56:, developed the Design for Assembly method (DFA), which could be used to estimate the time for manual assembly of a product and the cost of assembling the product on an automatic assembly machine. Recognizing that the most important factor in reducing assembly costs was the minimization of the number of separate parts in a product, he introduced three simple criteria which could be used to determine theoretically whether any of the parts in the product could be eliminated or combined with other parts. These criteria, together with tables relating assembly time to various design factors influencing part grasping, orientation and insertion, could be used to estimate total assembly time and to rate the quality of a product design from an assembly viewpoint. For automatic assembly, tables of factors could be used to estimate the cost of automatic feeding and orienting and automatic insertion of the parts on an assembly machine.
91:
credited the software with overall savings approaching $ 1 billion. In many companies DFA is a corporate requirement and DFA software is continually being adopted by companies attempting to obtain greater control over their manufacturing costs. There are many key principles in design for assembly.
31:
in mind. If a product contains fewer parts it will take less time to assemble, thereby reducing assembly costs. In addition, if the parts are provided with features which make it easier to grasp, move, orient and insert them, this will also reduce assembly time and assembly costs. The reduction of
40:
Design for assembly can take different forms. In the 1960s and 1970s various rules and recommendations were proposed in order to help designers consider assembly problems during the design process. Many of these rules and recommendations were presented together with practical examples showing how
78:
The DFA method, like the AEM method, was originally made available in the form of a handbook where the user would enter data on worksheets to obtain a rating for the ease of assembly of a product. Starting in 1981, Geoffrey
Boothroyd and Peter Dewhurst developed a computerized version of the DFA
48:
and was called the
Assembly Evaluation Method (AEM). This method is based on the principle of "one motion for one part." For more complicated motions, a point-loss standard is used and the ease of assembly of the whole product is evaluated by subtracting points lost. The method was originally
108:
watch. Both were designed for fully automated assembly. The
Walkman line was designed for "vertical assembly", in which parts are inserted in straight-down moves only. The Sony SMART assembly system, used to assemble Walkman-type products, is a
32:
the number of parts in an assembly has the added benefit of generally reducing the total cost of parts in the assembly. This is usually where the major cost benefits of the application of design for assembly occur.
41:
assembly difficulty could be improved. However, it was not until the 1970s that numerical evaluation methods were developed to allow design for assembly studies to be carried out on existing and proposed designs.
167:
Miyakawa, S. and Ohashi, T., "The
Hitachi Assembly Evaluation Method (AEM)," Proc. International Conference on Product Design for Assembly, Newport, Rhode Island, April 15–17, 1986.
75:
Most products are assembled manually and the original DFA method for manual assembly is the most widely used method and has had the greatest industrial impact throughout the world.
83:. There are many published examples of significant savings obtained through the application of DFA. For example, in 1981, Sidney Liebson, manager of manufacturing engineering for
120:(DFAA) rules. These DFAA rules help design a product that can be assembled automatically by robots, but they are useful even with products assembled by manual assembly.
59:
In the 1980s and 1990s, variations of the AEM and DFA methods have been proposed, namely: the GE Hitachi method which is based on the AEM and DFA; the Lucas method, the
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Boothroyd, G., "Design for
Assembly – A Designer's Handbook", Department of Mechanical Engineering, University of Massachusetts, Amherst, Nov. 1980.
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79:
method which allowed its implementation in a broad range of companies. For this work they were presented with many awards including the
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Boothroyd, G., Dewhurst, P. and Knight, W., "Product Design for
Manufacture and Assembly, 2nd Edition", Marcel Dekker, New York, 2002.
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Product Design for
Manufacture and Assembly G. Boothroyd and P. Dewhurst, Boothroyd Dewhurst, Inc. 1989 Marcell Dekker, Inc. 1994
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Boothroyd, G. "Assembly
Automation and Product Design, 2nd Edition", Taylor and Francis, Boca Raton, Florida, 2005.
87:, estimated that his company would save hundreds of millions of dollars through the application of DFA. In 1988,
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method and several others which were based on the original DFA method. All methods are now referred to as
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Boothroyd, G., "Design for assembly: The Road to Higher productivity", Assembly
Engineering, March, 1982.
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For more information on Design for
Assembly and the subject of Design for Manufacture and Assembly see:
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248:"IBM Proprinter Case Study". Engineering Systems Research Center. University of California at Berkeley
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Henchy, L.W., "American Manufacturing Fights Back", Business Solutions, Feb. 22, 1988, p.10.
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Simultaneous Engineering Study of Phase II Injector Assembly line Giddings & Lewis 1997
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Design and Analysis of Manufacturing Systems Rajan Suri University of Wisconsin 1995
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Assembly Automation and Product Design G. Boothroyd, Marcell Dekker, Inc. 1992
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Product Design for Assembly: The Methodology Applied G. Lewis and H. Connelly
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developed in order to rate assemblies for ease of automatic assembly.
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system for assembling small devices designed for vertical assembly.
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Starting in 1977, Geoff Boothroyd, supported by an NSF grant at the
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295:"Successful Design for Assembly" - February 26, 2007 article from
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Two notable examples of good design for assembly are the
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510:Architectural lighting design
118:design for automated assembly
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135:Design for manufacturability
81:National Medal of Technology
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549:Healthy community design
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116:The IBM Proprinter used
23:) is a process by which
1964:New product development
1929:Enterprise architecture
1857:IF Product Design Award
1816:Design Research Society
1368:Reliability engineering
145:Design for verification
1420:Top-down and bottom-up
769:User experience design
670:Packaging and labeling
643:Electric guitar design
581:Landscape architecture
1949:Innovation management
1832:European Design Award
1598:Intellectual property
1415:Theory of constraints
1378:Responsibility-driven
1218:For manufacturability
1122:Creativity techniques
960:Nuclear weapon design
774:User interface design
638:Corrugated box design
559:Interior architecture
130:Design for inspection
25:products are designed
1994:Unintelligent design
1974:Philosophy of design
1688:Design specification
1641:Comprehensive layout
1213:For behaviour change
1186:Probabilistic design
948:Power network design
485:Visual merchandising
442:Instructional design
420:Postage stamp design
2209:Product development
1914:Creative industries
1837:German Design Award
1746:Design infringement
1631:Architectural model
970:Organization design
965:Nucleic acid design
913:Experimental design
466:Traffic sign design
273:Further information
65:design for assembly
17:Design for assembly
1979:Process simulation
1954:Intelligent design
1278:Intelligence-based
1273:Integrated topside
1203:Framework-oriented
888:Behavioural design
759:Information design
437:Information design
263:2006-06-21 at the
254:2010-07-05 at the
89:Ford Motor Company
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1718:Website wireframe
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1171:Ecological design
1047:Activity-centered
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1005:Spacecraft design
799:Public art design
737:Video game design
715:Experience design
685:Production design
665:Motorcycle design
623:Automotive design
527:Ecological design
405:Film title design
297:Assembly Magazine
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1762:Geschmacksmuster
1736:Community design
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1348:Process-centered
1144:Design–bid–build
1112:Cradle-to-cradle
1092:Concept-oriented
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1010:Strategic design
980:Processor design
955:Mechanism design
923:Geometric design
883:Algorithm design
823:Jewellery design
754:Immersive design
648:Furniture design
593:Landscape design
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835:Game art design
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515:Building design
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27:with ease of
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2219:Design for X
1989:STEAM fields
1959:Lean startup
1944:Indie design
1760:
1727:Intellectual
1479:Value-driven
1457:Use-centered
1363:Regenerative
1343:Policy-based
1303:Mind mapping
1208:For assembly
1207:
1149:Design–build
1067:By committee
1052:Adaptive web
850:Sound design
808:glass design
806: /
791:applied arts
732:Level design
603:Urban design
554:Hotel design
505:Architecture
480:Video design
473: /
464: /
432:Illustration
425:Print design
395:Brand design
296:
276:
244:
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140:Design for X
117:
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102:Sony Walkman
99:
77:
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64:
61:Westinghouse
58:
51:
43:
39:
20:
16:
15:
2027:competition
1984:Slow design
1934:Form factor
1904:Concept art
1713:HTML editor
1393:Sustainable
1228:For testing
1072:By contract
928:Work design
903:Drug design
875:engineering
749:Icon design
727:Game design
705:Interaction
653:Sustainable
586:Sustainable
475:Type design
452:Photography
447:News design
390:Book design
385:Advertising
364:Disciplines
2203:Categories
2187:Wiktionary
2180:Wikisource
2134:technology
2104:principles
1703:Storyboard
1529:management
1524:leadership
1489:Privacy by
1328:Parametric
1298:Metadesign
1268:Integrated
1258:High-level
1243:Generative
1238:Functional
1107:Continuous
1102:Contextual
1077:C-K theory
1037:Approaches
779:Web design
633:CMF design
613:Industrial
471:Typography
36:Approaches
2173:Wikiquote
2159:Wikibooks
2109:rationale
2074:knowledge
2049:education
1969:OODA loop
1693:Prototype
1678:Flowchart
1636:Blueprint
1504:computing
1440:Universal
1388:Safe-life
1293:Low-level
1283:Iterative
1263:Inclusive
1248:Geodesign
1139:Defensive
1087:Co-design
1057:Affective
67:methods.
2166:Wikinews
2099:paradigm
2079:language
2059:engineer
2054:elements
2044:director
1729:property
1574:thinking
1564:strategy
1549:research
1509:controls
1467:Empathic
1398:Systemic
1358:Rational
1313:New Wave
1127:Critical
350:Designer
261:Archived
252:Archived
124:See also
104:and the
29:assembly
2152:Commons
2124:studies
2069:history
2037:student
2022:classic
2010:Design
1924:.design
1852:Graphex
1554:science
1544:pattern
1539:methods
1514:culture
1497:Design
1308:Modular
1161:Diffuse
1082:Closure
804:Ceramic
462:Signage
345:Outline
111:robotic
46:Hitachi
2214:Design
2129:studio
2114:review
2094:museum
2017:change
1825:Awards
1698:Sketch
1683:Mockup
1663:CAutoD
1604:Awards
1569:theory
1559:sprint
1534:marker
1499:choice
873:&
871:design
707:design
615:design
497:design
415:Motion
377:design
334:Design
106:Swatch
2012:brief
1899:Agile
1618:Tools
1595:Tools
1233:For X
869:Other
788:Other
156:Notes
85:Xerox
2089:load
2084:life
2064:firm
1651:CAID
1519:flow
1435:TRIZ
1323:Open
150:DFMA
1646:CAD
1626:AAD
1403:SOD
1383:RWD
1253:HCD
720:EED
569:EID
21:DFA
2205::
326:e
319:t
312:v
19:(
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