TEM INTRODUCTION LITERATURE REVIEW METHODOLOGY RESULT AND DISCUSSION

CONTENT

CHAPTER ITEM

PAGE APPROVAL DECLARATION ii DEDICATION iii ACKNOWLEGEMENT iv ABSTRACT v ABSTRAK vi CONTENT vii LIST OF FIGURES xi LIST OF TABLES xv LIST OF APPENDIX xvi

CHAPTER 1 INTRODUCTION

1.1 General Introduction 1 1.2 Objective 2 1.3 Scope 2 1.4 Problem Statement 3

CHAPTER 2 LITERATURE REVIEW

2.1 Development History of DFMA 4 2.1.1 Design for Assembly 5 2.1.2 Design for Manufacture 8 2.1.3 DFMA Software 9 2.2 Alternative “DFMA-like” theories 10 2.2.1 The Lucas DFA methodology 10 2.2.2 Cyber Cut 11 2.2.3 The Nippondenso Method 12 2.2.4 Producibility Measurement Tool 12 2.2.5 Feature Based Manufacturability Evaluation 12

CHAPTER 3 METHODOLOGY

3.1 Introduction 13 3.2 Tensile Testing 13 3.2.1 Purpose of Tensile Testing 13 3.2.2 Why Perform a Tensile Test or Tension Test? 14 3.2.3 Material and Other Specifications 14 3.2.4 Equipment 15 3.2.5 Procedures 16 3.3 Design for Manufacture and Assembly Method DFMA using Boothroyd and Dewhurst’s B D Analysis 18 3.3.1 Definition of Alpha and Beta Symmetry 23 3.3.2 Classification Systems Handling Code and Insertion Code 24 3.4 Parts for Elimination for Honda Civic Door 26 3.5 Parts for Elimination for Proton Wira Door 30

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 33 4.2 Result 34 4.2.1 Analysis Result of Assembly Time Elimination Part for Honda Civic Door 35 4.2.2 Analysis Result of Assembly Time Elimination Part for Proton Wira Door 4.3 Discussion 48 4.3.1 Total Assembly Time Elimination Part Analysis for Honda Civic Door 48 4.3.2 Total Assembly Time Elimination Part Analysis for Proton Wira Door 51 4.3.3 Comparison Result between Honda Civic Door and Proton Wira Door 52 4.4 Tensile Test Result Analysis for Honda Civic Door and Proton Wira Door 53 4.4.1 Result for Proton Honda Civic Door Skin 53 4.4.2 Result for Proton Wira Door Skin 61 4.5 Discussion 69 4.5.1 Tensile Testing Result on Honda Civic Door Skin and Proton Wira Door Skin 69

CHAPTER 5 CONCLUSION AND RECOMMENDATION