Optimization of Assembly Process and Design Efficiency Using DFMA: Case Study of Drill Grinder Machine

Abstract

Design for Manufacturing and Assembly (DFMA) is a combination of Design for Manufacturing (DFM) and Design for Assembly (DFA). The main objective of this case study is to analyse and redesign the drill grinder machine by using the DFMA method to reduce the parts of the machine, minimise the manufacturing cost of the product, reduce the time for assembly parts, and reduce the cost of assembly of the parts. A drill grinder machine is a machine that is used to sharpen dull and broken twist drill bits. The Boothroyd-Dewhurst method with a DFA worksheet will be used in this case study to analyse the drill grinder machine. The results showed that the efficiency design, after being improved, was better than the original design. The efficiency of the improved design was increased to 41%. Comparing the original design, which had 36% design efficiency, the design efficiency increased to 5%. Moreover, the manufacturing cost of the original design was 2344.58 USD. After the improvements were made, the manufacturing cost was reduced to 1510.99 USD. The number of parts in the drill grinder machine was reduced from 35 to 30 parts, and the assembly time for the parts was also reduced from 236.11 seconds to 220.66 seconds. Overall, the application of the DFMA method in designing the drill grinder machine made the product better with lower cost and assembly time.