Volvo Cars Corporation (VCC) is devoted to Lean and Six Sigma, and has lately considered an imple-mentation of Design for Manufacturing and Assembly (DFMA) with the purpose of improving their product design process and production. The goal for this project work is therefore to investigate if DFMA is a beneficial method for VCC to use, how DFMA can be used and suggest a DFMA method. A literature study is performed as a starting point to understand DFMA methods and its possibilities. Scientific articles, technical books and online sources is used during the study in order to gather in-formation regarding DFMA implementations, application areas, approaches and potential risks that need to be eliminated for a successful implementation. In order to map the product development and manufacturing processes of VCC interviews are per-formed. The interviews also gathered information regarding what VCC employees thinks of DFMA and how they wish to use it. This information is compiled into a demand specification where the de-mands are weighted after importance by the interviewees. After the pre-study, three idea generation sessions is performed with three different focus groups. The generated ideas are then evaluated and classified. The remaining ideas are classified with the purpose of enabling the possibility to use a morphological chart to build whole concepts from the single ideas. Three concepts are chosen amongst the generated concepts. These concepts are then evaluated against the weighted demand specification. The concept considered most suitable is further devel-oped which resulted in a proposed DFMA method for VCC. A case study on a product is performed in order to communicate, test and evaluate the final DFMA method. The project is rounded off with discussions regarding DFMA and the suggested method from sustain-ability point of view and how to motivate usage. All results and discussions from the project are handed over to the company, enabling further research on a possible implementation of DFMA in the organization. / Volvo Cars Corporation arbetar hängivet efter metoderna Lean och Sex Sigma och har avsikt att im-plementera Design for Manufacturing and Assembly (DFMA) i syfte att förbättra deras produkt- och produktutvecklingsprocess. Målet med detta arbete är att undersöka om DFMA är en värdefull me-tod för VCC att använda och hur metoden kan tänkas användas och implementeras inom organisat-ionen. Som utgångspunkt för att förstå DFMA metoden och dess möjligheter genomförs en litteraturstudie. Under studien granskades aktuella vetenskapliga artiklar, tekniska böcker och webbkällor i syfte att samla information om DFMA-implementeringar, användningsområden, tillvägagångsätt och potenti-ella risker som behövs elimineras för en lyckad implementation av metoden. Vidare utförs intervjuer i syfte att kartlägga produktutvecklings- och tillverkningsprocessen samt samla information om hur anställda ställer sig till, och önskar använda DFMA. Denna information sammanställs sedan till en kravspecifikation där kraven i sin tur viktas av intervjuobjekten efter hur viktiga de anses vara. Tre idégenereringssessioner utförs därefter med tre olika fokusgrupper. Dessa idéer gallras sedan ut och klassificeras för att sedan kombineras med hjälp av en morfologisk tabell i syfte att bygga kon-cept av de enskilda idéerna. Tre koncept väljs ut bland de genererade koncepten. Dessa koncept utvärderas sedan mot varandra med kravspecifikationen som bedömningsskala. Det koncept som bedöms som mest lämpligt vidare-utvecklas och en föreslagen metod för VCC tas fram. För att testa och illustrera den slutgiltiga meto-den genomförs en fallstudie på en produkt. Arbetet rundas av med diskussioner kring DFMA och den föreslagna metoden ur både hållbarhets-synpunkt och motivationssynpunkt. Samtliga resultat och diskussioner överlämnas sedan till företa-get för att möjliggöra vidare undersökningar kring en eventuell implementation av DFMA. / DFMA FMEA DFM DFA Lean Produktdesign Metodutveckling

CIDAN Machinery Sweden AB, ursprungligen AB Göteneds Mekaniska Verkstad, har tillverkat maskiner för plåtbearbetning och delar för industrin som utrustas med olika slags kontrollpaneler eller manöverlådor. Företaget vill nu undersöka möjligheter till förbättringar, både i kostnad som funktion och utformning gällande dessa manöverlådor. Målet med examensarbetet är att undersöka möjligheten att utforma en manöverlåda som ska ersätta tre befintliga modeller och leda till en mer ekonomiskt gångbar produkt med förbättringar inom områden som tillverkning, montering, användbarhet och hållbar utveckling. Manöverlådan har även som krav att använda sig av den befintliga elektroniken. Förstudien påbörjades med Quality Function Deployment som metod för att arbeta med kund och kvalitetsinriktad design. Stegen innefattade observationer och intervjuer med målgruppen, analys av befintlig konstruktion med en felriskanalys och en undersökning på alternativa material för att identifiera och vikta kundbehov som kan kopplas till tekniska specifikationer. Den insamlade informationen resulterade i en kravspecifikation som den nya produkten skulle uppfylla. Konceptutvecklingen påbörjades med en analys av företagets produktidentitet. Därefter delades manöverlådan in i delfunktioner och förslag på dellösningar genererades. Med en morfologisk matris togs 6 helhetslösningar fram. Slutligen valdes ett av två vidareutvecklade koncept som ansågs ha störst potential och skulle uppfylla specifikationen bäst. Konceptet förfinades i CAD med, bland annat, ökad modularitet och minskad vikt samt en förenklad form. Ritningar togs fram för att konceptet skulle vara redo för produktion. Resultatet blev en manöverlåda som uppfyller de satta kraven och ersätter två av tre befintliga modeller, med förbättringar inom miljö, kostnad och produktidentitet. En fullskalig prototyp togs slutligen fram tillsammans med företaget som visade att slutkonceptet gick att tillverka. / CIDAN Machinery Sweden AB, originally AB Göteneds Mekaniska Verkstad, has manufactured machines for sheet metal processing and parts for industry that are equipped with various control panels or control boxes. The company now wants to explore possibilities for improvement, both in cost as function and design regarding these control boxes. The aim of the degree project is to explore the possibility of designing a control box that will replace three existing models and lead to a more economically viable product with improvements in areas such as manufacturing, assembly, usability and sustainable development. The controlbox also has the requirement to use the existing electronics. During the prestudy, Quality Function Deployment was implemented as a method of working with customer and quality-oriented design. Steps included observations and interviews with the target group, analysis of existing design with a failure modes and effects analysis and a study of alternative materials to identify and weigh customer needs that can be linked to technical specifications. The information gathered resulted in a requirement specification that the new product would meet. Concept development initiated with an analysis of the company's product identity. Subsequently, the control box was divided into partial functions and suggestions for sub-solutions were generated. A morphological matrix was used to produce six complete solutions that were then evaluated and screened depending on how well they met the needs. Finally, one of two further developed concepts was considered to have the greatest potential and would best meet the specification. The result was a control box that fulfills the requirements and replaces two of three existing models, with improvements in environment, cost and productidentity. A full scale prototype was finally made in collaboration with the company which showed that the final concept could be manufactured.

After contacting Ragnar Tengstrand, the supervisor, I was determined to develop a baby carriage that will have a fan that gives cold during the summer period and a heat sink that will provide heat during the winter period. Only the frame of the stroller appeared within the delimitation of this project, but consideration was given to the location of the fan, powerbank, and the heat sink.   The work began with information searching for prams, competitors, medical visits and consumer interviews. Then a number of sketches were developed and were shown to the supervisor. From these terms, the one who was called "Product development of cooling/heating system for baby carriage" was chosen. This was further developed as well as CAD files, sketches and drawings were made for.

No description available.

No description available.

Necrotic enteritis (NE) is a disease that negatively affects broiler performance and has increasingly become a problem with the reduced use of antibiotics. There is increased interest to utilize alternative methods including coccidial vaccines and direct fed microbials (DFM) to reduce or prevent NE. Additionally, it has been demonstrated that reduced dietary Ca can reduce NE mortality. The objective of the first study was to examine the effects of Bacillus subtilis (DFM) in combination with attenuated (AV) and non-attenuated (NV) coccidial vaccines in broilers with NE. The objective of the second study was to determine the effects of DFM, antibiotic (BMD) or negative control (NC) with standard dietary Ca (0.9%) or below standard Ca (0.75%, 0.6%) in broilers with NE. To induce a natural NE occurrence, birds were vaccinated with the appropriate coccidial vaccine and then placed on reused litter from a previous flock exhibiting NE lesions and mortality. In the first trial DFM reduced BW and BW gain (P ≤ 0.05) during the starter phase (0 to 14 d). The addition of a DFM in the AV group resulted in decreased (P ≤ 0.05) BW gain and BW at 42 d. The DFM in the NV group resulted in improved (P ≤ 0.05) mortality corrected feed conversion ratio from 0 to 42 d. Overall, with a natural NE occurrence, the effect of DFM was variable depending on what type of coccidial preventative was utilized and was beneficial when used with NV. In the second trial BW and BW gain were increased in broilers fed 0.60% dietary Ca and DFM compared to 0.90% Ca and NC (P ≤ 0.05). Broilers fed 0.60% Ca had reduced NE mortality compared to broilers fed 0.90% Ca (P ≤ 0.05). Reducing dietary Ca to below industry standards was able to lessen the severity of NE though the addition of DFM was needed to improve BW. Overall, with a natural NE occurrence, the DFM was beneficial when used with NV and in diets with 0.6% dietary Ca. / Doctor of Philosophy / Necrotic enteritis (NE) is caused by the bacterium Clostridium perfringens and is a disease that reduces growth of broiler chicks and has increasingly become a problem in the chicken industry with the reduced use of antibiotics. Coccidiosis is a protozoal disease that causes intestinal damage and predisposes broilers to developing NE. Prevention of coccidiosis can be through medication or coccidial vaccines. Probiotics or direct fed microbials (DFM) have demonstrated the potential to reduce both coccidiosis and NE symptoms. Additionally, it has been shown that reducing the amount of calcium (Ca) in the diet can reduce chick death from NE. The first study examined the effects of a beneficial bacterium, Bacillus subtilis (DFM) in combination with two types of coccidial vaccines, attenuated (AV) and non-attenuated (NV). The second study investigated DFM with standard dietary Ca (0.9%) or below standard Ca levels (0.75%, 0.6%). To induce a "natural" NE disease occurrence, birds were vaccinated with the appropriate coccidial vaccine and then placed into pens. Pens contained reused litter from a previous flock of birds with NE (contained spores of Clostridium perfringens). In the first trial DFM reduced body weight of broilers during the first two weeks (P ≤ 0.05). The DFM decreased (P ≤ 0.05) BW gain and BW in the AV group but improved feed efficiency in the NV group (P ≤ 0.05). In the second trial BW and BW gain were increased in broilers fed DFM and lower Ca diets (0.6%) compared to those fed the standard (0.90%) Ca diets without DFM (P ≤ 0.05). Dead birds were reduced when broilers were fed lower Ca diets (0.6%) compared to broilers fed standard (0.90%) Ca diets (P ≤ 0.05). In conclusion, the DFM was beneficial when used with NV and in diets with lower Ca (0.6%) during a natural NE occurrence.

Este trabalho propõe uma metodologia de projeto para fabricação ou Design Methodology for Manufacturing (DFM) utilizando a Programação Geométrica (PG) e os métodos tipo Newton para resolver problemas de otimização não-linear, os quais definem e assistem o projeto de circuitos analógicos. Depois, essa metodologia é aplicada e validada através do projeto de uma fonte de referência. Nos últimos anos, a tendência do aumento na densidade de transistores previsto pela lei de Moore tornou o problema do projeto dos circuitos dimensionalmente mais complexo. Além disso, uma maior densidade de transistores implica na diminuição das dimensões características do processo tornando-o mais sensível às variações de processo e as condições ambientais. As diferenças apresentadas entre o circuito projetado e aquele testado dão evidências de perdas de rendimento, as quais são atribuídas numa grande proporção ao processo de projeto. Devido à grande responsabilidade que o projetista tem neste problema, o projeto analógico deve ser focado para novas abordagens que levem em conta o desempenho e o rendimento conjuntamente. Em primeiro lugar, a metodologia proposta obtém um ponto inicial com um conjunto de especificações de desempenho adequadas, o qual vai ser usado na análise do impacto que tem o mismatch e as variações de processo sobre as especificações. Uma vez que o comportamento estatístico e determinístico do circuito foi caracterizado, uma nova estratégia de melhoria de rendimento foi implementada usando PG. A intenção de obter um projeto com um conjunto de especificações de bom desempenho envolve diretamente o rendimento do circuito, pois um conjunto de especificações ótimo obtido através da estrutura típica da PG não garante a obtenção de um projeto comercial e competitivo. Assim, este trabalho estabelece um método de projeto que combina a facilidade na obtenção do ótimo global da Programação Geométrica com uma nova análise de mismatch e de pior caso a qual permitiu uma redução nos tempos de computação mantendo semelhantes os valores de desempenho nominais. Usando a metodologia de projeto para fabricação proposta neste trabalho foi obtido um projeto de uma fonte de referência com um rendimento maior que 37% comparado com uma estratégia de projeto típica, sem nenhuma penalização significativa nas especificações de desempenho. / This work proposed a Design Methodology for Manufacturing (DFM) using Geometric Programming (GP) and Newton-like methods to solve non-linear optimization problems, which define and aid the design of analog circuits. Afterwards, this methodology is applied and validated through the design of a voltage reference circuit. Over the last years, the tendency of the increasing on the transistor density predicted by the Moore Law has turned the circuit design problem dimensionally more complex. Additionally, a higher transistor density implies shrinkage on the feature dimensions of the process making it more sensitive to the process variations and environmental conditions. The differences between the designed circuit and the tested one give an evidence of yield losses, which are attributed in a great proportion to the design process. Due to the high responsibility of the designer on this problem, the analog design must be focused on new approaches that jointly manage performance and yield. In first place, the proposed methodology obtain a initial point with a suitable set of performance specifications, which will be used to analyze the impact of the mismatch and process variation over the design specifications. Once the statistical and deterministic behavior of the circuit was characterized, a new yield improvement strategy is implemented using Geometric Programming. Attempting to obtain a design with a set of high performance specifications directly involves the circuit yield, because an optimal performance set obtained by the traditional framework of GP does not assure the obtaining of a marketable and competitive design. So, this works establish a design method that combine the advantage of obtaining global optimum in Geometric Programming with a new mismatch and worst-case analysis that enabled a reduction in their computation time and maintain the initial nominal performance values. Using the design methodology for manufacturing proposed in this work, a voltage reference design with 37% better yield than one obtained with a typical design strategy without any significant penalty on their performance specs was achieved.

The purpose with this thesis was to develop a designguideline which will simplify the development of new products that will be laser welded. The need for this thesis has come forward from the quality problems that Volvo Construction Equipment, Components Division is having with their laser welding manufacturing unit. The reason for the problems emerges from the bad communication between the development unit and the manufacturing unit within the company when the products produced today was developed. This resulted in products that were hard to and in some cases almost impossible to weld.   To avoid these problems from occurring again it was needed to gather the experiences within this area and compile it and present in a brief a pedagogical manner. The information for the groundwork of our results has been gathered by interviews of several key persons in Volvo Construction Equipment, Components Division. Other information channels have been a literary study, visiting other companies, participating in the manufacturing processes and participation in the project for non-destructive testing.     We have considered the following subjects after compiling the gathered information:   ·         Product design ·         Choice of material ·         Weld joint design ·         The limiting dimensions of the laser welding unit ·         The Heat Affected Zone, HAZ, after laser welding ·         Washing/Cleanliness ·         Testing – Destructive or non-destructive     There is no other company in the world that welds products with the same method and the same material as they do in Volvo Construction Equipment, Components Division. The conclusion is that the complications that arose when the products that are manufactured today were developed can be avoided if our designguideline were to be followed in the future new development.

<p> </p><p><strong></strong></p><p>The purpose with this thesis was to develop a designguideline which will simplify the development of new products that will be laser welded. The need for this thesis has come forward from the quality problems that Volvo Construction Equipment, Components Division is having with their laser welding manufacturing unit. The reason for the problems emerges from the bad communication between the development unit and the manufacturing unit within the company when the products produced today was developed. This resulted in products that were hard to and in some cases almost impossible to weld.</p><p> </p><p>To avoid these problems from occurring again it was needed to gather the experiences within this area and compile it and present in a brief a pedagogical manner. The information for the groundwork of our results has been gathered by interviews of several key persons in Volvo Construction Equipment, Components Division. Other information channels have been a literary study, visiting other companies, participating in the manufacturing processes and participation in the project for non-destructive testing.</p><p> </p><p> </p><p>We have considered the following subjects after compiling the gathered information:</p><p> </p><p>·         Product design</p><p>·         Choice of material</p><p>·         Weld joint design</p><p>·         The limiting dimensions of the laser welding unit</p><p>·         The Heat Affected Zone, HAZ, after laser welding</p><p>·         Washing/Cleanliness</p><p>·         Testing – Destructive or non-destructive</p><p> </p><p> </p><p>There is no other company in the world that welds products with the same method and the same material as they do in Volvo Construction Equipment, Components Division. The conclusion is that the complications that arose when the products that are manufactured today were developed can be avoided if our designguideline were to be followed in the future new development.</p>

Este trabalho propõe uma metodologia de projeto para fabricação ou Design Methodology for Manufacturing (DFM) utilizando a Programação Geométrica (PG) e os métodos tipo Newton para resolver problemas de otimização não-linear, os quais definem e assistem o projeto de circuitos analógicos. Depois, essa metodologia é aplicada e validada através do projeto de uma fonte de referência. Nos últimos anos, a tendência do aumento na densidade de transistores previsto pela lei de Moore tornou o problema do projeto dos circuitos dimensionalmente mais complexo. Além disso, uma maior densidade de transistores implica na diminuição das dimensões características do processo tornando-o mais sensível às variações de processo e as condições ambientais. As diferenças apresentadas entre o circuito projetado e aquele testado dão evidências de perdas de rendimento, as quais são atribuídas numa grande proporção ao processo de projeto. Devido à grande responsabilidade que o projetista tem neste problema, o projeto analógico deve ser focado para novas abordagens que levem em conta o desempenho e o rendimento conjuntamente. Em primeiro lugar, a metodologia proposta obtém um ponto inicial com um conjunto de especificações de desempenho adequadas, o qual vai ser usado na análise do impacto que tem o mismatch e as variações de processo sobre as especificações. Uma vez que o comportamento estatístico e determinístico do circuito foi caracterizado, uma nova estratégia de melhoria de rendimento foi implementada usando PG. A intenção de obter um projeto com um conjunto de especificações de bom desempenho envolve diretamente o rendimento do circuito, pois um conjunto de especificações ótimo obtido através da estrutura típica da PG não garante a obtenção de um projeto comercial e competitivo. Assim, este trabalho estabelece um método de projeto que combina a facilidade na obtenção do ótimo global da Programação Geométrica com uma nova análise de mismatch e de pior caso a qual permitiu uma redução nos tempos de computação mantendo semelhantes os valores de desempenho nominais. Usando a metodologia de projeto para fabricação proposta neste trabalho foi obtido um projeto de uma fonte de referência com um rendimento maior que 37% comparado com uma estratégia de projeto típica, sem nenhuma penalização significativa nas especificações de desempenho. / This work proposed a Design Methodology for Manufacturing (DFM) using Geometric Programming (GP) and Newton-like methods to solve non-linear optimization problems, which define and aid the design of analog circuits. Afterwards, this methodology is applied and validated through the design of a voltage reference circuit. Over the last years, the tendency of the increasing on the transistor density predicted by the Moore Law has turned the circuit design problem dimensionally more complex. Additionally, a higher transistor density implies shrinkage on the feature dimensions of the process making it more sensitive to the process variations and environmental conditions. The differences between the designed circuit and the tested one give an evidence of yield losses, which are attributed in a great proportion to the design process. Due to the high responsibility of the designer on this problem, the analog design must be focused on new approaches that jointly manage performance and yield. In first place, the proposed methodology obtain a initial point with a suitable set of performance specifications, which will be used to analyze the impact of the mismatch and process variation over the design specifications. Once the statistical and deterministic behavior of the circuit was characterized, a new yield improvement strategy is implemented using Geometric Programming. Attempting to obtain a design with a set of high performance specifications directly involves the circuit yield, because an optimal performance set obtained by the traditional framework of GP does not assure the obtaining of a marketable and competitive design. So, this works establish a design method that combine the advantage of obtaining global optimum in Geometric Programming with a new mismatch and worst-case analysis that enabled a reduction in their computation time and maintain the initial nominal performance values. Using the design methodology for manufacturing proposed in this work, a voltage reference design with 37% better yield than one obtained with a typical design strategy without any significant penalty on their performance specs was achieved.