dfma paradigms as applied to the warring juicer dfma me-6960 presented by team alpha april 28 2003...

DFMA Paradigms as Applied to the Warring Juicer

DFMA ME-6960

Presented by Team Alpha

April 28 2003

Instructor

Dr. A.K.Balaji

Overview

Juicer Properties/Specifications. Manufacturing Processes. MATLAB® Code. Injection Molding Analysis. Assembly Analysis. Conclusions. Questions.

Product Specifications/Part List

Main Components Of the Juicer

Manufacturing Processes

MATLAB CODE FOR IM Parameters

1. Separating Forces for the Injection Molding Machine

2. Injection Molding Times3. Mold Base Cost4. Injection Mold Costs5. Optimum Number of Cavities6. Directs the User to the right tables and

Figures based on the Book “ Product Design For Manufacturing Assembly”, Boothroyd, Dewhurst and Knight.

MATLAB CODE FOR Sheet Metal Parameters

1. Cost Of Die Set (Cds)

2. Final Die Cost (Cd)

NOTE : Calculates For All Bending, Piercing and Blanking operations.

Base Cover Design Changes

New DesignOld Design

Base Cover Analysis

Old Design Die Costs : $ 64,725New Design Die Costs : $ 61,365

Difference $ 3,360

Motor Housing Design Changes

Old Design New Design

Motor Housing Part Analysis

Old Design Die Costs : $ 86,851New Design Die Costs : $ 89,971

Difference $ 3,120

Juicer Cover Design Changes

Old Design New Design

Juicer Cover Part Analysis

Old Design Die Costs : $ 51,656/-New Design Die Costs : $ 42,668/-

Difference $ 8,988/-

Juicer Container Design Changes

Old Design New Design

Juicer Container Part Analysis

Old Design Die Costs : $ 90,625/-New Design Die Costs : $ 86,185/-

Difference $ 4,440/-

Solution To The Clips

Solution to the Clip

Sheet Metal Analysis Results of the Clip

Cost Of Die Set (Cds) : $ 193.87

Final Die Cost (Cd) : $ 2004.12

Note: Part Eliminated.

Cost Analysis Comparison

0100002000030000400005000060000700008000090000

100000

Part Names

Die

Co

st Die Costs Old

Design

Die Costs NewDesign

Assembly Analysis

Modular Assembly LayoutAnalysis for Original DesignAnalysis for Modified Design

DFA Analyses Results

Time reduced from 246.74 s to 149.9 s. (39%) Part reduction from 43 to 29.( 33%) Assembly cost reduced from $1.07/unit to

$0.63/unit. ( 41%) Over $190,000 saved on assembly of 500,000

units.

Conclusions

Reduction in the number of parts from 43 to 29

Reduction in the die costs (IM) saved $13,660

Reduction in the die costs (SM) saved $ 2,500

Reduction in assembly costs saved 41%

For a production run of 500,000 units, the overall savings

are $ 207,160

Questions?Questions?