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
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
3.3.4 Preparation Report and Presentation Phase 40
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
4.4 Summary 81
viii
CHAPTER 5: RESULT AND DISCUSSION
