Date post: | 17-Dec-2015 |
Category: |
Documents |
Upload: | pearl-spencer |
View: | 218 times |
Download: | 1 times |
DFMA Paradigms as Applied to the Warring Juicer
DFMA ME-6960
Presented by Team Alpha
April 28 2003
Instructor
Dr. A.K.Balaji
Overview
Juicer Properties/Specifications. Manufacturing Processes. MATLAB® Code. Injection Molding Analysis. Assembly Analysis. Conclusions. Questions.
Product Specifications/Part List
Main Components Of the Juicer
Manufacturing Processes
MATLAB CODE FOR IM Parameters
1. Separating Forces for the Injection Molding Machine
2. Injection Molding Times3. Mold Base Cost4. Injection Mold Costs5. Optimum Number of Cavities6. Directs the User to the right tables and
Figures based on the Book “ Product Design For Manufacturing Assembly”, Boothroyd, Dewhurst and Knight.
MATLAB CODE FOR Sheet Metal Parameters
1. Cost Of Die Set (Cds)
2. Final Die Cost (Cd)
NOTE : Calculates For All Bending, Piercing and Blanking operations.
Base Cover Design Changes
New DesignOld Design
Base Cover Analysis
Old Design Die Costs : $ 64,725New Design Die Costs : $ 61,365
Difference $ 3,360
Motor Housing Design Changes
Old Design New Design
Motor Housing Part Analysis
Old Design Die Costs : $ 86,851New Design Die Costs : $ 89,971
Difference $ 3,120
Juicer Cover Design Changes
Old Design New Design
Juicer Cover Part Analysis
Old Design Die Costs : $ 51,656/-New Design Die Costs : $ 42,668/-
Difference $ 8,988/-
Juicer Container Design Changes
Old Design New Design
Juicer Container Part Analysis
Old Design Die Costs : $ 90,625/-New Design Die Costs : $ 86,185/-
Difference $ 4,440/-
Solution To The Clips
Solution to the Clip
Sheet Metal Analysis Results of the Clip
Cost Of Die Set (Cds) : $ 193.87
Final Die Cost (Cd) : $ 2004.12
Note: Part Eliminated.
Cost Analysis Comparison
0100002000030000400005000060000700008000090000
100000
Part Names
Die
Co
st Die Costs Old
Design
Die Costs NewDesign
Assembly Analysis
Modular Assembly LayoutAnalysis for Original DesignAnalysis for Modified Design
DFA Analyses Results
Time reduced from 246.74 s to 149.9 s. (39%) Part reduction from 43 to 29.( 33%) Assembly cost reduced from $1.07/unit to
$0.63/unit. ( 41%) Over $190,000 saved on assembly of 500,000
units.
Conclusions
Reduction in the number of parts from 43 to 29
Reduction in the die costs (IM) saved $13,660
Reduction in the die costs (SM) saved $ 2,500
Reduction in assembly costs saved 41%
For a production run of 500,000 units, the overall savings
are $ 207,160
Questions?Questions?