18

2.3.7.1 The Boothroyd-Dewhurst Method 18 2.3.7.2 The Lucas-Hull DFA Evaluation Method 19


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vi 2.3.7.3 The Hitachi Assembleability Evaluation Method 20

2.3.7.4 The Effort Flow Analysis 20

2.3.8 General Design Guidelines for Manual Assembly 21 2.3.8.1 Design Guidelines for Part Handling 21 2.3.8.2 Design Guidelines for Insertion and Fastening 23 2.3.9 The role of DFMA in optimizing design 28

2.4 Slicing Machine 29

2.4.1 History of Slicing Machine 29

2.4.2 The role of Slicing Machine 31

2.5 Summary 32

CHAPTER 3: METHODOLOGY

3.1 Introduction 33

3.2 Project Planning 33

3.3 Project Planning Phase 35

3.3.1 Planning Phase 35

3.3.1.1 Define the objective 35

3.3.1.2 Scope of Project 35

3.3.1.3 Problem Statement 36

3.3.1.4 Literature Review 36

3.3.1.5 Methodology 36

3.3.2 Implementation and Analysis Phase 36

3.3.2.1 DMFA Method Procedure 38

3.3.3 Result Phase 40


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vii CHAPTER 4: OPTIMIZATION OF CONCEPTUAL DESIGN OF SLICING MACHINE

4.1 Introduction 41

4.2 Proposed Original Design of Slicing Machine 42 4.2.1 Detail Original Product for Original Design 42 4.2.1.1 Product Description for Original Design 43 4.2.1.2 Product Structure and Part Quantity for Original Design 47 4.2.1.3 Bill of Materials for Original Design 51 4.2.1.4 Part Functions and Critics for Original Design 53 4.2.2 DFMA Analysis for Original Design 59 4.2.2.1 Design for Manufacturing (DFM) Analysis for Original 59

Design

4.2.2.2 Design for Assembly (DFA) Analysis for Original Design 61

4.3 Proposed Redesign of Slicing Machine 63

4.3.1 Part Elimination from Original Design 63 4.3.2 Detail Redesign Product for Proposed Design 64 4.3.2.1 Product Description for Proposed Design 64 4.3.2.2 Product Structure for Proposed Design 66 4.3.2.3 Bill of Materials for Proposed Design 72 4.3.2.4 Part Functions and Critics for Proposed Design 73 4.3.3 DFMA Analysis for Proposed Design 77 4.2.2.1 Design for Manufacturing (DFM) Analysis for Proposed 77

Design

4.2.2.2 Design for Assembly (DFA) Analysis for Proposed 79 Design


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viii CHAPTER 5: RESULT AND DISCUSSION

5.1 Introduction 82

5.2 Results 82

5.2.1 Results for Original of Slicing Machine 83

5.2.2 Suggestion for Redesign from DFMA Software 83

5.2.3 Results for Redesign of Slicing Machine 88

5.2.4 Results Comparison between Original Design and 89

Redesign of Slicing machine 5.3 Discussion 91

CHAPTER 6: CONCLUSION AND RECOMMENDATIONS 6.1 Conclusion 93

6.2 Recommendations 94

REFERENCES 96

APPENDIX A PSM 1 Gantt Chart 99

APPENDIX B PSM 2 Gantt Chart 100

APPENDIX C Manual Handling Table 101

APPENDIC D Manual Insertion Table 102

APPENDIX E Material and Process Selection Table 103

APPENDIX F 2D Drawing for Original Design of Slicing Machine 104

APPENDIX G 2D Drawing for Redesign of Slicing Machine 127

APPENDIX H DFMA Software Report for Original Design 143

of Slicing Machine APPENDIX I DFMA Software Report for Redesign 168

of Slicing Machine APPENDIX J DFMA Software Report for Comparison 184


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ix

LIST OF TABLES

2.1 DFMA results from 117 published case studies involving 56 companies data as of April 1999

10

2.2 Comparison of Original Design and New Designs of the Reticule Assembly

14

4.1 Bill of Material of overall number of part of original design 51 4.2 Parts functions and critics of original design 53 4.3 Material and process of each part of original design 59 4.4 Assembly Difficulties for Original Design of Slicing Machine 62

4.5 Eliminated Parts from Original Design 63

4.6 Bill of Material of overall number of part of improved design 72 4.7 Parts functions and critics of improved design 74 4.8 Material and process of each part in improved design 77 4.25 Assembly Difficulties of improved design 80

5.1 Suggestion for incorporate integral fastening elements 85 5.2 Suggestion for combine connected items 85 5.3 Suggestion for reduce the number of items in the assembly 85 5.4 Suggestion for reduce separate operation times 86 5.5 Suggestion for design locating into mating parts of the assembly 87

5.6 Suggestion for add assembly features 87

5.7 Suggestion for redesign the assembly 87

5.8 Suggestion for redesign of the items to eliminate or reduce of their handling difficulties

87

5.9 Suggestion for redesign of the individual assembly items to eliminate the need for grasping tools

88

5.10 Suggestion for redesign of the individual assembly items to eliminate handling difficulties causing the items require two hands


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x 5.11 DFMA results comparisons between original and new improved

design of product


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xi

LIST OF FIGURES

1.1 Old Method Cutting Process 2

2.1 Sequence of Analysis DFMA 7

2.2 DMFA Methodology 8

2.3 DFMA techniques 9

2.4 Survey on the importance of reductions produced by DFMA 11 2.5 Time to deliver comparison between DFMA+CE and the

Traditional Methods

12

2.6 Reticule assemblies – original design 13

2.7 Reticle assemblies – New Design 14

2.8 Geometrical features affecting part handling 21 2.9 Some other features affecting part handling 22 2.10 Incorrect geometry can allow part to jam during insertion 23 2.11 Provision of air-relief passages to improve insertion into blind

holes

23

2.12 Design for ease of insertion – assembly of long stepped bushing into counter bored hole

24

2.13 Provision of chamfers to allow easy insertion 24

2.14 Standardize parts 25

2.15 Single-axis pyramid assemblies 25

2.16 Provision of self-locating features to avoid holding down and alignment

26

2.17 Design to aid insertion 26

2.18 Common fastening methods 27

2.19 Insertion from opposite direction requires repositioning of assembly

27

2.20 The first bread-slicing machine by Otto Frederick 30 2.21 Examples of slicing machine in manufacturing industry 31


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xii

3.1 Project Planning Phase 34

3.2 Design For Assembly (DFA) Software 37

3.3 Design For Manufacture (DFM) Software 37

3.4 DFMA Method Procedures 39

4.1 View for top layer and bottom layer subassembly for original design of slicing machine

42

4.2 Views of portions subassembly of original design

43

4.3 Product structure of original design 45

4.4 Assembly drawing of original design 46

4.5 Framework of original design 46

4.6a Top Layer of original design 47

4.6b Top Layer of original design 47

4.7a Bottom Layer of original design 48

4.7b Bottom Layer of original design 48

4.8 Front Side of original design 49

4.9 Back Side of original design 49

4.10 Right Side of original design 50

4.11 Left Side of original design 50

4.12 Top Side of original design 51

4.13 Design for Manufacturing Window of original design 60 4.14 Design for Assembly Window of original design 61 4.15 DFA analysis on the framework of original design 62 4.16 Views of the top layer and the bottom layer of improved design 65 4.17 Views of the right side, left side, front side, back side and the top

side of the redesigned slicing machine of improved design

65

4.18 Product structure of improved design 67

4.19 Assembly drawing of improved design 68

4.20 Framework of improved design 68

4.21 Top Side of improved design 69


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xiii

4.23 Front Side of improved design 70

4.24 Back Side of improved design 70

4.25 Right Side of improved design 71

4.26 Left Side of improved design 71

4.27 Top Layer of improved design 72

4.28 DFM window for Redesign of Slicing Machine 78 4.29 DFA Window for Redesign of Slicing Machine 79 4.30 DFA analysis on the framework of improved design 80

5.1 Before and After of Slicing Machine 89


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xiv

LIST OF ABBREVIATIONS, SYMBOLS AND NOMENCLATURE

DFMA = Design for Manufacture and Assembly DFA = Design for Assembly

DFM = Design for Manufacture

BD-DFA = Boothroyd Dewhurst Design for Assembly AEM = Assembly Evaluation Method

OD = Optimization Design

KTP = Knowledge Transfer Program BDI = Boothroyd Dewhurst Inc. CE = Concurrent Engineering ASF = Assembly Sequence Flowchart MOP = Measures of Performance

UTeM = Universiti Teknikal Malaysia Melaka PSM 1 = Projek Sarjana Muda 1

PSM 2 = Projek Sarjana Muda 2 BDI = Boothroyd Dewhurst Inc IPM = Interior Point Method FEA = Finite Element Analysis


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1 This chapter discusses the background of the project, problem statement, objective and scope of the project.

1.1 Background of Project

This project is actually related to the industry based. In other words, this project solve a problem that occurs in a factory. TR Technology Sdn Bhd is the factory that was selected for collaboration with this project. TR Technology Sdn. Bhd. is located at Seksyen 16, Shah Alam, Selangor. TR Technology Sdn Bhd is a factory which runs a business based on the process of stamping and cutting. Among the activities run in this factory is the process of cutting rubber sheets. In accordance with the process, the problem that arises is the cutting method of the sheets, which they are still using old-fashioned clasp knives. By using this outdated method, it has had wasted the time and cost, the workers’ energy, productivity and the output of the product. To solve of the factory problems, DFMA concept is chosen as a main concept for this project.

The DFMA concept is chosen due to the following factors :-

a) It can increase the quality of new produces during the developmental period, including design, technology, manufacturing and service.

b) It can decrease the cost, including the cost of design, technology, manufacturing, delivery, technical support and discarding.

INTRODUCTION

CHAPTER 1


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2 c) Shorten the development cycle time, including the time of design, manufacturing

preparing, and repeatedly calculation. (Xie, 2002).

1.2 Problem Statement

At the TR Technology Sdn. Bhd, the rubber sheets cutting process is still done by using the conventional method which is using clasp knives (refer to Figure 1.1).

Figure 1.1: Conventional Cutting Process

Therefore, TR Technology Sdn. Bhd. has asked UTeM committee to assist in developing a slicing machine that can reduce wastage material, labor working duration and increase the productivity. The problem arising here is to design a slicing machine that is not yet available in the market. Besides that, the new design of slicing machine has to meet the requirements of the clients, TR Technology Sdn. Bhd. There are also other problems that occurred at this factory. There are :-

a) Ineffective cost-down activities and strategies.

b) Requirement for better improvement in productivity to be competitive in market need further concerted effort.


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3

1.3 Objectives

The main objective of this project is to improve the design of the slicing machine. Specific objective as follows

:-a) To reduce the number of parts through DFMA method.

b) To identify the most appropriate material and process for the product. c) To improve the original design by using DFMA method.

1.4 Scope of Project

The scopes of this project are set at an early stage of the project to ensure that the objective of the project can be achieved. The scopes for this project are

:-a) To design a 3D modeling using Solidwork software.

b) To use a Boothroyd-Dewhurst software for product evaluation.


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4 This chapter covers on the explanation about Design for Manufacturing and Assembly (DFMA) and Optimizing Design (OD). Besides that, this chapter is also highlight the relationship between DFMA and OD.

2.1 Optimization Design (OD)

According to Monge (2001), such design optimization is derived from a formula and solved to gain insight into the converter design tradeoffs and particularities. Until then, a discrete optimization approach is comprised from a genetic algorithm to develop a completely automated user-friendly software design tool, capable of providing globally optimum designs for systems with different sets of specification, in a period of time.

Engineering design optimization is an emerging technology, with its application both shortens design-cycle time and finds new designs that are not only feasible, but optimal, based on the design criteria. In the early days, optimization design had to begin by deriving a formula for design requirements. After that, an initial design is synthesized which must be tested against the requirements, hence creating a prototype and performing experiments. A build-up of a computer model may follow, using one of the many engineering analysis codes, and then the design is validated experimentally since these codes are not accurate. Such a design is found to have defaults in some parts, it is then altered and the process repeats again. The process is executed on and on until the requirements are met or changes are made to fit

LITERATURE REVIEW

CHAPTER 2


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5 performance. This concludes that the process is time consuming and seldom produces the perfect design, just a feasible one (Johnson, 2004).

Optimization methods are formulated to bring out the best values of system design and operating policy variables – values that will lead to the optimum level of performance. When combined with more detailed and accurate simulation methods in short of building an actual model, can be the primary way of estimating the likely impacts of system designs and operating policies (Loucks, 2005).

Optimization can be a subject of dealing the problems of minimizing or maximizing a

certain function in a finite dimensional Euclidean space over a subset of that space which is usually determined by functional inequalities (Anjos and Zhang, 2006).

2.2 The Usage of Optimization Design in Improving Design

With engineering design optimization, it reduces both the time for the design iteration loop and finds the optimum design based on specifications. Unlike the traditional process, the iteration loop is computerized. An optimization problem is posed for which the design variables, the design objectives and all constrai8nts are specified. An appropriate engineering analysis code is combined with an optimization algorithm, which serves as the design modifier (Johnson, 2004).

The history of the application of optimization in engineering goes a long way. In common application areas of engineering such as transportation, production planning, design and data fitting, power plants and so on, uses widely the two special classes of optimization problems, linear least squares and linear optimization problems. The introduction of highly efficient Interior Point Method (IPM) based algorithms and software for convex optimization since the 90s has motivated people to apply convex optimization models in numerous areas of engineering, such as communications, automatic control systems, signal processing, networks, product and shape design, truss topology design, electronic circuit design, data analysis and modeling, statistics and finance, engineering (Anjos and Zhang, 2006).


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6

2.3 Design for Manufacturing and Assembly (DFMA)

2.3.1 History of DFMA

Before the Second World War, Ford and Chrysler use the DFM philosophy in their design and manufacturing process of the weapons, tanks and other military products. It was in the beginning of the 1970’s, when Dr. Geoffrey Boothroyd and Dr. Peter Dewhurst, who founded the Boothroyd Dewhurst Inc. (BDI) in1982, they were the pioneers in this new technology. The “DFMA” in actual became their company trademark. They created and developed the DFMA concept which is used in developing the products of their company, the DFMA software system. 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. They also do a lot of work examining the economic justification of each design revision (Xie, 2005).

2.3.2 What is DFMA?

The term “DFMA” comes with the combination of DFA (Design for Assembly) and DFM (Design of Manufacturing) as shown on Figure 2.1. The basic concept of it is that the design engineers apply the DFMA paradigm or software to analyze the manufacturing and assembly problems at the early design stage. In other words, all the possible factors that will affect the outcome will occur just as in the design stage. Less precious time will be wasted on the early design stage as during repeatedly redesign stage, and costs are reduced in the meantime (Xie, 2005).


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1 This chapter discusses the background of the project, problem statement, objective and scope of the project.

1.1 Background of Project

This project is actually related to the industry based. In other words, this project solve a problem that occurs in a factory. TR Technology Sdn Bhd is the factory that was selected for collaboration with this project. TR Technology Sdn. Bhd. is located at Seksyen 16, Shah Alam, Selangor. TR Technology Sdn Bhd is a factory which runs a business based on the process of stamping and cutting. Among the activities run in this factory is the process of cutting rubber sheets. In accordance with the process, the problem that arises is the cutting method of the sheets, which they are still using old-fashioned clasp knives. By using this outdated method, it has had wasted the time and cost, the workers’ energy, productivity and the output of the product. To solve of the factory problems, DFMA concept is chosen as a main concept for this project.

The DFMA concept is chosen due to the following factors :-

a) It can increase the quality of new produces during the developmental period, including design, technology, manufacturing and service.

b) It can decrease the cost, including the cost of design, technology, manufacturing, delivery, technical support and discarding.

INTRODUCTION


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2 c) Shorten the development cycle time, including the time of design, manufacturing

preparing, and repeatedly calculation. (Xie, 2002).

1.2 Problem Statement

At the TR Technology Sdn. Bhd, the rubber sheets cutting process is still done by using the conventional method which is using clasp knives (refer to Figure 1.1).

Figure 1.1: Conventional Cutting Process

Therefore, TR Technology Sdn. Bhd. has asked UTeM committee to assist in developing a slicing machine that can reduce wastage material, labor working duration and increase the productivity. The problem arising here is to design a slicing machine that is not yet available in the market. Besides that, the new design of slicing machine has to meet the requirements of the clients, TR Technology Sdn. Bhd. There are also other problems that occurred at this factory. There are :-

a) Ineffective cost-down activities and strategies.

b) Requirement for better improvement in productivity to be competitive in market need further concerted effort.


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3 1.3 Objectives

The main objective of this project is to improve the design of the slicing machine. Specific objective as follows :-

a) To reduce the number of parts through DFMA method.

b) To identify the most appropriate material and process for the product. c) To improve the original design by using DFMA method.

1.4 Scope of Project

The scopes of this project are set at an early stage of the project to ensure that the objective of the project can be achieved. The scopes for this project are :-

a) To design a 3D modeling using Solidwork software.

b) To use a Boothroyd-Dewhurst software for product evaluation.


(4)

4 This chapter covers on the explanation about Design for Manufacturing and Assembly (DFMA) and Optimizing Design (OD). Besides that, this chapter is also highlight the relationship between DFMA and OD.

2.1 Optimization Design (OD)

According to Monge (2001), such design optimization is derived from a formula and solved to gain insight into the converter design tradeoffs and particularities. Until then, a discrete optimization approach is comprised from a genetic algorithm to develop a completely automated user-friendly software design tool, capable of providing globally optimum designs for systems with different sets of specification, in a period of time.

Engineering design optimization is an emerging technology, with its application both shortens design-cycle time and finds new designs that are not only feasible, but optimal, based on the design criteria. In the early days, optimization design had to begin by deriving a formula for design requirements. After that, an initial design is synthesized which must be tested against the requirements, hence creating a prototype and performing experiments. A build-up of a computer model may follow, using one of the many engineering analysis codes, and then the design is validated experimentally since these codes are not accurate. Such a design is found to have defaults in some parts, it is then altered and the process repeats again. The process is executed on and on until the requirements are met or changes are made to fit

LITERATURE REVIEW


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5 performance. This concludes that the process is time consuming and seldom produces the perfect design, just a feasible one (Johnson, 2004).

Optimization methods are formulated to bring out the best values of system design and operating policy variables – values that will lead to the optimum level of performance. When combined with more detailed and accurate simulation methods in short of building an actual model, can be the primary way of estimating the likely impacts of system designs and operating policies (Loucks, 2005).

Optimization can be a subject of dealing the problems of minimizing or maximizing a certain function in a finite dimensional Euclidean space over a subset of that space which is usually determined by functional inequalities (Anjos and Zhang, 2006).

2.2 The Usage of Optimization Design in Improving Design

With engineering design optimization, it reduces both the time for the design iteration loop and finds the optimum design based on specifications. Unlike the traditional process, the iteration loop is computerized. An optimization problem is posed for which the design variables, the design objectives and all constrai8nts are specified. An appropriate engineering analysis code is combined with an optimization algorithm, which serves as the design modifier (Johnson, 2004).

The history of the application of optimization in engineering goes a long way. In common application areas of engineering such as transportation, production planning, design and data fitting, power plants and so on, uses widely the two special classes of optimization problems, linear least squares and linear optimization problems. The introduction of highly efficient Interior Point Method (IPM) based algorithms and software for convex optimization since the 90s has motivated people to apply convex optimization models in numerous areas of engineering, such as communications, automatic control systems, signal processing, networks, product and shape design, truss topology design, electronic circuit design, data analysis and modeling, statistics and finance, engineering (Anjos and Zhang, 2006).


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6 2.3 Design for Manufacturing and Assembly (DFMA)

2.3.1 History of DFMA

Before the Second World War, Ford and Chrysler use the DFM philosophy in their design and manufacturing process of the weapons, tanks and other military products. It was in the beginning of the 1970’s, when Dr. Geoffrey Boothroyd and Dr. Peter Dewhurst, who founded the Boothroyd Dewhurst Inc. (BDI) in1982, they were the pioneers in this new technology. The “DFMA” in actual became their company trademark. They created and developed the DFMA concept which is used in developing the products of their company, the DFMA software system. 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. They also do a lot of work examining the economic justification of each design revision (Xie, 2005).

2.3.2 What is DFMA?

The term “DFMA” comes with the combination of DFA (Design for Assembly) and DFM (Design of Manufacturing) as shown on Figure 2.1. The basic concept of it is that the design engineers apply the DFMA paradigm or software to analyze the manufacturing and assembly problems at the early design stage. In other words, all the possible factors that will affect the outcome will occur just as in the design stage. Less precious time will be wasted on the early design stage as during repeatedly redesign stage, and costs are reduced in the meantime (Xie, 2005).