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How Can Product/Process
Designs Be A
Factor To A Waste-Free Industrialized System?
100% functional purchased
parts
and materials is the objective
Basic
Principles of Design for Assembly/Formation
A. Design
for assembly/formation
-
Minimize
the number of parts.
-
Minimize
assembly surfaces.
-
Design
for z-axis assembly.
-
Improve
assembly access.
-
Maximize
part conformity.
-
Maximize
part regularity.
-
Optimize
part handling/placement.
-
Keep
away from separate fasteners whenever possible.
-
Supply
parts with basic "self-locking" features.
-
Push
toward modular design.
-
Avoid
mixtures of procedure/ process technologies.
-
Specialized
piece part packaging is well-matched with the process's
material handling and automation schemes.
B. Design for simplest
flow (minimum parts, kits, subassemblies, test, paper work,
etc.)
Why should testing be
minimized? Testing is used to detect the presence of failures,
(sometimes cause by external
failures), induced by the industrialized process.
Testing is …
C. Design for minimum
uniqueness/distinctiveness (common parts, processes, workflow,
etc.)
How much does it cost in
time and dollars to add a part?
Initial Cost
- Drafting/changing
the print
- Securing/updating
the print number
- Changing the Bill
Of Material
- Print reviews
by Development, Process, and Quality Engineering as well
as the Purchasing department
- Releasing of the
new Print
- Making and
distributing the new print
- Purchasing Quote
cycle. Finding suppliers, etc.
- Supplier
survey
- Possible tooling
costs
- Possible test
equipment expenses
- Qualification costs
On Going Cost
- Inspection costs
(training, etc.)
- Stock costs
(inventory, etc.)
- Getting part to the
assembly line
- Storage for part on
the assembly line
- Added tracking and
ordering for the production
- Added purchasing
tracking
- Carrying cost
(inventory turns)
You MUST work with you
suppliers and become their partners in order to achieve 100%
useable, (no waste in time or parts), incoming purchased
materials. Designing the assembly for simplicity and minimum
uniqueness helps in the removal of defects. This includes NOT
having duplicate parts with different part numbers. This is a
really large waste of resources based on the above information.
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