Manual assembly workers have nowadays a much higher workload than before. Not only do they have to deal with many more product variants, but as aconsequence they also receive many more information signals that they have to act upon. This study focuses on the information assembly workers receive through visual instructions. By conducting a literature review in the domains of product development with focus on design for assembly, cognition related to informationin instructions and different instruction formats like paper, tablet, and augmented reality (AR), commonalities and differences could be identified. Assembly operations are generally divided in handling a part and joining a part, and instructions should inform the assembly worker about when what should be assembled where and how. Each of these aspects has an impact on the overall complexity of the assembly process. To realise which of these aspects is most critical for an assembly worker can be of help in creating and delivering effective, tailor made instructions. The main finding is that there is not a one size fits all solution when it comes to the effectiveness of instructions, but that the type of instructions and the way they are delivered should in the first place be adjusted to the complexity of the assembly operations and secondly - if possible - also adjusted to the experience of the worker. The outcomes mentioned in this document should help laying the foundation for rules and guidelines when it comes to manual assembly instructions and its factors to consider.

This master thesis report describes the development process of a modernized handguard for the AK4B battle rifle, which is the main armament for the Swedish Home Guard. The project was carried out in cooperation with ALTEN Sweden AB. The goal of the project was to develop a new, competitive handguard design and to establish a complete design documentation as a foundation for production. This documentation consisted of a final material selection, process plan with suitable manufacturing methods and engineering drawings. The project was initiated with a problem definition to establish a thorough understanding of the product to be improved and enabling a determination of aspects that might be of importance to the product development. From this, research areas could be selected and studied to acquire necessary insights to complete the project goals. The product development process implemented is mainly inspired by Ulrich & Eppinger, and includes the stages concept development, detail design and testing & refinement. Thus, well-established methodology was implemented, ensuring credibility and a qualitative result. Throughout the stages ofthe product development process, a product specification was established, before generating concepts and selecting a final candidate which were refined based on the selection of materials and elaborated process plan. Finally, a verification of the requirements was concluded using several methods to prove the performance of the product. The results presents a developed product fulfilling established requirements and includes required documentation for production. Overall, the product is considered to have great potential for customer satisfaction, and to perform well in a final testing according to military standards.

Formsprutning är en tillverkningsmetod somställer krav på produkters utformning. För att göra en lämplig ingötsplacering räcker inte alltid riktlinjer utan en produktspecifik analys kan vara nödvändig. Materialval kräver en tydlig kravspecifikation och kan med fördel göras i samråd med en materialexpert. Riktlinjer för Design for manufacturing and assembly inkluderar bland annat rekommendationer för formgivning. Detta kandidatarbete strävar efter att hjälpa produktutvecklare att tidigt i produktutvecklingsprocessen ta hänsyn till tillverkningsaspekter. Baserat på litteraturstudier, intervjuer och fallstudier har riktlinjer tagits fram för materialval, design for manufacturing and assembly och formgivning för formsprutning. Arbetet är avgränsat till att endast titta på formsprutningsbara termoplaster. Arbetet, som genomförts vid Linköpings universitet, är en del av projektet Säkra monteringsverktyg som resulterade i ett portabelt dödmansgrepp. Defallstudier som genomfördes inom projektetbehandlar värdering av koncept utifrån produktionsperspektiv, materialval och formsprutningsanalyser i programmet Moldflow. Arbetet resulterade i riktlinjer för applicering av metoden design for manufacturing and assembly, formsprutningsanpassning samt materialval. Fallstudien i Säkra monteringsverktyg utmynnade ien värdering av koncept utifrån produktionsaspekter, ett materialval baserat på projektets kravspecifikation och rekommendationer för produktens utformning med syfte att optimera dess tillverkning. En slutsats av arbetet är att produktionsanpassning av produktens utformning bör ske tidigt i utvecklingsprocessen. En annan slutsats är att besök i industrin, hos exempelvis ett formsprutningsföretag, leder till bättre förståelse av vilka krav som behöver uppfyllas för att en produkt ska vara möjlig att producera. Om simuleringsprogram för formsprutning finns bör det användas i kombination med riktlinjer för produktutformning. Ytterligare en slutsats som gjorts är att materialval underlättas genom tidig kontakt med materialleverantörer. Materialvalet baseras på kravspecifikationen och därför bör kraven tydliggöras och dess rimlighet kontrolleras innan materialvalet sker. / Injection molding is a manufacturing method that requires specific features to attain manufacturability. Gating suitability requires analysis and mere guidelines do not always provide the correct gate placement. Material selection requires a pronounced specification and is preferably supervised by an expert. Guidelines concerning design for manufacturing and assembly include, among other things, recommendations directly affecting the shape of the product. The aim for this bachelor thesis is to aid product developers and designers in taking manufacturing aspects into account early in the product development process. This is achieved by providing them with guidelines regarding material selection, injection molding, as well as design for manufacturing and assembly. The thesis is limited to thermoplastic materials suitable for injection molding and its results are based off thorough literature research, interviews and case studies. This bachelor thesis project, which is conducted at Linköping University,is a part of a project calledSafe manual assembly tools, and the resulting portable enabling device developed in Safe manual assembly toolsis used as case studies in this thesis. The case studies include: evaluation of concepts concerning manufacturability; material selection; and injection molding analysis through the software Moldflow. The thesis results in guidelines concerning design for manufacturing and assembly, injection molding and material selection. The case study is requited with concept selection suggestions, a selection of material that meets the specification of requirements stated in Safe manual assembly tools and design recommendations that aim to improve the manufacturability of the concept. This bachelor thesis concludes that design alterations striving to meet requirements for manufacturability should be made early in the devolpment process. Visiting the polymer-based product manufacturing industry offers better insight into which requirements that need to be fulfilled to make a product producible. Injection molding simulation software, if such is available, should be used in combination with design guidelines.The thesis also concludes that material selection is simplified through early contact with suppliers of material. Material selection is based off the specification of requirements and therefore requirements specified in the specification should be clarified and have their plausibility confirmed before the selection takes place.

Ces travaux contribuent à l'amélioration de la fabrication de pièces complexes de turbomachine. Elles sont principalement composées de veines fluides souvent délimitées par des pales, dont la fonction première est de transférer de l'énergie entre un fluide et une partie mécanique. Dans ce cas précis, la géométrie de ces pièces est essentielle pour obtenir un bon rendement du mécanisme. Cependant, lors de l'usinage, les flexions des pales et/ou de l'outil ainsi que les interférences locales occasionnent des défauts géométriques pouvant nuire à l'efficacité du système. Dans le but de résoudre cette problématique, une approche globale est utilisée dans ce mémoire. Elle débute par l'étude de la conception de ces pièces, en introduisant des concepts de Design For Manufacturing, utilisables grâce à la proposition d'indicateurs de fabricabilité par usinage 5-axes de pièces de turbomachine. Cette démarche permet donc de garantir que les pièces conçues sont économiquement réalisables. Les travaux ont continué avec la mise en place d'une méthodologie d'aide au choix de la meilleure stratégie d'usinage basée sur des critères de respect des besoins fonctionnels de la pièce et des critères économiques. La seconde partie de ce mémoire est consacrée à l'étude d'une approche novatrice permettant la réduction des interférences locales lors de l'usinage par le flanc de surfaces non développables. Cette méthode, baptisée Computation of Adapted Tool Shape, optimise la forme de l'outil, pour une trajectoire et une surface données, afin d'obtenir un meilleur respect des besoins fonctionnels de la pièce. La dernière partie de ces travaux définit le domaine d'application de cette nouvelle méthode par sa mise en oeuvre sur des études de cas académiques et industriels.

隨著奈米積體電路時代的來臨, 在微影技術,半導體製造技術和電路設計技術的進步已導致新的機會來整合大部份在系統中被使用到的電子功能。例如經過SoC技術提供的單晶片解決方案 - 由可重複使用的矽智財共同構成的單晶片系統 (舉例來說: 微處理器矽智財、數位信號處理矽智財、記憶體矽智財和其他的明星矽智財共同構成的單晶片系統) 可以和其他的整合系統溝通。這種包括多項技術的整合方式漸漸增加DFM 的要求, 進而創造在半導體價值鏈之中新虛擬的整合鏈模式。 對於先進產品發展, 經由現存的分解方式價值鏈﹐從每個單一鏈節 （無晶圓設計，矽智財，電路設計自動化, 設計服務，光罩製造，晶圓製造和封裝／測試）所創造的聯合價值無法在短時間超越IDM (舉例來說: 無法提供較早的上市時間)。因此針對先進產品突破性的發展,整合每個單一鏈節變成重要的主題。本研究針對這一個整合議題提供一個新的設計合作平台作為解決方案。 研究將以 DFM議題在半導體價值鏈中的影響作為分析。針對公司和公司間的溝通界面, 設計合作平台將會提供更多的併進價值鏈知識整合。 / Advances in lithography, semiconductor processes and circuit design techniques at the nanometer IC era have led to new opportunities to integrate most of the electronic functions encountered in systems. The single-chip solution through System on Chip (SoC) which comprises reusable Silicon IP (SIP) such as Microprocessor, Digital Signal Processing (DSP), Memory and other Star SIPs enabling the system to communicate with other systems. This multidisciplinary approach calls for increasing Design for Manufacturing (DFM) needs among semiconductor value chain to enable a whole new virtual integrated chain. Through the existing disintegrated value chain, the synergized value contributed from each single node (fabless, SIP provider, EDA, design service, mask foundry, wafer foundry and assembly/test) could not fulfill the time-to-market benefit as the IDM provides for advanced product development. To integrate each single chain node becomes the important topic for advanced product breakthrough. A new design collaboration platform is proposed to address this integration issue. Study was conducted among this semiconductor value chain for the DFM (Design for Manufacturing) issue. The design collaboration platform addresses the inter-firm communication interface among the value chain to provide more concurrent value chain knowledge integration. By applying Fine’s double helix model with the evidence from DFM case, I successfully predict the re-integration trend of semiconductor industry post the disintegration model.

[pt] A necessidade de aumentar a produtividade no setor da construção civil estimulou investimentos em soluções digitais e a incorporação de princípios de manufatura na cadeia construtiva. A implementação de elementos estruturais padronizados fabricados fora do canteiro de obra é considerada uma prática válida para atingir este objetivo. O projeto para fabricação e montagem é um conceito que envolve diretrizes a serem consideradas no desenvolvimento do projeto, cuja finalidade é facilitar a fabricação e montagem de componentes. A metodologia BIM pode incorporar análises de planejamento e construtibilidade para apoiar a tomada de decisão no contexto de construções replicáveis em escala de concreto armado. A presente investigação inclui uma revisão sistemática da literatura que orientou a pesquisa. Com base na SLR (Structured Literature Review), foi desenvolvido um Manual de Entrega de Informações que propõe um novo fluxo de trabalho no qual os estudos de planejamento construtivo e princípios de fabricação e montagem são agregados nos estágios iniciais do projeto para aproveitar a colaboração intrínseca da metodologia BIM. Para ilustrar o fluxo de trabalho proposto no IDM (Information Delivery Manual) desenvolvido é apresentado um experimento de um complexo de escolas. As informações do modelo parametrizado serviram como dados de entrada para as análises realizadas permitindo assim que pudessem ser comtemplados diferentes cenários de soluções estruturais. Os resultados obtidos pelo experimento indicam que a consideração de elementos de concreto pré-fabricado nem sempre vai contra os interesses econômicos, práticos e estéticos. Por fim, as análises de planejamento e construtibilidade são parâmetros importantes nas tomadas de decisão para aprimorar a identificação de oportunidades de melhorias no projeto e potencializar a eficiência de trabalho no canteiro de obra. / [en] The need to increase the civil construction sector stimulates investments in digital solutions and manufacturing principles in construction industry. The employment of standardized structural elements manufactured off-site construction, such as structural precast element, is considered a valid practice to achieve this purpose. The Design for Manufacturing and Assembly (DFMA) is a concept that involves guidelines considered in the development of the project and has the objective to facilitate the manufacturing and assembly of a product or component. Building Information Modeling (BIM) methodology can incorporate planning and constructability analysis to support decision making in the context of scalable and replicable concrete building projects. The present investigation includes a Structured Literature Review (SLR) that guided the research. Based on the SLR, an Information Delivery Manual (IDM) was developed to propose a new workflow in which the studies of construction planning and the application of manufacturing and assembly principles are considered in the early stages of design to take advantage of the collaboration intrinsic to the BIM methodology. An experiment of a school complex is presented to illustrate the workflow proposed in the developed IDM. The parametric model information was the key input to run analyzes in different structural solutions scenarios. The results indicated that the consideration of precast concrete elements does not always contradict economic, practical and aesthetic interests. Finally, planning and constructability analyzes are important parameters in decision-making, enhancing the recognition of opportunities for improvement in the project and increasing the efficiency of work in the construction site.

En el proceso de diseño se toman decisiones que pueden afectar a la fabricabilidad del producto. Cuando el diseñador es experto, considera las limitaciones, las propiedades y el coste de fabricación en la fase de materialización o de detalle. El problema surge cuando el diseñador no es experto o cuando no hay suficiente información y conocimiento de fabricación disponible. Tomando como referencia la teoría de Diseño Axiomático y las técnicas de DFM, se propone una metodología para identificar, definir y formalizar la información de fabricación que debería estar disponible en el diseño para diseñar para fabricar (DFM). También se propone un prototipo de modelo de información para desarrollar una futura herramienta informática que facilitaría la aplicación de esta metodología y que permitiría guiar al diseñador durante el diseño. La metodología ha sido aplicada a una biela de un motor de combustión interna alternativo (MCIA), y a los procesos que se están usando actualmente para fabricarla: forja en matriz cerrada y forja de polvo de metal. / Experience and knowledge of the designer are key elements during the design process. In the embodiment and detailed design phases is when the expert designers take into account the manufacturing process constraints, capabilities and costs. A problem arises when the designer is inexpert or when not enough manufacturing information and knowledge is available. This work presents a methodology, based on the Axiomatic Design Theory and on DFM techniques, to determine the explicit manufacturing process knowledge that the designer should have to design for manufacturing. This methodology has been the basis to develop the model information approach. This model is the first step to develop software to assist in the methodology application and to guide the designer during the design process. The methodology has been applied to a particular component (connecting rod). The manufacturing processes considered are forging and powder metallurgy, which are the main processes currently used in the manufacturing of connecting rods.

La « conception pour la fabrication » ou DFM (Design for Manufacturing) est une méthode maintenant classique pour assurer lors de la conception des produits simultanément la faisabilité, la qualité et le rendement de la production. Dans l'industrie microélectronique, le Design Rule Manual (DRM) a bien fonctionné jusqu'à la technologie 250nm avec la prise en compte des variations systématiques dans les règles et/ou des modèles basés sur l'analyse des causes profondes, mais au-delà de cette technologie, des limites ont été atteintes en raison de l'incapacité à sasir les corrélations entre variations spatiales. D'autre part, l'évolution rapide des produits et des technologies contraint à une mise à jour « dynamique » des DRM en fonction des améliorations trouvées dans les fabs. Dans ce contexte les contributions de thèse sont (i) une définition interdisciplinaire des AMDEC et analyse de risques pour contribuer aux défis du DFM dynamique, (ii) un modèle MAM (mapping and alignment model) de localisation spatiale pour les données de tests, (iii) un référentiel de données basé sur une ontologie ROMMII (referential ontology Meta model for information integration) pour effectuer le mapping entre des données hétérogènes issues de sources variées et (iv) un modèle SPM (spatial positioning model) qui vise à intégrer les facteurs spatiaux dans les méthodes DFM de la microélectronique, pour effectuer une analyse précise et la modélisation des variations spatiales basées sur l'exploitation dynamique des données de fabrication avec des volumétries importantes. / The DFM (design for manufacturing) methods are used during technology alignment and adoption processes in the semiconductor industry (SI) for manufacturability and yield assessments. These methods have worked well till 250nm technology for the transformation of systematic variations into rules and/or models based on the single-source data analyses, but beyond this technology they have turned into ineffective R&D efforts. The reason for this is our inability to capture newly emerging spatial variations. It has led an exponential increase in technology lead times and costs that must be addressed; hence, objectively in this thesis we are focused on identifying and removing causes associated with the DFM ineffectiveness. The fabless, foundry and traditional integrated device manufacturer (IDM) business models are first analyzed to see coherence against a recent shift in business objectives from time-to-market (T2M) and time-to-volume towards (T2V) towards ramp-up rate. The increasing technology lead times and costs are identified as a big challenge in achieving quick ramp-up rates; hence, an extended IDM (e-IDM) business model is proposed to support quick ramp-up rates which is based on improving the DFM ineffectiveness followed by its smooth integration. We have found (i) single-source analyses and (ii) inability to exploit huge manufacturing data volumes as core limiting factors (failure modes) towards DFM ineffectiveness during technology alignment and adoption efforts within an IDM. The causes for single-source root cause analysis are identified as the (i) varying metrology reference frames and (ii) test structures orientations that require wafer rotation prior to the measurements, resulting in varying metrology coordinates (die/site level mismatches). A generic coordinates mapping and alignment model (MAM) is proposed to remove these die/site level mismatches, however to accurately capture the emerging spatial variations, we have proposed a spatial positioning model (SPM) to perform multi-source parametric correlation based on the shortest distance between respective test structures used to measure the parameters. The (i) unstructured model evolution, (ii) ontology issues and (iii) missing links among production databases are found as causes towards our inability to exploit huge manufacturing data volumes. The ROMMII (referential ontology Meta model for information integration) framework is then proposed to remove these issues and enable the dynamic and efficient multi-source root cause analyses. An interdisciplinary failure mode effect analysis (i-FMEA) methodology is also proposed to find cyclic failure modes and causes across the business functions which require generic solutions rather than operational fixes for improvement. The proposed e-IDM, MAM, SPM, and ROMMII framework results in accurate analysis and modeling of emerging spatial variations based on dynamic exploitation of the huge manufacturing data volumes.