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Helpsheet for M6421 mid-term quiz

by: yjn728

Helpsheet for M6421 mid-term quiz M6421

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Helpsheet for mid-term quiz quiz coverage: lecture1-6 quiz type: 5 MCQs and 1 calculation time: 30 min
Advanced Design for Manufacturing
Prof. Lye Sun Woh
Study Guide
50 ?




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This 1 page Study Guide was uploaded by yjn728 on Monday October 17, 2016. The Study Guide belongs to M6421 at Nanyang Technological University taught by Prof. Lye Sun Woh in Fall 2016. Since its upload, it has received 8 views. For similar materials see Advanced Design for Manufacturing in MAE at Nanyang Technological University.


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Date Created: 10/17/16
Categories of Assemblies:Mechanical fastening, Joining methods, Adhesive bonding Minimal Paths:AB; CD Minimal Cuts:AC; AD; BC; BD 75-80% of product manufacturing costs are determined in the design stage S = (A ∩ B) U (C ∩ D) Aim:Designprocessbywhichproductscanbeassembledwitheaseinmind. Minimal Paths Benefits: Fewer parts&Easier to grasp….-less time&reduce assembly costs R AB0.9 * 0.95 = 0.855 R CD0.85 * 0.8 = 0.68 Assembly System Selection(manual, robot, high speed) System Reliability Bound: 1.Expected annual production volume(low-man) Rsu = 1 – (1 – 0.9 * 0.95) (1 – 0.85 * 0.8)= 0.9536 (All paths working) 2.Payback period(short-man) Uptime or Mean time between failures (MTBF) 3.Number of part numbers in the assembly(2arm-few index-few) Mean Response Time (MRT);Mean Time to Repair (MTTR) 4.Number of product styles in the assembly(high-man) Downtime = MRT + MTTR 5.Equipment costs(Low Capital Cost-man) Availability = Uptime/(Uptime+Downtime)=MTBF/(MTBF+MRT+MTTR) C = Computed Cost Repair/replace policy  Non-repairable, partially-repairable or fully repairable? F = Fixed Cost  Terms of warranty: implied or express  Obligations of manufacturer, wholesaler, retailer, customer? V = Variable Cost  Is the level and frequency of repair known to all staff? Total Assy Cost = Transf Assy Cost + Man Assy Cost + Cost of Part Assy and  Are the repair procedures known? Insersion Maintenance and Repair Issues: Operations, Human, Environment Transfer Assy Cost = Transfer Assy Cost per Part * No. of Parts Maintenance/ Repair Design Rules FR = Assembly Feed Rate (Assy per Min) Testing (Equipment, Test points, Diagnostic);Handling and Access; OTC = Transfer Assy Cost, cents Fasteners and Connectors; Replacements (Modular, Part replacement); OTC = Transfer Assy Cost, cents Protection (Adjustments, Damage); Assembly (Order and Subassemblies); OCC = Work Carrier Assy Cost, cents Safety (Tools, Signs and Parts) Impact of Waste: Finance, Ecology, Human Payback Period (sec) = Number of Eco-Effectiveness: emulate the healthy abundance of nature. Operational Days * Work Hours/day Intelligent Design Solutions, Product capable of Regeneration * 3600 Eco-Efficiency: Enhancement of Product or Service Value Manning Assy Cost = Manning Assy Cost per Part*No. of Parts Approach: Seeks to improve the process efficiency in the creation of goods NW < 7: use rotary indexing machine NW≥7: use in-line machine andservices.Thisisusuallyrelatestousingfewerresources, generatingless Manning Assy Cost per [Part/Assy] waste and pollution. Design on Waste Minimization = [60/FR * (WS *NW/SNOW# + WA * NW/WNOW#] cents Design for Waste Minimization: Observe priorities for recyclability; Adopt # Nearest Largest Integer向上取整 low-impact materials; Create safe products of long-term value; Toxic and SNOM -No. of manned workstations per supervisor Pollution Reduction WS -Supervisor rate (cts/sec) Toxic Reduction % Change in the number or amount of toxic particulates WNOM -No. of manned workstations per tech per unit volume= (Current – Original) number / Original number assembly worker, to manage (load/unload) % Change in the types of toxic substances feeders and assemblies = (Current – Original) number of types / Original number of types WA -Worker rate (cts/sec) Industrial Ecology Material Flow Systems: Linear and Open, Quasi NW No. of work station Cyclic/Cascading, Cyclical Flow QFD-4PhaseProcess:ProductPlanningMatrix;Part/AssemblyDeployment Checking for redundant parts Matrix; Process Planning Matrix; Manufacturing Planning Matrix 1.Whentheproductisinoperation, do adjacentparts move withrespectto each other? 2.Must adjacent parts be made of different materials? 3.Must QFD Product Planning (PP) Matrix : Objective(To establish customer adjacent parts be able to separate for assembly or service? relationships and information gathering in developing of products that α symmetry - rotational symmetry of a part about an axis perpendicular to satisfies customers) Intent(QFD is meant for planning and not a problem the axis of insertion solving or analytical tool), Inputs, Format, Analysis and Determination of β symmetry - rotational symmetry of a part about its axis of insertion. Priority Issues, Outputs Corollary: handle two parts, assembly time is reduced by 1/3. Voice of the Customer: Survey Target; Voice Means; Voice Quality; Voice Cost of feeding and orienting a part Handling and Filter; Voice Organization and Grouping; Others CF = (60/FR) * Rf cents Key reminder: The whole intent is to "listen to the Voice of the Customer Rf - Cost of feeder per unit time, Response(Technical Portion): Technical Requirements; Relationships; FR - Desired Feedrate (parts/min) CompetitiveTechnicalAssessments;OperationalGoalsandTargets;Column Cf - the feeder cost Weights; Co-Relationships Eo - the equipment’s factory overhead ratio The ratio of technical requirements to customer requirements should be Pb - the payback period in months kept somewhere between 1 and 1.5 Sn - the number of shifts worked per day Direction of Improvement:↑bigger is better; ↓smaller is better; H - Number of hours per shift a target is best choice, if can’t meet, should on low side of target W - Number of working days per month ⃝meeting a definite target; Cost of part insertion, CI = (60/FR) * WC cents WC - Cost of insertion per unit time, Column weight: 9 - strong symbol, 3 - moderate symbol, 1 - weak symbol. Ci - Cost of Workhead Insertion cost Represents a combination of both the customers' level of importance and Insertion Efficiency Insertion Rate Required (FR) vs Equipment Rate (1 the strength of the relationships. unit/part per sec or 60 parts/min) Positive Co-Relationships: Improve one technical requirement would help Reliability: remain functional 2. for a stated interval of time a related requirement or have beneficial results to another. 3. Stated operating conditions 4.expressed as a probability. Analysis and Determination of Priority Issues: Analysis of Customer Failure:Product ceases to function normally:catastrophically or due to drift Information Portion of the Matrix(3); Factor Interpretation and Positioning Early failure, Random failures, Aging failures (Catch-up Position, Position of Current Strength, Opportunity); Establish Failure Rate, λ= 1 / MTBF= No. of Failures/ Total Operating Hours Priorities(Goal, Sales Point, improvement ratio=goal/current, compute raw In Series: λs =Σλi, MTBFs = 1 / Σ(1/MTBF1 + 1/MTBF2 + …) weight, A, B, C categories, Decision column) Rs = (R1)(R2) … (Rn)  advanced-technology-based processes In Parallel: Rp = 1 - (1-R1)(1-R2)(1-R3)  More energy and resource efficient  Integrate sustainable manufacturing techniques into their business practices  Seek to reduce costs and supply-chain risks FMECA: Failure Mode, Effects and Critical Analysis  Enhance product appeal to customers For each component, identify and list all possible failure modes. DFM is about producibility engineering - guaranteed easily manufactured Steps in FMECA parts subject to a set of criteria. 1.Determine the causes of failure DesignrulesforDirectManufactureandTool-basedManufacturemaydiffer 2.For each failure mode, determine its effect on the operation of the Masscustomizedbatchsize,abilitytohandlecomplexgeometrypartprofile system as a whole, or parts of it. and assemblies without much tooling, limited material type selection, 3.Identify failure detection means (eg. aids, gauges, readout devices) inherent material property structures, outer and core material variations 4.Rate the severity of a failure mode, SR (Minor 1) are design considerations for direct manufacture 5.Rate the frequency of occurrence of a failure mode, FR(Low1-3) Design Rules for Tool-based Design to Manufacture consists of two main 6.Detection Probability rate, PDR(Very High 1) aspects; DFM for product and manufacture process. Risk Priority NumberRPN=Severity Rating (SR) * Frequency Rating (FR) * Minimize Part Types and Number, Modular Design, Standardization, Multi- Probability of Detection Rating (PDR) functional and Multi-Use are the design considerations in DFM for product. P ∩P = P P P UP = P +P -P P Ease of fabrication and assembly are key design considerations for DFM for Fault does not occur when one of the minimal paths are not triggered! manufacturing process. minimal path: all the components must function to ensure system works. minimal cut: all the components must fail in order for the system to fail.


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