AME 546: Design For Assembly (Chapter 3 of Textbook) : Satyandra K. Gupta

AME 546:
Design for Assembly

(Chapter 3 of Textbook)
Satyandra K. Gupta
Smith International Professor
Aerospace and Mechanical Engineering Department
University of Southern California
Design for Assembly
• Reduce Assembly Time

• Reduce Defect Rates
Assembly Index
• DFA index Ema
• Nmin = theoretical minimum number of parts
• ta = basic assembly time for one part
• tma = estimated time to complete the assembly of the product
Boothroyd et al.
How to reduce assembly
time?
Components of Assembly Time
• Assembly Time for Individual Operations

• Number of Assembly Operations
How to reduce defect rate?
Defect Rate Reduction
• Minimize number of assembly operations

• Simplify individual operations
Learning Objectives
• Estimate time for completing a given assembly

• How to simply product to reduce number of parts
• How to simplify assembly operations
• How to estimate defect rates in assemblies
• How to mistake proof designs
Estimating Assembly Time
• Handling Time
• Insertion Time
How would you
estimate assembly time?
Observations
• There is no accurate method in terms of producing

absolute values
• Most of the focus is on relative value
– Comparing options
Effect of Symmetry
Effect of Symmetry
Effect of Part Thickness and
Size on Handling Time
Effect of Weight on Handling Time
Parts Requiring Two hands
for Manipulation
• The part is heavy
• Very precise or careful handling is required
• The part is large or flexible
• The part does not have holding features, thus
grasping the part is difficult
Insertion Operations
Clearance Definition
• dimensionless diametral clearance c = (D-d)/D
• D = hole diameter
• d = peg diameter
Boothroyd et al.
Boothroyd et al.
Avoiding Jamming
Boothroyd et al.
Effect of Threads
Boothroyd et al.
Boothroyd et al.
Strap Example
Strap Example (Cont.)
There is an error in this description.

Other Estimation Methods
• Physically perform assembly and record times

– Not useful during design
• Use proprietary databases for estimating assembly
time
• You can use data from previous assemblies in your
organization
– Find similar operations and interpolate among them
Learning Objectives
Why assembly is needed?
• Material needs to be different
• Large motion is needed between parts
– Small motions can be incorporated by thin hinges
• Need access for service/repair/recycling
Discussion Problem #1
• Estimate the manual assembly time and design efficiency of the piston
assembly shown in Figure 3.56. Suggest a redesign of this assembly to
reduce the number of parts and increase the assembly efficiency. Estimate
the manual assembly time and design efficiency of the redesigned
assembly. The assembly sequence of the piston assembly is as follows:
– The base is placed in a fixture.
– The piston is inserted into the base. The piston must be carefully aligned, because
the piston rod does not engage the hole in the bottom of the base before it must
be released.
– The piston stop is inserted into the cylinder.
– The spring is inserted into the cylinder and tangles severely with others in bulk.
– The cover is placed onto the base and held in place to maintain alignment.
– The two screws are inserted and driven home to secure the cover.
Practice Figure
HW #2 (Due 11:59PM Sunday Feb 7th)
• Figure 3.59 shows an exploded
view of a diaphragm assembly
from a gas flow meter. Determine
a suitable assembly sequence
for this product and carry out an
analysis for manual assembly.
Estimate the assembly time,
together with the design
efficiency.
• Develop a redesign for this
assembly with a reduced part
count and reduced assembly
time. Estimate the assembly time
and design efficiency for manual
assembly of the redesigned
assembly.
Prepare Sketch or CAD model of the redesigned assembly

Learning Objectives
How to Simply Assembly Operations
• Design for easy handling

• Design for easy insertion
• Simplify fastening operations
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Other Important
Guidelines
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Accounting for
Acquisition Time
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Boothroyd et al.
Learning Objectives
Boothroyd et al.
Control Design Example
Boothroyd et al.
Discussion Problem #2
• The final assembly of a new high-performance

aircraft engine turbocharger involves 182 assembly
operations. The assembly time has been estimated,
using the DFA standard data times, to take 1700 s.
– Using this information, determine the probability that any
given one of the completed turbochargers contains an
assembly error. Assume that with attention to quality being
the central issue in aircraft manufacture, the assembly
workers perform at 2× the quality level of the benchmark
Motorola workers; that is, make assembly mistakes at only
half the rate.
Learning Objectives
How will you design a product
so that human operators do not
make mistakes during
assembly?
Some tips on mistake proofing
the design from assembly point of view
• Reduce number of assembly operations
• Simplify assembly operations
• Avoid operation characteristics that lead to human
errors
– Operations that difficult to understand
– Ambiguity due to part shape
– Forgetting an operation
– Operation competition cannot be visually verified
References
• Geoffrey Boothroyd, Peter Dewhurst, Winston A.

Knight. Product Design for Manufacture and
Assembly. Third Edition, CRC Press (Chapter 3)

AME 546: Design For Assembly (Chapter 3 of Textbook) : Satyandra K. Gupta

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AME 546:

Design for Assembly

• Reduce Assembly Time

• Nmin = theoretical minimum number of parts

• ta = basic assembly time for one part

• tma = estimated time to complete the assembly of the product

• Assembly Time for Individual Operations

• Minimize number of assembly operations

• Estimate time for completing a given assembly

• There is no accurate method in terms of producing

There is an error in this description.

• Physically perform assembly and record times

Prepare Sketch or CAD model of the redesigned assembly

• Design for easy handling

• The final assembly of a new high-performance

• Geoffrey Boothroyd, Peter Dewhurst, Winston A.

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