ME701A
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DESIGN FOR MANUFACTURE AND ASSEMBLY
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Course-Title:
Design for Manufacture and assembly
Course Number:
ME701A
Department:
Mechanical Engineering
Other interested faculty:
Dr. J. Ramkumar (ME), Dr. S. Bhattacharya (ME), Dr. V.K. Jain (ME)
Expected enrollment:
15-20 students
Pre requisites:
TA 202 or equivalent
Aimed at:
Advanced undergraduates and postgraduates
Other Departments:
Aerospace Engineering, Chemical Engineering. Civil Engineering. and Design Programme
Course description:
The success of a product in the market depends on many factors. These include cost, reliability and time to market. With globalization, companies need to devise techniques in order to remain competitive in the current scenario. To this end, design and manufacturing operations no longer function in isolation but have to interact closely. Design for manufacture and assembly (DFMA) is a technique of integrated pro duct development process as opposed to the serial or "over the wall" philosophy. The advantages of implementing DFMA include reduced time-to- market, reduced number of subcomponents, enhancement in quality, and reduced product and process cost. DFMA has been applied successfully in many automobile, aerospace, telecommunications, medical equipment, and consumer products companies. The basic objective of this course is to acquaint the participants with the concepts of the pro duct design process and simultaneous engineering by integrating design for manufacturing and design for assembly to arrive at a good quality product in a cost effective way in less time. With consumers becoming environmentally conscious, design for environment will also be covered. Each module will cover relevant case studies during their discussion.
Course Contents
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Module
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Topic
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No. of hours
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1: Introduction
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DFMA: overview
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01
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2: Pro duct design Process
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Need identification and problem
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01
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definition Conceptual design
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02
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Embodiment design
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02
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3: Selection of materials and shapes
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Overview of engineering materials
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01
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and standards for
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materials selection Selection of materials
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02
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Introduction to limits, fits and tolerances
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01
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Selection of shapes
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01
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Co-selection of materials and shapes
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02
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4. Design For X
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The concept of manufacturability
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01
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Limitations of manufacturing
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01
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Design of jigs and fixtures
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01
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Design for manufacturability
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05
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Design for assembly
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05
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Design for environment
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01
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5: Modeling and simulation
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Mathematical modeling and
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02
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Finite element analysis
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02
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Simulation
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02
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Rapid prototyping
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02
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6: Design for reliability
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Reliability theory and design for
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02
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Failure mode and effects analysis
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01
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Design for safety
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01
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Design for Quality
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01
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Design optimization
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02
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Total = 42
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Reference Texts:
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G. Dieter, Engineering Design - a materials and processing approach, 4th Edition, McGraw Hill, NY, 2009.
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G. Boothroyd, P. Dewhurst and W. Knight, Product design for manufacture and assembly, 3rd Edition, CRC Press, 2011.
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M. F. Ashby and K. Johnson, Materials and Design - the art and science of material selection in product design, ButterworthHeinemann, 2 003.
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0. Molloy, S. T:lley and E.A. Warman, Design for manufacturing and assembly: Concepts, architectures anc implementation, Springer, 1998.
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David M. Anderson, Design for manufacturability and concurrent engineering; How to design for low cost, design in high quality, design for lean manufacture, and design quickly for fast production, CMC Press, 2004.
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Karl Ulrich and Steven Eppinger, Product design and development, 4th Edition, Tata McGraw Hill, 2008.
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G. Pahl, W. Beitz and J. Feldhusen, Engineering design: A systematic approach, 3rc Edition, Springer, 2007.
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S. S. Rao, Enginering optimization: theory and practice, 4th Edition, John Wiley, NJ, 2009.
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