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Design for Assembly (DFA) methodologies help the designer to take into account the assembly process during the development phases of a product (specifications, conceptual design and detailed design), thus improving the assembly process of the product. After a bibliographic review, it is verified that the most extended DFA methodologies are: Boothro...
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... For that, the methods define various evaluation criteria to evaluate the suitability of automation. In specific further developments, the methods and the requirements described therein are combined in different constellations to consider better suitability of the method in connection with the product under consideration [7][8][9][10][11][12][13]. ...
... For the assembly time, the processes are classified as reaching, gripping, and bringing, and the process itself and the assembly time are calculated [17]. The modified Westinghouse method simplifies and differs from the superordinate method in creating the joining sequence diagram and eliminating non-essential components [9,13]. ...
... However, this approach focuses on the assembly processes to identify tasks for humans and functions with a high automation potential. The Hitachi-AEM is categorized as an evaluation method for the assembly process [9,13,18]. According to the Hitachi AEM, two key figures are determined and evaluated to assess the product design. ...
Due to its high complexity and the varied assembly processes, hybrid assembly systems characterized by human–robot collaboration (HRC) are meaningful. Suitable use cases must be identified efficiently to ensure cost-effectiveness and successful deployment in the respective assembly systems. This paper presents a method for evaluating the potential of HRC to derive automation suitability based on existing or to-be-collected time data. This should enable a quick and favorable statement to be made about processes, for efficient application in potential analyses. The method is based on the Methods–Time–Measurement Basic System (MTM-1) procedure, widely used in the industry. This ensures good adaptability in an industrial context. It extends existing models and examines how much assembly activities and processes can be optimized by efficiently allocating between humans and robots. In the process model, the assembly processes are subdivided and analyzed with the help of the specified MTM motion time system. The suitability of the individual activities and sub-processes for automation are evaluated based on criteria derived from existing methods. Two four-field matrices were used to interpret and classify the analysis results. The process is assessed using an example product from electrolyzer production, which is currently mainly assembled by hand. To achieve high statement reliability, further work is required to classify the results comprehensively.
... The paper is a contribution to the improvement of the assembly methods in the field of technological construction of product design in terms of assembly [5,8] or in the area of methodologies known as DFA (Design for Assembly) [3]. ...
In practical applications, statically predetermined pairs are frequently encountered. Designers use them to improve product stiffness. This paper describes a method to reduce the effects of problematic assembly in sliding pairs, which are often statically predetermined. Additionally, it addresses the crucial assembly problem of repetitive accuracy, particularly in assembly line design.
... The Lucas method includes a scale point for assessing the difficulty of implementing assembly processes. This technique provides design efficiency, feeding index, and fitting index [22,23]. Dochibhatla et al. [23] concurrently conquered the Lucas and B&D methodologies implementation. ...
... Ezpeleta et al. [22] Throughout all phases of product development, a novel DFA method for enhancing assembly has been created. ...
A product redesign strategy can effectively shorten design lead time and reduce the manufacturing cost of innovative development for the manufacturing industry to stay competitive. Identification of function components is the basis of product redesign. Existing practices to identify the critical component and customer requirements are considered while complaint and historical failure data, crucial for improving product reliability, are frequently ignored. The objective of the article is to develop an integrated framework of product redesign and innovation considering customer requirements and product failure modes. The novel framework integrates the design for manufacturing and assembly (DFMA) and design for reliability (DFR) approaches, as well as finite element analysis to address the cost reduction of product redesign at early-stage, reliability improvement, and higher customer satisfaction. The proposed integrated framework is validated using an example of an Indonesian SME’s cooking stove. The redesigned cooking stove showed substantial improvements with 5.46% cost reductions, 20.32% design efficiency, and an 52.81% safety factor.
... Remirez et al. (2019), in the study on solar panels, developed a new design approach for longlasting and large-size (Ll-Ls) products by combining them with DFA methods [11]. Ezpeleta et al. (2019) stated that DFA methods support designers in the design phase and this situation has a positive effect on production efficiency [12]. Gao et al. (2019) made an application that could set an example for applying the DFMA method in the construction industry [13]. ...
... Remirez et al. (2019), in the study on solar panels, developed a new design approach for longlasting and large-size (Ll-Ls) products by combining them with DFA methods [11]. Ezpeleta et al. (2019) stated that DFA methods support designers in the design phase and this situation has a positive effect on production efficiency [12]. Gao et al. (2019) made an application that could set an example for applying the DFMA method in the construction industry [13]. ...
The purpose of this research is to show the benefits to be obtained by redesigning production processes for small and medium-sized enterprises, which aim to grow but cannot develop due to runaway production. In this study, an exemplary approach is presented using the principles of Design for Assembly (DFA) in an enterprise aiming to grow in the elevator industry. Within the scope of the research, the doorframe assembly process of the semi-automatic elevator door, which is the most produced in the elevator industry, was examined. According to this; Design improvement studies were carried out in the assembly processes of the side profiles, head plate, forehead plate, floor plate and their subparts used in the production of the case. In the design improvement, the B&D design efficiency measurement principles were used. As a result of the improvements; The semi-automatic door frame, which is 98 pieces in its current design, has been reduced to 55 pieces with the new design. With the reduction in the number of parts and design changes, the total assembly time was reduced by 33.8% in assembly time. As a result of the improvements, the Design Efficiency has been increased from 8.5% to 12.8%.
... In the literature, several DFA methodologies have been studied but the most extensive are those of Boothroyd and Dewhurst [14], Lucas methodology [15], Modified Westinghouse methodology [16], and Hitachi-AEM methodology [17]. Other research studies have combined the 4 methodologies mentioned above to come up with a methodology that allows the product development method to be reinforced in all phases of the design process [18]. However, these methodologies do not allow the study of product design problems at the beginning of the product life cycle, so researchers have proposed new analysis indicators to determine the correct assembly sequences from a ranked list [19]. ...
A mechanical product is the result of collaboration between different domains. In this paper
we focus on the collaborative work that brings together the system engineer and the designer in the
realization process of a mechanical system. A design solution, conceived in the CAD environment,
is considered valid if all the specification requirements, defined in the MBSE (Model Based System
Engineering) domain, are met. Thus, the preliminary study of these requirements has a major
influence on the choice and validation of the design solution. In this paper a methodology for
handling the requirements has been detailed. These requirements are classified into two main
categories. The first one deals with the product performance and the second addresses the process
performance in order to generate the best assembly sequence. Depending on the response of the
designed solution to these requirements, it becomes easy to decide not only whether the design
solution can be validated or not but also to choose the most optimal assembly sequence that ensures
the best operation quality. A validation example of a speed reducer is used to demonstrate the added
value of the proposed approach.
... There are many DFA methodologies, but the most widespread are Boothroyd-Dewhurst (B&D) methodology, Lucas methodology, Hitachi-AEM methodology, and Westinghouse methodology. B&D methodology gives four Proceedings of the Second Asia Pacific International Conference on Industrial Engineering and Operations Management Surakarta, Indonesia, September 14-16, 2021 indicators for its implementation: assembly time, assembly cost, the minimum number of component, and design efficiency (Ezpeleta et al., 2019). As for the critical assumptions used in B&D methodology: a) Parts are added one at a time during assembly. ...
... (Zhang, Chu and Xue, 2019) Identification of product aspects that may be enhanced based on internet feedback for product redesign. (Ezpeleta et al., 2019) During all phases of product development, a novel DFA approach to enhance assembly has been developed. (Butt and Jedi, 2020) Using the DFMA methodology, this research redesigns the TTC conveyor system for cost and design efficiency gains. ...
Changes in lifestyles and consumer need the manufacturing industry to offer new products to stay competitive. A new product could be developed by improving the current product design (redesign) and aiming at cost reduction, higher customer satisfaction, and product reliability. Design for Manufacturing and Assembly (DFMA) is a concurrent product and process development approach that focuses on cost reduction by considering ease to manufacture and assembly. Besides manufacturability, product reliability is also an essential factor in the early design phase. The consequences of unreliable products could be very costly and even lead to market share loss. The primary purpose of this study is to provide insight based on current literature and propose future research opportunities on product redesign based on the integration of DFMA and Design for Reliability (DFR). Scopus database is used to obtain relevant articles, and bibliometric analysis is applied to a literature review to gratify the objective. This paper results in a systematic review of the past five years by investigating and discussing past and current DFMA and DFR for product redesign. The further research direction of product redesign framework based on DFMA approach and reliability prediction in the early design phase of product development.
... The most widespread design for assembly methodologies (B&D methodology, Lucas methodology, Hitachi AEM methodology, Modified Westinghouse methodology) assist designers in making decisions during the design process [26]. These methodologies allow the designer to: ...
A literature review on the assembly design methodologies (DfA) oriented to the assembly of large and heavy parts, reveals the need to develop a DfA methodology. In addition, the lack of DfA evaluation methods for on-site assembly is also observed. The most widespread DfA methodologies are more oriented toward the improvement of factory assembly processes, where the assembly processes are well defined and standardised. Hence, this article presents a new methodology for the design of assemblies with large and heavy parts on site, called OSIA (On-Site Installation Analysis). OSIA methodology aims to provide data (indicators). On the one hand the theoretical basis of the OSIA methodology is based on three key concepts: i) analysis of assembly operations similar to the one used by the SMED methodology; ii) generic implementation process of DfA methodologies; and, iii) compilation of assembly operation times and estimation of standard times per operation. On the other hand, the steps in the implementation of the methodology are summarized in: i) database development with assembly operations and standard times; ii) assembly operations analysis; iii) calculation of assembly time; and iv) product optimization. In this way, OSIA methodology supports the designer in the specification phase, detailed design phase and in the redesign processes, providing the designer with indicators that make it possible to optimise the design of the parts and reduce the assembly operations of a product on site. Keywords: Design for assembly; Design for assembly for large and heavy parts; Design for assembly on site; Design for installation.
... The most widespread design for assembly methodologies (B&D, Lucas, Hitachi AEM) assist designers in making decisions during the design process [16]. These methodologies allow the designer to estimate the assembly time of the product parts at the factory, optimise the product assembly process and compare different products from the assembly point of view. ...
... In the OSIA methodology as in the Hitachi-AEM methodology [3], the "part handling" analysis used in most of the more widespread DfA methodologies is discarded. While Hitachi-AEM focuses on "part movements and insertion" performed in a manufacturing environment (the principle of one motion for one part) [16], OSIA focuses on the "assembly operations" performed during the assembly of the product on site. The concept of assembly operation used in OSIA is similar to the concept of "operation" used in the SMED methodology [17]. ...
A literature review on the assembly design methodologies (DfA) oriented to the assembly of large and heavy parts, reveals the need to develop a DfA methodology. In addition, the lack of DfA evaluation methods for on-site assembly is also observed. The most widespread DfA methodologies are more oriented toward the improvement of factory assembly processes, where the assembly processes are well defined and standardised. Hence, this article presents a new methodology for the design of assemblies with large and heavy parts on site, called OSIA (On-Site Installation Analysis). OSIA methodology aims to provide data (indicators). On the one hand the theoretical basis of the OSIA methodology is based on three key concepts: i) analysis of assembly operations similar to the one used by the SMED methodology; ii) generic implementation process of DfA methodologies; and, iii) compilation of assembly operation times and estimation of standard times per operation. On the other hand, the steps in the implementation of the methodology are summarized in: i) database development with assembly operations and standard times; ii) assembly operations analysis; iii) calculation of assembly time; and iv) product optimization. In this way, OSIA methodology supports the designer in the specification phase, detailed design phase and in the redesign processes, providing the designer with indicators that make it possible to optimise the design of the parts and reduce the assembly operations of a product on site.
The success of a product in the market is largely defined by the quality of design decisions made during the early stages of development. The product design requires designers to balance multiple objectives such as functionality, cost, and user satisfaction, while addressing the challenges posed by increasing product variants and customization demands. To tackle these challenges, one approach is to structure a comprehensive model that incorporates design for assembly (DFA) guidelines during the formulation of product architecture in the conceptual phase of development. While numerous strategies have been proposed in the literature, information is often scattered, making it difficult for readers to gain a comprehensive understanding of the topic. This paper systematically reviews the role and impact of DFA in product development, consolidating and presenting the information coherently. The review provides an overview of the methods developed, along with their potential benefits and limitations. A common framework is identified that defines the structure of the models, helping designers integrate assembly consideration into their design processes, thus reducing assembly time, cost, and complexity. The framework describes the operational setting, including the domain and context in which models operate, and offers a classification of possible methods and desired outputs. Additionally, the review identifies the industry in which case studies have been most frequently presented, and the software used to facilitate the process. By connecting with such a framework, future models can be created following a structured approach, and existing models can be classified and upgraded accordingly.
Nowadays, product development is very important to remain competitive in the market, one of which is to reduce the assembly of time and cost design. This article discusses the study of iron products on the market. Based on the problems found in the SMEs of Electronic Services, this iron has many components and complex designs that take time-consuming to assemble. Therefore, the purpose of this article is to redesign the ironing.Improvements to the design of iron products are based on the problems present in this product. This problem is obtained by distributing questionnaires to Electronic Services SMEs. The improvements are carried out using the Design for Assembly (DFA) method to evaluate the design with ease of assembly processes.This paper attempt to improve the design of ironing products according to the problems obtained from the initial questionnaire, which is to reduce the assembly time and costs using DFA.The result of these improvements is a reduction in the amount of assembly time and costs and an increase in efficiency. The actual design assembly time is 358.16 to 269.70 seconds on the proposed design. The actual design assembly cost budget is 956.81,- rupiahs, reduced to 720.50, in the proposed design. Then the actual design efficiency of 21.77% increased to 24.74%.Iron design improvements are based on problems and complaints received from the electronic services SMEs, then analysed using the DFA method. Therefore, the improvements in the design of the ironing product are present in two components, that is the back cover and the handle.
