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Cost Reduction Study of Automotive Part Using Dfa Method: Car Seat

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Cost Reduction Study of Automotive Part Using Dfa Method: Car Seat COST REDUCTION STUDY OF AUTOMOTIVE PART USING DFA METHOD: CAR SEAT MUHAMMAD BIN MOHD NOOR Report submitted in fulfillment of the requirements for the awards of the degree of Bachelor of Mechanical Engineering with Automotive Engineering Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG JUNE 2012 vii ABSTRACT Design for Assembly (DFA) has been widely used in industry and has produced many successes. Some of the methods known in the DFA industry now are the Boothroyd- Dewhurst DFA method, Hitachi Assemblability Evaluation Method (AEM) and the Lucas –Hull DFA method. With these well-known methods, many important changes and developments carried out either manually or through the automatic assembly. The goals of this project are to analyse existing car seat using Boothroyd-Dewhurst DFA and Hitachi Assemblability Evaluation Method (AEM) in terms of assembly time, assembly cost and assembly efficiency. The car seat that has been used in this project is a car seat of Proton Wira. The original car seat has been analysed and showed that Boothroyd-Dewhurst DFA has low percentage design efficiency compare to Hitachi AEM DFA method. The assembly cost of both methods is same. The assembly time of both methods also calculated. viii ABSTRAK Reka bentuk untuk pemasangan (DFA) telah digunakan dengan meluas dalam industri dan telah menghasilkan banyak kejayaan. Beberapa cara mengetahui dalam industri DFA sekarang ialah kaedah Boothroyd-Dewhurst DFA, cara menganalisis Hitachi Assemblability (AEM) dan kaedah Lucas DFA-Hull. Dengan kaedah-kaedah terkenal ini, banyak pertukaran-pertukaran yang penting dan perkembangan-perkembangan dijalankan sama ada secara manual atau melalui perhimpunan automatik. Matlamat- matlamat projek ini akan menganalisis tempat duduk wujud menggunakan Boothroyd- Dewhurst DFA and Hitachi Assemblability Evaluation Method (AEM) dalam soal masa pemasangan, kecekapan kos pemasangan dan pemasangan. Tempat duduk yang telah digunakan dalam projek ini ialah satu tempat duduk Proton Wira. Tempat duduk asal telah dianalisis dan ditunjukkan yang Boothroyd-Dewhurst DFA mempunyai kecekapan reka bentuk peratus rendah berbandingan kaedah Hitachi AEM DFA. Kos pemasangan kedua-dua kaedah sama. Masa pemasangan kedua-dua kaedah turut dikira. ix TABLE OF CONTENTS Page EXAMINER APPROVAL DOCUMENT i TITLE PAGE ii SUPERVISOR’S DECLARATION iii STUDENT’S DECLARATION iv DEDICATION v ACKNOWLEDGEMENTS vi ABSTRACT vii ABSTRAK viii TABLE OF CONTENTS ix LIST OF TABLES xii LIST OF FIGURES xiii LIST OF SYMBOLS xv LIST OF ABBREVIATIONS xvi CHAPTER 1 INTRODUCTION 1.1 Introduction 1 1.2 Problem Statement 3 1.3 Project Objectives 3 1.4 Scopes of Study 4 1.5 Expected Outcomes 4 1.6 Report Arrangement 5 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction 6 2.2 Design for Assembly (DFA) 6 2.3 General Design Guidelines for Manual Assembly 7 2.3.1 Design Guidelines for Part Handling 8 2.3.2 Design Guidelines for Insertion and Fastening 9 x 2.4 Design for Assembly Method 16 2.4.1 Boothroyd-Dewhurst DFA Method 16 2.4.2 Hitachi Assemblability Evaluation Method (AEM) 24 2.4.3 Lucas-Hull DFA Method 31 2.5 Comparison of DFA Method 34 2.6 Previous Research 40 2.7 Conclusion 43 CHAPTER 3 METHODOLOGY 3.1 Introduction 44 3.2 Design of Project Study 46 3.3 Disassemble and Measuring the Product 47 3.4 Drawing of the Product 48 3.5 Example of Manual Calculations of Boothroyd DFA Method 50 3.6 Example of Manual Calculations of Hitachi AEM DFA Method 52 3.7 Conclusion 53 CHAPTER 4 PRELIMINARY RESULT AND DISCUSSION 4.1 Introduction 54 4.2 Product Information 54 4.3 Product Design Analysis using Boothroyd-Dewhurst DFA 58 4.3.1 Original Design Analysis 63 4.3.2 Original Design Calculations 66 4.3.3 Redesign 1 Analysis 67 4.3.4 Redesign 1 Calculations 70 4.3.5 Redesign 2 Analysis 71 4.3.6 Redesign 2 Calculations 74 4.3.7 Redesign 3 Analysis 75 4.3.8 Redesign 3 Calculations 78 4.4 Product Design Analysis for Hitachi AEM DFA Method 79 4.4.1 Original Design Analysis 79 4.4.2 Original Design Calculations 84 4.4.3 Redesign 1 Analysis 85 4.4.4 Redesign 1 Calculations 90 xi 4.4.5 Redesign 2 Analysis 91 4.4.6 Redesign 2 Calculations 95 4.4.7 Redesign 3 Analysis 96 4.4.8 Redesign 3 Calculations 100 4.5 Summary 101 4.5.1 Results of Boothroyd DFA method 101 4.5.2 Results of Hitachi AEM DFA method 101 4.6 Conclusion 102 CHAPTER 5 CONCLUSIONS AND RECOMMENDATIONS 5.1 Introduction 103 5.2 Conclusion 103 5.3 Recommendations for Future Works 104 REFERENCES 105 APPENDICES A1 Manual Handling 106 A2 Manual Insertion 107 B1 Gantt Chart FYP 1 108 B2 Gantt Chart FYP 2 109 xii LIST OF TABLES Table No. Title Page 2.1 Manual assembly worksheet for the original design 22 2.2 Manual assembly worksheet for redesign 1 23 2.3 Manual assembly worksheet for redesign 2 24 2.4 Hitachi AEM DFA method worksheet 28 2.5 Assemble of a pneumatic pump 30 2.6 DFA methods comparison table 34 2.7 Previous Research of Boothroyd DFA Method and Hitachi AEM 40 DFA method 3.1 Table for computation of design efficiency 51 4.1 Reference specification of dimension and weight of Proton Wira 55 4.2 The main components of the car seat 58 4.3 Boothroyd DFA worksheet for original design analysis 65 4.4 Boothroyd DFA worksheet for redesign 1 analysis 69 4.5 Boothroyd DFA worksheet for redesign 2 analysis 73 4.6 Boothroyd DFA worksheet for redesign 3 analysis 77 4.7 Assembly process and operation of the original car seat 74 4.8 Hitachi AEM worksheet for original design analysis 83 4.9 Assembly process and operation of the redesign 1 car seat 86 4.10 Hitachi AEM worksheet for redesign 1 analysis 89 4.11 Assembly process and operation of the redesign 2 car seat 92 4.12 Hitachi AEM worksheet for redesign 2 analysis 94 4.13 Assembly process and operation of the redesign 3 car seat 97 4.14 Hitachi AEM worksheet for redesign 3 analysis 99 4.15 Results of Boothroyd DFA method 101 4.16 Results of Hitachi AEM DFA Method 101 xiii LIST OF FIGURES Figure No. Title Page 2.1 Geometrical features affecting part handling 8 2.2 Geometrical features affecting part handling 8 2.3 Incorrect geometry can allow part to jam during insertion 11 2.4 Provision of air-relief passages to improve insertion into blind 11 holes 2.5 Design for ease of insertion: assembly of long stepped bushing 12 into counter-bored hole 2.6 Provision of chamfers to allow easy insertion 12 2.7 Standardize parts 13 2.8 Single-axis pyramid assembly 13 2.9 Provision of self-locating features to avoid holding down and 14 alignment 2.10 Design to aid insertion 14 2.11 Common fastening methods 15 2.12 Insertion from opposite directions requires repositioning of 15 assembly 2.13 Alpha and beta rotational symmetries for various parts 18 2.14 General rule for size and thickness 18 2.15 Selected manual insertion time standards, seconds 19 2.16 Original design 21 2.17 Redesign 1 22 2.18 Redesign 2 23 2.19 Hitachi’s AEM procedure 25 2.20 Direction of motion of a part 26 2.21 Fixture & forming requirements 27 2.22 Joining & processing requirements 27 2.23 Other symbols without penalty points 28 2.24 Assemble of a pneumatic pump 29 xiv 2.25 Original drain pump assembly design 32 2.26 Redesign using the Lucas DFA method 33 3.1 Flow chart 45 3.2 Car seat drawing 48 3.3 Product tree of the car seat 49 3.4 Pneumatic piston sub-assembly 50 3.5 Assemble of a screw to a body 52 4.1 Location of car seat 55 4.2 Car seat Proton Wira 55 4.3 Product tree of the car seat 56 4.4 Redesign 1 67 4.5 Modification of back rest assembly 68 4.6 Modification of bolts and nuts 68 4.7 Redesign 2 71 4.8 Modification of front back adjuster assembly 72 4.9 Redesign 3 76 4.10 Modification of pump assembly 76 4.11 Assembly sequences of the original car seat 80 4.12 Assembly sequences of the redesign 1 car seat 85 4.13 Assembly sequences of the redesign 2 car seat 91 4.14 Assembly Sequences of the redesign 3 Car Seat 96 xv LIST OF SYMBOLS Ema Design efficiency Nmin Theoretical minimum number of parts Ta Total assembly time Tma Estimated time to complete the assembly of the product E Assemblability evaluation score ratio K Assembly cost ratio α Rotational symmetry of a part about an axis perpendicular to its axis of insertion β Rotational symmetry of a part about its axis of insertion T Time xvi LIST OF ABBREVIATIONS NM Theoretical Minimum Number of Parts TM Total Assembly Time DFA Design for Assembly DFM Design for Manufacture DFMA Design for Manufacture and Assembly AEM Assemblability Evaluation Method AOPDO Assembly-Oriented Product Design and Optimization IDEFO Integration Definition for Function Modelling CA Component Accessibility PA Product Assemblability SAS Spreadsheet Analysis DFAA Design for Automatic Assemblies ADE Assemblability Design Efficiency FYP 1 Final Year Project 1 FYP2 Final Year Project 2 ASF Assembly Flow Flowchart 1 4 4 4 4 CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION Seat comfort or discomfort evaluation is a key aspect in seat design. Functionality of the seat can easily be evaluated through available state-of-the-art technology solutions but comfort or discomfort and aesthetic factors are still very much relying on human‟s perception.
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