Process Selection - From Design to Manufacture Part 1 doc

[...]...//SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 10 – [1 16 /16 ] 13 .5.2003 7:42PM //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 11 – [1 16 /16 ] 13 .5.2003 7:42PM Preface to first edition In order to facilitate the achievement of the required quality and cost objectives for the manufacture of a component design solution it is necessary to carry out... providing Design for Manufacture (DFM) and cost related information for the designer (1. 11 1. 20) A review of cost estimation techniques for the early stages of design and a method for relating product cost to material cost, total batch size and level of underlying technology can be found in References 1. 21 1. 24 //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 3 – [1 18 /18 ] 8.5.2003 9 :11 PM... Compounds Bulk Molding Compounds //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 1 – [1 18 /18 ] 8.5.2003 9 :11 PM Part I A strategic view Some background to the problem and placing process selection and costing into the context of modern product introduction and the application of techniques in design for manufacture and assembly 1. 1 Problems In today’s environment, manufacturing businesses... design for manufacture and assembly techniques requires additional up-front effort when compared with the more conventional design activity, overall the effect is to reduce the time -to- market quite considerably This is primarily due to fewer engineering changes, fewer parts to detail, //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 6 – [1 18 /18 ] 8.5.2003 9 :11 PM 6 A strategic view document... into the context of modern product introduction processes and the application of techniques in design for manufacture Part II presents the manufacturing process information maps (PRIMAs) and their selection Part III is concerned with methods and data for costing design solutions //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 12 – [1 16 /16 ] 13 .5.2003 7:42PM xii Preface to. .. ‘producibility’ guidelines, to modify component designs for subsequent manufacture The use //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 8 – [1 18 /18 ] 8.5.2003 9 :11 PM 8 A strategic view Fig 1. 9 Examples of part- count reduction (after 1. 34 ,1. 38) of techniques to assist costing of component designs also aids the process of cost optimization Since few formal DFM methods exist, unlike... product introduction process are summarized in Figure 1. 2 (1. 25) Fig 1. 2 Problems with the traditional approach to product introduction //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 4 – [1 18 /18 ] 8.5.2003 9 :11 PM 4 A strategic view 1. 3 Competitive product introduction processes Faced with the above issues, some companies are currently making dramatic changes to the way in which new... //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 7 – [1 18 /18 ] 8.5.2003 9 :11 PM Techniques in design for manufacture and assembly 7 Fig 1. 7 Pump assembly and test machine overall assembly results Fig 1. 8 Results from 60 product studies Similar savings have been reported by others involved with the application of techniques in design for manufacture and assembly (1. 34) It is also worth commenting that the designs... supporting tools and techniques The process runs across the functional structure and includes customer and supplier representation The PIM process is owned by a senior manager and each product introduction project is also owned by a senior member of staff Fig 1. 3 TheTRW PIM process //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH0 01. 3D – 5 – [1 18 /18 ] 8.5.2003 9 :11 PM Techniques in design for manufacture. .. relative cost coefficient assigned to a component design T ¼ process time in seconds for processing an ideal design of component by a specific process V ¼ volume of material required in order to produce the component Vf ¼ finished volume of the component Wc ¼ waste coefficient A //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 14 – [1 16 /16 ] 13 .5.2003 7:42PM xiv Notation used . Selection //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 2 – [1 16 /16 ] 13 .5.2003 7:42PM //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 3 – [1 16 /16 ] 13 .5.2003 7:42PM Process Selection From design to manufacture Second. //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D – 1 – [1 16 /16 ] 13 .5.2003 7:42PM Process Selection //SYS 21/ //INTEGRAS/B&H/PRS/FINALS_0 7-0 5-0 3/0750654376-CH000-PRELIMS.3D. forming 11 7 3 .10 Spinning 12 1 3 .11 Powder metallurgy 12 4 3 .12 Continuous extrusion (metals) 12 8 4 Machining processes 13 1 4 .1 Automatic and manual turning and boring 13 2 4.2 Milling 13 6 4.3 Planing