Šis ištirtas DFM metodas padeda atkreipti projektuotojų dėmesį į tas presuojamojo liejimo formavimo ypatybes, kurios yra linkusios didinti gaminio apdirbimo sąnaudas. Tyrime naudojame „šešių laipsnių koduojančia sistema“ tam, kad nustatyti galutines preliminarias ruošinio apdirbimo sąnaudas. Čia pabrėžiamos tos ypatybes, kurios žymiai didina kainą, kad projektuotojai galėtų sumažinti gaminamos detalės sudėtingumą. Naudojant pristatytą metodologiją, projektuotojai gali įvykdyti ruošinių apdirbimo sąnaudų įvertinimą ankstyvojoje konstravimo stadijoje. Tai gali būti įvikdyta pasitelkiant jų apytiksle vieta ir orientacija. Išsamūs matmenys nėra būtini. Metodologija parodo tai, ką detalių charakteristikos įtakoja kainai, kad pagerintų perkonstruotą detalę. / The master’s thesis present the rewiew of design manufacture method. Mechanical part design plays an important role whether company will succeed in market or will fail. From my point of view there are three main measures of the DFM (Design For Manufacture) process: cost, quality and time, which are pivotal in design process. Regardless of the product being designed – whether it is an entire system or some small subpart of a larger product - the customer and management always want it cheaper, better and faster. In this project has described a systematic approach for calling designers attention to those features of injection molding that tend to increase the tooling cost to manufacture parts – and for estimating the relative costs of tooling. The system employs a six – digit coding system for determining total relative tooling cost, which groups parts according to their similarity in tool construction difficulty. The system highlight those features that significantly increase cost so that designers can minimize difficult – to – produce features.

These master’s theses present the review of design support methods. Mechanical part design plays an important role whether company will succeed in market or will fail. In the first part I describe some systematical design support methods and tools, such like axiomatic design and group technology. From my point of view there are three measures of the design process: cost, quality and time, which are pivotal in design process. Regardless of the product being designed – whether it is an entire system or some small subpart of a larger product – the customer and management always want it cheaper, better and faster. Design decisions directly determine the materials used, the goods purchased, the time when it should be purchased, the part to be assembled, the shape of those parts, the product sold, and, in the end, the scope of management. In the next parts I describe main CIM (computer integrated manufacturing) elements and DFX (design for X) methods, and importance to use these systems and methods in factories. The development of the DFX strategies arose from the need to understand what is important after the design stage. Since design typically will set 70% of the cost of a product, it is very important to make sure designs are made with the correct objective in mind. In the case study I’m describing production of bikes. I propose some of the possibilities to make easier manufacturing, using DFX methodology. During this work I tried to apply theoretical knowledge about design... [to full text]

<p><strong>Sammanfattning</strong><em> </em></p><p>Detta examensarbete inom produkt- och processutveckling har genomförts på uppdrag av SMS Smart Media Solutions AB i Stockholm. Syftet med arbetet har varit att ta fram och utveckla ett stativ som ska kunna hålla upp till 4 stycken datorskärmar och som tillåter ergonomisk anpassning och användning. Under projektets gång har antalet skärmar utökats från 4 till 8 för att tillmötesgå uppkomna kund- och marknadskrav. Målet med examensarbetet har varit att ta fram en färdig prototyp som ska kunna ligga till grund för tillverkning av stativet.</p><p>Under utvecklingsarbetet har verktyg som QFD, funktionsanalys, Ishikawa-diagram, Pugh’s jämförelsematris och FMEA använts för att säkerställa att kund-, marknads-, kvalitets och funktionskrav uppfylls. Arbetet inleddes med en idégeneringsfas som utmynnade i ett antal olika koncept. Koncepten utvärderades utifrån kravspecifikation, funktion, antal standardkomponenter och pris. Konceptet som ansågs starkast utvecklades till en prototyp vilken i sin tur testades och utvärderades.</p><p>Resultatet av examensarbetet är att det utvecklade stativet är infört i SMS Smart Media Solutions’ produktportfolio och kommer att finnas med i SMS’ produktkatalog för 2010. Stativet motsvarar alla krav som satts upp i kravspecifikationen och alla problemen som definierats i problemformuleringen har lösts.</p><p> </p> / <p><strong>Abstract</strong></p><p>This thesis in product and process development has been made in cooperation with SMS Smart Media Solutions AB in Stockholm. The aim of the thesis has been to develop a new display bracket that can carry up to 4 monitors and that allows ergonomically adjustments and usage. During the project the amount of maximum monitors has been changed from 4 to 8 to meet the demand of the customers and the market. The goal of the thesis has been to develop a prototype that would be the ground of the future bracket that will be offered in SMS Smart Media Solutions’ product portfolio.</p><p>To make sure that the developed bracket meets all the demands and criteria, tools like QFD, analysis of function, Ishikawa diagram, Pugh’s matrix and FMEA have been used. The process of the product development started with brainstorming and concept generation. The developed concepts were evaluated using analysis of requirements, costs, functions and the amount of used standard components. The winning concept was carried on into a prototype that was tested, evaluated and improved.</p><p>The result of the thesis is that the developed bracket has been integrated to SMS Smart Media Solutions’ product portfolio and will be added to SMS’ product catalogue for 2010. The final bracket met all the criterions that were set in the specification of requirements and all the problems form the problem statement were solved.</p>

The main objective of the thesis &#8220;Conceptual Product Development in Small Corporations&#8221; is by the use of a case study test the MFD&#8482;-method (Erixon G. , 1998) combined with PMM in a product development project. (Henceforth called MFD&#8482;/PMM-method). The MFD&#8482;/PMM-method used for documenting and controlling a product development project has since it was introduced been used in several industries and projects. The method has been proved to be a good way of working with the early stages of product development, however, there are almost only projects carried out on large industries which means that there are very few references to how the MFD&#8482;/PMM-method works in a small corporation. Therefore, was the case study in the thesis &#8220;Conceptual Product Development in Small Corporations&#8221; carried out in a small corporation to find out whether the MFD&#8482;/PMM-method also can be applied and used in such a corporation.The PMM was proposed in a paper presented at Delft University of Technology in Holland 1998 by the author and Gunnar Erixon. (See appended paper C: The chart of modular function deployment.) The title &#8220;The chart of modular function deployment&#8221; was later renamed as PMM, Product Management Map. (Sweden PreCAD AB, 2000). The PMM consists of a QFD-matrix linked to MIM (Module Indication Matrix) via a coupling matrix which makes it possible to make an unbroken chain from the customer domain to the designed product/modules. The PMM makes it easy to correct omissions made in creating new products and modules.In the thesis &#8220;Conceptual Product Development in Small Corporations&#8221; the universal MFD&#8482;/PMM-method has been adapted by the author to three models of product development; original-, evolutionary- and incremental development.The evolutionary adapted MFD&#8482;/PMM-method was tested as a case study at Atlings AB in the community Ockelbo. Atlings AB is a small corporation with a total number of 50 employees and an annual turnover of 9 million &#8364;. The product studied at the corporation was a steady rest for supporting long shafts in turning. The project team consisted of management director, a sales promoter, a production engineer, a design engineer and a workshop technician, the author as team leader and a colleague from Dalarna University as discussion partner. The project team has had six meetings.The project team managed to use MFD&#8482; and to make a complete PMM of the studied product. There were no real problems occurring in the project work, on the contrary the team members worked very well in the group, having ideas how to improve the product. Instead, the challenge for a small company is how to work with the MFD&#8482;/PMM-method in the long run! If the MFD&#8482;/PMM-method is to be a useful tool for the company it needs to be used continuously and that requires financial and personnel resources. One way for the company to overcome the probable lack of recourses regarding capital and personnel is to establish a good cooperation with a regional university or a development centre.

Sammanfattning Detta examensarbete inom produkt- och processutveckling har genomförts på uppdrag av SMS Smart Media Solutions AB i Stockholm. Syftet med arbetet har varit att ta fram och utveckla ett stativ som ska kunna hålla upp till 4 stycken datorskärmar och som tillåter ergonomisk anpassning och användning. Under projektets gång har antalet skärmar utökats från 4 till 8 för att tillmötesgå uppkomna kund- och marknadskrav. Målet med examensarbetet har varit att ta fram en färdig prototyp som ska kunna ligga till grund för tillverkning av stativet. Under utvecklingsarbetet har verktyg som QFD, funktionsanalys, Ishikawa-diagram, Pugh’s jämförelsematris och FMEA använts för att säkerställa att kund-, marknads-, kvalitets och funktionskrav uppfylls. Arbetet inleddes med en idégeneringsfas som utmynnade i ett antal olika koncept. Koncepten utvärderades utifrån kravspecifikation, funktion, antal standardkomponenter och pris. Konceptet som ansågs starkast utvecklades till en prototyp vilken i sin tur testades och utvärderades. Resultatet av examensarbetet är att det utvecklade stativet är infört i SMS Smart Media Solutions’ produktportfolio och kommer att finnas med i SMS’ produktkatalog för 2010. Stativet motsvarar alla krav som satts upp i kravspecifikationen och alla problemen som definierats i problemformuleringen har lösts. / Abstract This thesis in product and process development has been made in cooperation with SMS Smart Media Solutions AB in Stockholm. The aim of the thesis has been to develop a new display bracket that can carry up to 4 monitors and that allows ergonomically adjustments and usage. During the project the amount of maximum monitors has been changed from 4 to 8 to meet the demand of the customers and the market. The goal of the thesis has been to develop a prototype that would be the ground of the future bracket that will be offered in SMS Smart Media Solutions’ product portfolio. To make sure that the developed bracket meets all the demands and criteria, tools like QFD, analysis of function, Ishikawa diagram, Pugh’s matrix and FMEA have been used. The process of the product development started with brainstorming and concept generation. The developed concepts were evaluated using analysis of requirements, costs, functions and the amount of used standard components. The winning concept was carried on into a prototype that was tested, evaluated and improved. The result of the thesis is that the developed bracket has been integrated to SMS Smart Media Solutions’ product portfolio and will be added to SMS’ product catalogue for 2010. The final bracket met all the criterions that were set in the specification of requirements and all the problems form the problem statement were solved.

A reading machine from LVI which can scan and read a text for visual impaired people needed a redesign to stay competitive. This redesign is done by two students. The students made a specialized method to execute the redesign. They found out that the focus of the redesign should lay on: easy to use, reliable result and appealing for the user. With this taken in consideration the students achieved to design a more competitive reading machine. Prototypes where made for a new camera arm (which goes high enough to scan A3 format) and a new control panel. The students gave a recommendation how to continue with the project from now on.

Detta examensarbete inom integrerad produktutveckling utfördes vid Högskolan i Skövde i samarbete med Ericsindustrier i Töreboda. Rapporten beskriver metodiken samt processen som utförts i projektet för att uppnå samtliga målsättningar. Syftet bestämdes till en omkonstruktion av en justerskruv placerad i en expanderbar duschstång. Denna duschstång anses vara en viktig del av Ericsindustriers produktsortiment. Grunden till behovet av en omkonstruktion ansågs vara antalet komponenter samt komponenternas montering. Detta krävde att komponentantalet minimerades genom DFx-principer där samma material eftersträvades genom produkten. Försämrad kvalité och hållfasthet definierades som kritiska områden då Ericsindustrier önskade att upprätthålla likvärdig kundnöjdhet samt att produkten skulle hålla för minst 200 N efter omkonstruktionen. Projektets struktur följde en femstegsmodell där designprocessen inleddes med en förstudie. Fokus låg på informationsinsamling, observationer samt kartläggning av nuläget. Genereringsfasen genomsyrades av metodik för att utforska lösningsrymden. Detta innefattade bland annat brainstorming, morfologisk matris samt skissning. I projektet har prototyper haft en stor inverkan då de har fungerat både som generering samt utvärdering av lösningar. De har även agerat som kommunikation till företag samt användare genom hela processen. Iterationer har präglat hela processen för att uppnå en produktutveckling. För att upprätthålla en användarcentrerad design innefattade projektet flertalet användartester. Fötterna till duschstången samt de två rören som bildar själva duschstången identifierades till separata problem. Dessa problem har diskuterats med företaget. Konceptval utfördes efter önskemål från företaget, tester, DFxprinciper samt diskussioner tills det mynnade ut i ett slutgiltigt koncept. Detta koncept uppfyllde de utsatta kraven samt behoven. Konceptet ansågs vara en prisvärd, högkvalitativ samt miljövänlig produkt. / This bachelor degree project in integrated product development was carried out at the University of Skövde in collaboration with Ericsindustrier in Töreboda. The report describes the methodology and the process that has been carried out in the project to achieve all the stated objectives. The scope was determined to be a redesign of an adjusting screw placed in an expandable shower rod. The shower rod is considered an important part of Ericsindustrier's product range. The reason for the need of a reconstruction was the number of components and the components assembly. The component number was required to be minimized by using DFx principles where the same material was sought throughout the product. Decreased quality and lower durability were defined as critical areas since Ericsindustrier wanted to maintain customer satisfaction and the product must hold for at least 200 N after the redesign. A five-stage model formed the basis of the project structure where the design process began with a preliminary study. The focus was on information gathering, observations and mapping of the current situation. The generation phase was imbued with methodology to explore solution space. This included, among other things, brainstorming, morphological matrix and sketching. In the project, prototypes had a great impact as they functioned as both generation and evaluation of solutions. They have also acted as communication with companies and users throughout the process. Iterations have characterized the whole process to achieve a product development. In order to maintain a user-centred design, the project included several user tests. The feet of the shower rod and the two pipes that form the shower rod itself were identified as separate problems. These issues have been discussed with the company. Concept selection was carried out according to the wishes of the company, tests, DFx principles and discussions until it ended in a final concept. This concept met the required requirements and needs. Therefore, it was an affordable, high quality and environmentally friendly product.

A indústria aeronáutica mundial tem se desenvolvido de modo acelerado em termos tecnológicos e de processos de fabricação aplicados. Com isso, tem se buscado melhores soluções durante o desenvolvimento do projeto e fabricação de aeronaves, visando uma melhor qualidade final dos produtos, redução dos ciclos e custos de fabricação, repetibilidade do processo (padronização), problemas com formação e reposição de mão de obra, além da garantia da competitividade da empresa no mercado global. Uma forma para se inovar tecnologicamente e tornar o negócio mais moderno, atrativo e competitivo, é sempre que possível, automatizar a produção e tornar a montagem mais barata, com mais qualidade, inovadora e da forma mais flexível possível. Sendo assim, este trabalho visa o desenvolvimento de um modelo de análise de processo que utiliza os requisitos e conceitos do DFX e Produção Enxuta, voltado para aplicação específica no desenvolvimento de projetos aeronáuticos com foco em automação da produção. O objetivo da ferramenta é auxiliar os engenheiros que atuam no desenvolvimento de projetos de aeronaves, para que os benefícios da automação na produção possam ser alcançados com a utilização do modelo de análise proposto. O trabalho inicia-se com a apresentação do ambiente da indústria aeronáutica mundial, com foco nos processos e novidades tecnológicas aplicadas nos novos produtos. Em seguida são apresentados os princípios da metodologia DFX, a revisão teórica dos conceitos de Produção Enxuta e também aplicações de Automação nos diferentes setores da indústria. Na sequencia é apresentado o modelo de análise desenvolvido em forma de fluxogramas, elaborado com as regras e plano de ações a ser executado durante o desenvolvimento, visando a automação na produção. Dois estudos de caso são apresentados para demonstrar e validar o modelo desenvolvido. Por fim, os resultados são discutidos e a conclusão estabelecida. / Worldwide Aeronautical Industry has been developed faster and faster in terms of technology and its manufacturing processes applied. Thus, it has been planning to reach better results during the aircraft development and manufacturing phases, aiming to get products with high quality, to decrease cycles times and manufacturing costs, to provide a repeatability of processes (standardization), problems with learn ship and reposition of man power and also to assure the company competitiveness in the global market. One way to innovate technologically and to become the business more modern, attractive and competitive, as always as possible is to automate the production to make it cheaper, with a high quality, innovation and with the most flexible condition. Therefore, this thesis aims to develop a model of process analysis using the requirements and concepts of DFX and Lean Manufacturing for specific application on aeronautical projects development with a focus on production automation. The main goal of the guideline is to drive the engineers who work on aircraft development phases, about the automation benefits that can be achieved when using the proposed analytical model. This study starts with the presentation of worldwide aeronautical industry environment, focusing on processes and technologies innovation applied on new products. Next, is presented the principles of DFX methodology, a theoretical review and concepts of Lean Manufacturing and also applications of Automation on new products. Subsequently, it has shown the principles of DFX methodology, theoretical review of Lean Manufacturing concepts and also applications of Automation in different industry sectors. Following is presented the model of analysis developed in form of flowcharts, drawn up the rules and actions plan to be taken during development, aiming automation in production. Two case studies are presented to demonstrate and validate the model developed. Finally, the results are discussed and the conclusion drawn.

A indústria aeronáutica mundial tem se desenvolvido de modo acelerado em termos tecnológicos e de processos de fabricação aplicados. Com isso, tem se buscado melhores soluções durante o desenvolvimento do projeto e fabricação de aeronaves, visando uma melhor qualidade final dos produtos, redução dos ciclos e custos de fabricação, repetibilidade do processo (padronização), problemas com formação e reposição de mão de obra, além da garantia da competitividade da empresa no mercado global. Uma forma para se inovar tecnologicamente e tornar o negócio mais moderno, atrativo e competitivo, é sempre que possível, automatizar a produção e tornar a montagem mais barata, com mais qualidade, inovadora e da forma mais flexível possível. Sendo assim, este trabalho visa o desenvolvimento de um modelo de análise de processo que utiliza os requisitos e conceitos do DFX e Produção Enxuta, voltado para aplicação específica no desenvolvimento de projetos aeronáuticos com foco em automação da produção. O objetivo da ferramenta é auxiliar os engenheiros que atuam no desenvolvimento de projetos de aeronaves, para que os benefícios da automação na produção possam ser alcançados com a utilização do modelo de análise proposto. O trabalho inicia-se com a apresentação do ambiente da indústria aeronáutica mundial, com foco nos processos e novidades tecnológicas aplicadas nos novos produtos. Em seguida são apresentados os princípios da metodologia DFX, a revisão teórica dos conceitos de Produção Enxuta e também aplicações de Automação nos diferentes setores da indústria. Na sequencia é apresentado o modelo de análise desenvolvido em forma de fluxogramas, elaborado com as regras e plano de ações a ser executado durante o desenvolvimento, visando a automação na produção. Dois estudos de caso são apresentados para demonstrar e validar o modelo desenvolvido. Por fim, os resultados são discutidos e a conclusão estabelecida. / Worldwide Aeronautical Industry has been developed faster and faster in terms of technology and its manufacturing processes applied. Thus, it has been planning to reach better results during the aircraft development and manufacturing phases, aiming to get products with high quality, to decrease cycles times and manufacturing costs, to provide a repeatability of processes (standardization), problems with learn ship and reposition of man power and also to assure the company competitiveness in the global market. One way to innovate technologically and to become the business more modern, attractive and competitive, as always as possible is to automate the production to make it cheaper, with a high quality, innovation and with the most flexible condition. Therefore, this thesis aims to develop a model of process analysis using the requirements and concepts of DFX and Lean Manufacturing for specific application on aeronautical projects development with a focus on production automation. The main goal of the guideline is to drive the engineers who work on aircraft development phases, about the automation benefits that can be achieved when using the proposed analytical model. This study starts with the presentation of worldwide aeronautical industry environment, focusing on processes and technologies innovation applied on new products. Next, is presented the principles of DFX methodology, a theoretical review and concepts of Lean Manufacturing and also applications of Automation on new products. Subsequently, it has shown the principles of DFX methodology, theoretical review of Lean Manufacturing concepts and also applications of Automation in different industry sectors. Following is presented the model of analysis developed in form of flowcharts, drawn up the rules and actions plan to be taken during development, aiming automation in production. Two case studies are presented to demonstrate and validate the model developed. Finally, the results are discussed and the conclusion drawn.

Parker Hannifin QCDE aim to eliminate as much wasted time, materials and resources as achievable by implementing Design for Manufacturing and Assembly principles into a modified version of their Product Development Process. The modified Product Development Process was developed within this project with the objective of aiding the company to remain competitive within their field, as well as continue to efficiently develop and produce high quality products.   A literature study was performed to gain a greater understanding of the multiple Design for Excellence methods and their possibilities to enhance the Product Development Process at Parker Hannifin QCDE. The literature study included various sources such as academic books and scientific articles.   An empirical study was conducted and the use of the current Internal Product Development Process was evaluated in conjunction with a detailed evaluation of the designated coupling. An additional aspect that was explored includes an evaluation of the extent of Design for Manufacturing and Assembly that is implemented into the current Internal Product Development Process.   The Generation chapter of this thesis outlines the sequence and process implemented for generating the modified Internal Product Development Process and implementing Design for Manufacturing and Assembly. The results of this thesis project included implementing Design for Manufacturing and Assembly in the form of checklists. The multiple Design for Excellence checklists were inspired in part by the information obtained from the literature study and the authors interpretation. The finished concept has been provided to Parker Hannifin QCDE in the form of a pamphlet including instructions of how to implement the checklists into the modified Internal Product development process.   The discussion chapter within this report consists of a conclusion and deliberation regarding the methodology used within this thesis. The results obtained from this thesis have been dissected and evaluated along with implications and potential weaknesses in the work.