Case Study Two:
Educational Seating
BY LIAM SMYTH
GMIT LET TERFRACK
Introduction
Product: A (Normal educational
chair)
Product: B (DFM designed
educational chair)
PRODUCT A
PRODUCT A: Overview
Product A is a normal educational chair that is commonly used throughout Ireland
Simple chair design that is effective and provides the function of a chairs without aesthetically
design given to it
Product A requires a number of processes to be completed during its manufacturing.
The design is a pre-existing design that has had limited amount of Design for Manufacture
consideration given to it
Unfortunately the author was unable to design a specific chair and has limited knowledge in
terms of the chairs manufacturing
Product A will be now explained broken down in terms of the Design for Manufacture principles
that have been applied and those that have been not
Principle One Applied
First principle applied: Use Standard Components
The chair has a total of two components used to create the chair
Base of chair is symmetrical will both side components the identical
Base consists of two sub-assemblies, with a total of three required to complete the chair.
Advantages of using this principles:
1.
Ease of fabrication and repeatability
2.
Common component throughout Product A
3.
Ease of Replacement if base becomes damaged
4.
Can be manufactured in large batches quantities
Use Standard Components
Base of Chair
Symmetrical View: Base of Chair
Principle Two Applied
Second principle applied: Minimise the Total Number of parts & Subassemblies
Product A consists of two parts, however has three sub-assemblies
Not complicated or complex to assembled in a final product
Use of standard components throughout
Advantages of using this principles:
1.
Allows for damaged part to be easily replaced if damaged
2.
Limited confusion or complexity in assembling Product A
3.
Reduction in the amount of material required
Minimise the Total Number of parts &
Subassemblies
Chair Assembled
Chair Dis-assembled into the two components
Principle Three Applied
Third principle applied: Design Parts for Ease of Fabrication
Use of common component throughout Product A
However this principle applies to the chair seat
One process required to create seat (Injection Moulding)
Advantages of using this principles:
1.
Ease of repeatability due injection moulding
2.
Requires one process to create seat
3.
Ease of mass producing Product As seat
4.
Reduction in labour cost and time
5.
Short lead and set up time
Design Parts for Ease of Fabrication
Plastic Seat for
Injection Moulding
Injection Moulding Method
for creating the seat
Designed for Storage
Product A has been designed to incorporate and allow the ease of storage of them
Chairs can be stored away easily and neatly to piles of ten
Prevents them taking up to much space when being stored
However area of concern for anyone in close proximity of the stacked chairs
Can easily tip and fall over
Health hazard to anybody if they fall
These make the author feel unsafe over storage of these chairs
Ease of Storage
Single Chair
Stacked Chair
Design for Manufacture principles not
applied
Principle one not Applied
First principle not applied: Avoid separate Fasteners
Currently two types fasteners used throughout the chair
A weld and screw fastener are both used
Weld fastener the main issues, if breaks or damaged possible replacement of whole chair base
Three sub-assemblies required before chair is complete
Disadvantages of not using this principles:
1.
More complexity in creating the product (has to be assembled before sold to the consumer)
2.
Product cant be disassembled and reassembled a number of times
3.
Decreases product flexibility
4.
Longer lead and set up time
5.
Increased Labour
Avoid separate Fasteners
Top Weld Joining Two-Subassemblies together
Educational Chair Base
First Weld to create Sub-assemblies
Principle Two Not Applied
Second principle not applied: Minimise the Total Number of Subassemblies
Total of seven parts required to create the chair (small amount of total components)
One sub-assembled part and one component required to create the finalised chair
Three sub-assemblies used in the base assembly
Disadvantages of not using this principles:
1.
Complexity in assembling the chair base (Three sub-assemblies)
2.
Error may occur during sub-assemblies creations
3.
Increased Labour cost
4.
Longer lead time
Top Long & Short Rail
Sub-Assembly One & Two
Sub-Assembly Three
Final Assembled Product
Conclusion of Product A
Evident that some consideration given to the use of Design for Manufacture principles
Could have been given more consideration, which would have accomplished the complete chair
Relatively high labour cost, repeatability may be difficult due to fasteners used
Relatively high lead, set up and manufacturing time associated with some parts of this product
Advantages of using the principles that have not been applied:
1. Use a single fastener throughout (screw) instead of the weld it will allow the product to self
assembled and remove the need for sub-assemblies
2. Will see an improvement in the manufacturing and cost of the chair
3. Allow the replacements of damaged parts to easily occur, with the need to replace the whole base
PRODUCT B
PRODUCT B: Overview
Product B is designed with the use of Design for Manufacture principles
Pre-existing design by Denis Fuzii which has been modified to accommodate the clients brief and
ensure it is not a plagiarized piece of furniture
Product B requires a limited number of processes to manufacturer the table.
The design has been completed with the total use of Design for Manufacture centred around its
modified design
There are a number of advantages to the use of Design for Manufacture:
1.
2.
3.
4.
Reduction in lead, production and set up time
Less processes required to complete the table
Ease of fabrication and repeatability
Less expensive to the manufacturer and consumer
Product will be now explained broken down in terms of the Design for Manufacture principles
that have been applied
Principle One Applied
First principle applied: Minimise the Total Number of parts & Subassemblies
Total of twenty two parts, fifteen more than product A, but product A has no sub-assemblies
However some of the components become redundant when expanding chair to larger size
Has only two common components throughout the creation of the chair (Side component and centre rail
Reduction in the complexity and confusion of assembling of Product B
No sub-assemblies required in Product B
Advantages of using this principles:
1.
No sub-assemblies required
2.
Reduction in confusion or complexity in assembling/placement of parts
3.
Reduction in Labour cost
4.
Short lead time
Minimise the Total Number of parts &
Subassemblies
Assembled DFM Chair
Dis-assembled DFM Chair
Principles Two Applied
Second principles applied: Use Standard Components & Design parts for Multi-Use
Side component and centre rail are a standard component throughout Product B
Both components used in assisting in the expansion of the chair to accommodate more people
Ease of replacement if side component and centre rail becomes damaged
Ease of fabrication and repeatability as only requires one process
Advantages of using this principles:
1.
Ease of fabrication and repeatability
2.
Common component throughout Product B
3.
Ease of Replacement if either component becomes damaged
4.
Components Flexibility to used throughout the same product/and other variations of chairs
5.
Lead and set up time remain the equal
Use Standard Components & Design
parts for Multi-Use
CAD Rendered and Scale
Model of DFM Chair
Common Component & Multi
Use parts
Expansion of Product
Two Separate DFM Educational Chairs
Two Separate Joined DFM Educational Chairs
Principle Three Applied
Third principle applied: Design Parts for Ease of Fabrication
Use of common component throughout Product B
Designed to allow for the ease of manufacturing
Two machines required to create the table, however only one needed to manufacture Product B
Limited processes required to create Product B
Advantages of using this principles:
1.
Ease of repeatability due CNC use
2.
Processes along with set ups remain equal throughout its production
3.
Ease of mass producing Product B
4.
Product can be used straight was after being processed on CNC
5.
Reduction in labour cost and time
6.
Short lead and set up time
Design Parts for Ease of Fabrication
Both DFM Table & Chair Designed Products Cut on Laser.
Due to CNC availability a full size product could not be
manufactured during these tutorials.
DFM Educational Chair Drawn in AutoCAD
ready to be transferred for the CNC
Principle four Applied
Fourth principle applied: Avoid separate Fasteners
Currently no fastener used, with interlocking joints the only self fastener used
Product B depends on tightness of joints and friction to hold it together
Can allow the easy assemble and disassemble of Product B
Advantages of using this principles:
1.
Ease of assembly on the consumer
2.
Product can be disassembled and reassembled a number of times
3.
Increased product flexibility
4.
Allows the product to be ready for use straight of the CNC
Avoid separate Fasteners
Scale Model with Joining Method Displayed.
This Joining Method Used throughout the
DFM Educational Chair.
Principle five Applied
Fifth principle applied: Minimise Handling
Designed to be flat packed product
Ease of storage and packaging
Advantages of using this principles:
1.
Product B can be sold flat packed
2.
Ease of storage and packaging
3.
Can be safely stored due to its capability of been disassembled
4.
Allowed for the incorporation of Product B to be abled to be disassembled
5.
Product Flexibility seen with the ease of storage
6.
Longer lead and set up time
Minimise Handling
Assembled DFM Chair
Dis-assembled DFM Chair
Conclusion of Product B
Evident significant consideration given to Design for Manufacture principles
Ease to manufacture, assemble and disassemble with its current design
Ideal for mass manufacture with CNC being used to manufacture the product
CNC allows for high accurate precision and ease of repeatability of components
Relatively low lead, set up and manufacturing time associated with this product
With additional components the product can expand to cater for a larger number of people
Advantages of using Design for Manufacture in the design process:
1.
Reduction in lead, set up and manufacturing time
2.
Easier to manufacture and repeatability of product B
3.
Reduction in manufacturing cost, with increase in profits
4.
Product B Capable of mass production
5.
Flexibility in Product B and its components
Conclusion of Both Products
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