DFMA Paradigms as Applied to the Warring Juicer

1
DFMA Paradigms as Applied to the Warring Juicer

• DFMA ME-6960
• Presented by Team Alpha
• April 28 2003
• Instructor
• Dr. A.K.Balaji

2
Overview

• Juicer Properties/Specifications.
• Manufacturing Processes.
• MATLAB Code.
• Injection Molding Analysis.
• Assembly Analysis.
• Conclusions.
• Questions.

3
Product Specifications/Part List
4
Main Components Of the Juicer
5
Manufacturing Processes
6
MATLAB CODE FOR IM Parameters

• Separating Forces for the Injection Molding
  Machine
• Injection Molding Times
• Mold Base Cost
• Injection Mold Costs
• Optimum Number of Cavities
• Directs the User to the right tables and Figures
  based on the Book Product Design For
  Manufacturing Assembly, Boothroyd, Dewhurst and
  Knight.

7
MATLAB CODE FOR Sheet Metal Parameters

• Cost Of Die Set (Cds)
• Final Die Cost (Cd)
• NOTE Calculates For All Bending, Piercing and
  Blanking operations.

8
Base Cover Design Changes

• New Design

Old Design
9
Base Cover Analysis

• Old Design Die Costs 64,725
• New Design Die Costs 61,365
• Difference 3,360

10
Motor Housing Design Changes
Old Design
New Design
11
Motor Housing Part Analysis

• Old Design Die Costs 86,851
• New Design Die Costs 89,971
• Difference 3,120

12
Juicer Cover Design Changes
Old Design
New Design
13
Juicer Cover Part Analysis

• Old Design Die Costs 51,656/-
• New Design Die Costs 42,668/-
• Difference 8,988/-

14
Juicer Container Design Changes
Old Design
New Design
15
Juicer Container Part Analysis

• Old Design Die Costs 90,625/-
• New Design Die Costs 86,185/-
• Difference 4,440/-

16
Solution To The Clips
Solution to the Clip
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Sheet Metal Analysis Results of the Clip

• Cost Of Die Set (Cds) 193.87
• Final Die Cost (Cd) 2004.12
• Note Part Eliminated.

18
Cost Analysis Comparison
19
Assembly Analysis

• Modular Assembly Layout
• Analysis for Original Design
• Analysis for Modified Design

20
DFA Analyses Results

• Time reduced from 246.74 s to 149.9 s. (39)
• Part reduction from 43 to 29.( 33)
• Assembly cost reduced from 1.07/unit to
  0.63/unit. ( 41)
• Over 190,000 saved on assembly of 500,000 units.

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Conclusions

• Reduction in the number of parts from 43 to 29
• Reduction in the die costs (IM) saved 13,660
• Reduction in the die costs (SM) saved 2,500
• Reduction in assembly costs saved 41
• For a production run of 500,000 units, the
  overall savings
• are 207,160

22
Questions?