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WHAT IS DFMA/DFA (DESIGN FOR ASSEMBLY) | ENGINEERING SPIRIT | YouTubeToText
YouTube Transcript: WHAT IS DFMA/DFA (DESIGN FOR ASSEMBLY)
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Summary
Core Theme
Design for Manufacture and Assembly (DFMA) is a methodology focused on optimizing product design by reducing components and processes, thereby lowering costs and improving efficiency.
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dfma is a methodology
for optimizing a new concept or an
existing design with respect to
manufacture and assembly
by reducing the number of components or
processes needed by eliminating excess
components we also eliminate the
drawings of these components the need to
keep them up to date
the risk of wrong production of the
components the need to store them
as well as the risk of incorrect
assembly of the product itself
the cheapest component is one that does
not exist
the dfma process consists of four steps
conceptualization analysis redesign and conclusion
conclusion
to understand each of these steps we are
going to apply the dfma process to a
simple everyday product a tea set
which includes a teacup with an ear a
the tea cup its ear and saucer are made
from ceramic
while the spoon is made from stainless steel
steel
during the conceptualization phase we
review the user requirements of the product
product
so what are the user requirements of a
domestic tea set
well from a functional standpoint it
it should be possible to pick it up
easily with one hand without getting
burnt and to place it on a flat surface
like a table whenever needed
it should include a mechanism for
stirring the liquid and it should
protect other surfaces from spillage and
finally from a commercial standpoint it
should be affordable and attractive to
the target market
during analysis we assembled the product
piece by piece on paper to build an
assembly diagram
an assembly diagram consists of five
different types of objects components
processes combined components the main
assembly and sub-assemblies
the goal of analysis is to uncover at
this early stage any excess components
or processes which may exist
a component is made up of a single piece
and is supplied as is for assembly
in our tea set components include the
spoon the ear the cup
and the saucer
individual components in the assembly
diagram are evaluated by means of three
elimination questions
the answers to these questions help
determine whether the component can be
eliminated without the loss of
functionality through integration with
other components
components that could lose their right
to exist in their current form are
referred to as suspect components
a process is an action done on a
combination of components during assembly
assembly
the application of glue to attach the
ear to the cup is a process
if the component requires a protective
layer like a coating then the
application of the coating is also a process
process
if the coating is on a component you buy
like a galvanized bolt it's not seen as
being separate and the two are
considered to be one
component processes are also evaluated
using the elimination questions and
those that could be eliminated are
a combined component consists of several
components but is delivered as a
combination and cannot be easily dismantled
dismantled
a ball bearing or photocell is a
combined component
a main assembly is the product for which
the assembly diagram is made it consists
of components combined components and
sub-assemblies in our case this would
include the saucer the cup with its ear
and the spoon
a sub-assembly is a combination of two
or more components treatments or
processes which must first be assembled
before they can be incorporated into the
main assembly or another sub-assembly
in our example the cup and its ear
together form a sub-assembly
let's now look at the three elimination
questions to find suspect components and
suspect processes
the first question is
should the component move or be able to
move in relation to the preceding
component in the assembly diagram
look at the cup's ear
does the ear need to move in order for
it to function
the answer is no and in fact it doesn't
move because it is glued to the cup
then we ask
are there fundamental reasons for the
component being made of a different
material which does not otherwise occur
in the product
once again let's look at the ear
the ear does not need to be of a
material different than the cup it too
is made of ceramic so the answer is no
the final elimination question is this
should the component be fitted or
removed separately because otherwise
assembly or disassembly of other
theoretically essential components would
be impossible
so in our example we ask
does the ear need to be detachable in
order to execute any of the processes
associated with the product like
drinking or cleaning
the answer is once again no
if the answer to each of the three
elimination questions is no then the
component in this case the ear becomes a
suspect component and a candidate for
integration with another component
consequently the process of gluing the
ear to the cup also becomes a suspect process
process
if during the analysis phase components
or processes are marked as suspect then
a redesign can be considered in our
example we marked the ear as a suspect
component and the gluing of the ear to
the cup as a suspect process
so now we ask ourselves is there any way
we could eliminate these suspects while
retaining the functionality of the
product and perhaps even improving it
we can make the ear an integral part of
the design and production of the cup so
that the cup and ear are a single piece
of ceramic
this will eliminate the ear as a
separate component and eliminate the
process of gluing of the ear to the cup
once the redesign is done the results
are incorporated into a new target
this final step of the dfma process
primarily involves the creation of a
report in which we capture key
information like details of the
participants in the dfma process
date and location it was held key user requirements
requirements
outcome of the analysis including
assembly diagrams
description of alternative designs and
finally the evaluation of key issues and
action points
it is at the conclusion of the dfma
process that real work begins where
ideas and actions make their way into
the real product and when the results of
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