Design For Manufacture And Assembly (DFMA) Evaluation Of Car Audio Front Panel

Mellvyne, Sigo (2007) Design For Manufacture And Assembly (DFMA) Evaluation Of Car Audio Front Panel. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Design for Manufacturing and Assembly (DFMA) is a technique for reducing the cost of a product by breaking the product down into its simplest components. This paper is a detailed study which on the improvement of car audio front panel by using the DFMA approach. The Boothroyd-Dewhurst which concentrates on manual assembly methodology was used for the analysis of the existing product design in order to simplify and reduce the number of parts. Based on the assembly worksheet analysis of the current design, the number of parts for the current design is 25 parts with the number of operation assembly is 32. The time needed to complete assembly the current product is 146.12 seconds. Meanwhile, the assembly cost for the current product is 5.86 cents. As a result, the design efficiency for the current design is 20%. To ensure that the improvement of the current design is achieved, the analysis for the improved design must be made using the Boothroyd-Dewhurst method. Based on analysis done, it is found that the number of parts for the improved design can be reduced to 16 parts with the number of operation for the product assembly is reduced to 18. In order to assemble the current design, the time needed is 71.97 seconds. In the meantime, the assembly cost for the improved design is 2.89 cents. It is found that the design efficiency for the improved design is 67%. The comparison between assembly worksheet analysis for the current design and the improved design are also made to obtain the percentage of improvement Therefore, the improvement in term of the number of parts is 36%, 50.7% improvement in assembly time, 50.7% improvement in assembly cost, 43.8% improvement in the number of operation and 70% improvement in design efficiency.

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