Optimization Of Injector Gun Design Using Design For Manufacturing And Assembly (DFMA) At The Conceptual Design Stage

Azlinda, Mohamad (2013) Optimization Of Injector Gun Design Using Design For Manufacturing And Assembly (DFMA) At The Conceptual Design Stage. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Every company wants to produce low cost products, high quality and faster time to market. Design for Manufacturing and Assembly (DMFA) is a methodology that can be applied to many products in the manufacturing industry. This study focuses on Boothroyd-Dewhurst DFMA method to analyze the injector gun, which emphasis on cost reduction and parts count reduction. The purpose of this study is to optimize the current design of injector gun for oil palm tree fertilization application at the conceptual design stage. This study applies the DFMA Boothroyd-Dewhurst software by using two types of applications. The original design of the product was analyzed using DFA software applications to get the total assembly time, assembly costs and the percentage of DFA index. Then, DFM Concurrent Costing software application was used to analyze the cost of manufacturing for each part of the product which the materials and processes involved. Lastly, the DFMA analysis was carried out by using the DFA software. It provides overall total cost per unit of manufacturing and assembly of the product. Based on the results obtained, the original design had been modified. Using the same software and methods, new product design is analyzed. Results of both analyzes are compared to identify the extent of DFMA methodologies impacting the design optimization of the injection gun. The results show a reduction of 52% assembly time, the total cost of a product reduced by 28% and the percentage of DFA index change from 34% to 72%, an increase of 53%. For future studies, a number of methodologies such as simulation and Design for Environment (DFE) should be implemented simultaneously with the DFMA method.

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