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Design for Quality, Manufacturing and Assembly – Introduction

Design for Quality, Manufacturing and Assembly – Introduction


Hello, I am Palaniappan Ramu from the Department
of Engineering Design at IIT, Madras. This course is titled DFX where x is a variable
usually it is used to refer manufacturing and assembly. In this particular course, we are going to
cover 4 modules which is designed for robustness, design for manufacturing, design for assembly,
and design for sustainability. First, I will give an overview of the entire
course. And then my co-instructor Professor Saravana
Kumar will talk about design for manufacturing and assembly while I give an overview about
design for quality and sustainability. The whole idea of design for x is to see how
one can make an intelligent or wise decision at the design stage while trying to account
for some activities that come at a later point, meaning after design such as manufacturing,
assembly, quality control, or robustness, and sustainability. So we cannot wait until we face all these
things, come back and make a change in the design. Hence we want to account for these at the
design stage itself. So the entire scientific frame work on how
to foresee the problems in each of these cases and account them at the design stage itself
is what DFX is. For instant there are also other sorts of
X like serviceability, but we do not cover all that. We only cover the DFMA which is manufacturing
and assembly and design for quality and sustainability. So under design for quality, I will introduce
concepts on robustness. Robustness is nothing but when there is enough
variation in the input there should be limited variation in the output. So irrespective of the usage condition, the
performance of a machine or an automotive should not vary too much, that is the idea
of robust design. So we will introduce concepts of robustness
and how this concept of robustness can be used in driving design for quality. Quality is usually associated with the manufacturing
phase. The moment the product is designed and is
sold to a customer the performance becomes a reliability issue, until it is with the
manufacturer, it is a quality issue. So we will introduce concepts on design of
experiments how to design specific experiments to understand the variability in the performance. How to quantify that variability and how to
control that variability to attain a robust design and hence a quality design will be
discussed in DFQ which is designed for quality. The quality in this particular case will be
achieved thru the concept of robustness. The last part of the course will talk about
design for sustainability. Today sustainability is a big buzz word often
times our designs are mostly reactive designs meaning we design, we manufacture, we use
the product and then worry about how to dispose the different components of the product. This is called reactive design. If you want to account for sustainability
at the design stage itself then it is called a proactive or an active design. So we are talking about an active design here
which is DFS, design for sustainability. So usually sustainability is quantified by
the environmental impact and it has different aspects of course the environmental, the social
aspects, so how to account for all these things in terms of quantifying and bringing them
into the design stage will be covered in the design for sustainability part. Usually this design for quality and sustainability
is widely used in the industry per say any industry, but more specifically in automotive
and aerospace industry today, of course biomedical electronics also it is widely used. So anyone who is interested in being placed
in such companies or someone who is already working in those companies where people see
lot of variability in the manufactured components or there is variability in the performance. And they want to understand how to reduce
the variability by identifying the right factors and conducting those designed experiments
to identify these factors should take these courses. There are also other names to this design
for quality because basically the idea here is to account for the variability, so sometimes
it is called design for variance or design for variability, and off late people started
using the word design for uncertainties. And latest machine learning techniques and
associated artificial intelligence techniques are also widely used to understand these uncertainty
characteristics. I hope this conceptually interest you and
you will register for this course and benefit out of this course. I hope to see you guys in my course and over
to my co-instructor, Prof. Saravana Kumar who will talk about design for manufacturing
and assembly. Greetings to one and all. My colleague Prof. Palaniappan Ramu has nicely
introduced the course on DFX.As I rightly point that the various attributes associated
with the manufacturing and quality control aspects of product has to be accounted for
in the design stage. To emphasize the point, about 20% of the cost
is associated with the design stage, but it decides the 80% of the cost that goes into
manufacturing, assembly or quality control, marketing and finally the disposal of the
product. So to look into all these aspects how the
design can efficiently manage both the operation as well as the end of the part. So specifically coming to design for manufacturing
and assembly, manufacturability is associated with the cost of manufacturing as well as
ability to attain specific attributes or part features in the part. Certain surface finishes or certain feature
dimensions may not be possible for us to manufacture using certain processes. So to account for the process planning and
to ensure that the design is manufacturable within the facility and the infrastructure
that is available for achieving the same one has to relook at the need for certain features
in the design and also predict the cost of manufacturing. Manufacturing and assembly cannot be looked
at as 2 different activities because the cost associated with the overall manufacturing
is the cost of manufacturing components and then the cost of assembly. If the degree of difficulty of manufacturing
is reduced it will increase the degree of difficulty as well as cost of assembly. That is if we make the component simpler so
that the manufacturability is improved, the assembly difficulty will increase and vice
versa. So these 2 attributes can be looked at as
two separate entities. So in this course we will look at methods,
which can quantify the cost associated with manufacturing and the cost associated with
assembly. We will look at tools that can specifically
analyze manufacturability of processes like sheet metal or plastic injection molding process. And assembly, we will look at manual as well
as robotic or the automated assembly lines. Along with this DFM and A, the quality and
the robustness and reliability and sustainability of the product is important and I hope this
course will take care of the additional qualities that you can develop as a design engineer
and be a value edition to your other courses. Thank you.

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3 thoughts on “Design for Quality, Manufacturing and Assembly – Introduction

  1. I want to see all the lecture of design for quality, manufacturing and assembly course
    so please advise

  2. This is an intro video. If you are interested, please enroll for the course at https://onlinecourses.nptel.ac.in/noc18_me53/preview . The course is free. If you want to take an exam , you need to register with a small fee. Details are available at the above link

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