Design for manufacturability PDF
Preview Design for manufacturability
TOOL AND MANUFACTURING ENGINEERS HANDBOOK VOLUME VI DESIGN FOR MANUFACTURABILITY SOCIETY OF MANUFACTURING ENGINEERS OFFICERS AND DIRECTORS, 1992 President Ronald P. Harrelson, CMfgE Douglas E. Booth, CMfgE, PE Caterpillar Institute Bond Robotics, Inc. Rita M. Hiiyer, CMfgT President-Elect Veeder-Root Co . Frank H. McCarthy, CMfgE, PE Jim C. Hoover Raytheon Company (retired) Northrop Corporation Second Vice President Elvin W. Keith, Jr., CMfgE, PE Charles A. Templeton, CMfgE, PE E. W. Keith & Associates Charles A. Templeton Machine Ken K. Koch, CMfgE, PE Third Vice President Parker Hannifin Corp. Gustav J. Oiling, PhD, CMfgE, PE Chrysler Corporation Homer P. Lane, CMfgE, PE Engineering Consultant Secretary/Treasurer Clinton 0. Larson, CMfgE, PE James F. Lardner Honeywell, Inc . Deere & Co. (retired) James K. Long AMP Inc. James F. Barcus, Jr. Black & Decker Corp. (retired) Alan T. Male, PhD, PE Consultant Russ G. Biekert, PhD, CMfgE Allied-Signal Aerospace Co. Paul A. Misegades, CMfgE General Electric Company Joseph E. Brown (Retired) Louis M. Papp, CMfgE, PE Windsor-Essex County Dev. Comm. Gary L. Cline, CMfgE Brunswick Corp. John T. Parsons Jack L. Ferrell JuTohrr T. PmmsC ompany TRW Inc. (retired) Michael Reggia, CMfgE, PE Thiokol Leon W. Fortin, PE L. W. Fortin Consultants Gerald Reynolds Perkin-Elmer Corporation Donald G. Foster, CMfgE, PE Consultant Vern L. Stumpenhorst Ford New Holland Inc. Keith M. Gardiner, PhD, PE Lehigh University Ronald H. Vander Weerd, CMfgE Pella-Rolscreen Company James M. Hardy Hardy Associates TOOL AND MANUFACTURING ENGINEERS HANDBOOK FOURTH EDITION VOLUME VI D ES IG N FO R MANU FACTU RAB IL ITY A reference book for manufacturing engineers, managers, and technicians Ramon Bakerjian, CMfgE Handbook Editor Philip Mitchell Staff Editor Produced under the supervision of the SM E Reference Publications Committee in cooperation with the SME Technical Divisions Society of Manufacturing Engineers One SME Drive Dearborn, Michigan ISBN NO. 0-87263-402-7 Library of Congress Catalog No. 91-060347 Society of Manufacturing Engineers (SME) Copyright 01992, 1976, 1959, 1949 by Society of Manufacturing Engineers, One SME Drive, P.O. Box 930, Dearborn, Michigan 48121 All rights reserved, including those of translation. This book, or parts thereof, may not be reproduced in any form without written permission of the copyright owner. The Society does not, by publication of data in this book, ensure to anyone the use of such data against liability of any kind, including infringement of any patent. Publication of any data in this book does not constitute a recommendation of any patent or proprietary right that may be involved. The Society of Manufacturing Engineers, as well as all contributors and reviewers of information in this volume, disclaim any and all responsibility for use of the information contained herein by readers and users of this Handbook. First edition published 1949 by McGraw-Hill Book Co. in cooperation with SME under earlier Society name, American Society of Tool Engineers (ASTE), and under title Tool Engineers Handbook. Second edition published 1959 by McGraw-Hill Book Co. in coop- eration with SME under earlier society name, American Society of Tool and Manufactur- ing Engineers (ASTME), and under title Tool Engineers Handbook. Third edition pub- lished 1976 by McGraw-Hill Book Co. in cooperation with SME under current Society name and under title Tool and Manufacturing Engineers Handbook. Printed in the United States of America. PREFACE The first edition, published as the Tool Engineers Handbook in 1949, established a useful and authoritative editorial format that was successfully expanded and improved in the publication of highly acclaimed subsequent editions published in 1959 and 1976. Now, with continuing dramatic advances in manufacturing technology, increasing competitive pressure both in the United States and abroad, and a significant diversi- fication of the information needs of the modern manufacturing engineer, comes the need for further expansion of the Handbook. As succinctly stated by Editor Frank W. Wilson in the preface to the second edition: “...no ‘bible’ of the industry can indefinitely survive the impact of new and changed technology. ” Although greatly expanded and updated to reflect the latest in manufacturing technology, the nature of coverage in this edition is deeply rooted in the heritage of previous editions , constituting a unique compilation of practical data detailing the specification and use of modern manufacturing equipment and processes. Other volumes in this Handbook series include: Volume I, Machining, published in March 1983; Volume 11, Forming, in April 1984; Volume 111, Materials, Finishing and Coating, in July 1985; Volume IV, Quality Control and Assembly, in January 1987; and Volume V, Manufacturing Management, in April 1989. The scope of this edition is multifaceted, offering a ready reference source of authoritative manufacturing information for daily use by engineers, managers , and technicians, yet providing significant coverage of the fundamentals of manufacturing processes, equipment, and tooling for study by the novice engineer or student. Uniquely, this blend of coverage has characterized the proven usefulness and reputation of SME Handbooks in previous editions and continues in this edition to provide the basis for acceptance across all segments of manufacturing. In this, and other TMEH volumes, in-depth, coverage of all subjects is presented in an easy-to-read format. A comprehensive index cross-references all subjects , facilitating quick access to infor- mation. The liberal use of drawings, graphs, and tables also speeds information gathering and problem solving. This volume of the Tool and Manufacturing Engineers Handbook (TMEH) series has two audiences; the manufacturing engineer or manager and the product designer. Both should find all of the chapters beneficial. The first half of the book-chapters 1 through 8 -addresses background information and topics of Design for Manufacturability (DFM): an introduction to DFM, how it relates to Concurrent Engineering (CE) , management issues, getting started in DFM, how to justify using DFM, applying quality tools to DFM, and how DFM is affecting computer technology (and vice versa). Chapters 9 and 10 cover topics starting with the creative thinking process to combining DFM with geometrical dimensioning and tolerancing (GDT) . Figure 9-2 (while rather lighthearted for Handbook-style material) sums up the situation found in manufacturing that DFM will overcome, knocking down the walls between depart- ments. Chapters 11 through 16 cover product design information that TMEH contributors felt was important for the designer to know when committing pen to paper or mouse to pad. This is meant to be non-process related material. There are no detailed descriptions of processes, drawings of typical machines, or tables of feeds and speeds, that material can be found in the first four volumes of this edition. The designer should V know when the job begins what are allowable tolerances, surface finishes, geometries, and so on, for a particular process or material that is being used. Finally, two appendices are included to help the reader get further along in DFM. Appendix A shows how large and small companies are applying DFM to their products and organizations. Some of these case studies are familiar and others border on being proprietary. Appendix B lists various DFM products and services. Neither appendix is an exhaustive listing of successes or services. The reference material contained in this volume is the product of incalculable hours of unselfish contribution by hundreds of individuals and organizations, as listed at the beginning of each chapter. No written words of appreciation can sufficiently express the special thanks due these many forward-thinking professionals. Their work is deeply appreciated by the Society; but more important, their contributions will undoubtedly serve to advance the understanding of manufacturing management throughout industry and will certainly help to spur major productivity gains in the years ahead. Industry as a whole will be the beneficiary of their dedication. Further recognition is due the members of the SME Reference Publication Commit- tee for their expert guidance and support as well as the many members of the SME Technical Activities Board. The Editors SME staff who participated in the editorial development and production of this volume include : EDITORIAL TYPESETTING GRAPHICS Thomas J. Drozda Shari L. Smith Judy Munro Director of Publications Supervisor Art Director Robert E. King Kathy Allison Typesetter Publications Manager Marcia Theisen Ramon Bakerjian Typesetter Handbook Editor Philip Mitchell Staff Editor Suzanne Kosacheff Technical Copy Editor Frances Kania Gregory J. Ross Editorial Secretary Ross Services Dorothy Wylo Donna Hicks Editorial Secretary Adcomp Services vi SME The Society of Manufacturing Engineers is a professional society dedicated to advancing manufacturing through the continuing education of manufacturing manag- ers, engineers, technicians, and other manufacturing professionals. The specific goal of the Society is to advance scientific knowledge in the field of manufacturing and to apply its resources to research, writing, publishing, and disseminating information. “The purpose of SME is to serve the professional needs of the many types of practitioners that make up the manufacturing community.. .The collective goal of the membership is the sharing and advancement of knowledge in the field of manufacturing for the good of humanity. ’ ’ The Society was founded in 1932 as the American Society of Tool Engineers (ASTE). From 1960 to 1969 it was known as the American Society of Tool and Manufacturing Engineers (ASTME), and in January 1970 it became the Society of Manufacturing Engineers. The changes in name reflect the evolution of the manufac- turing engineering profession and the growth and increasing sophistication of a technical society that has gained an international reputation for being the most knowledgeable and progressive voice in the field. Associations of SME- The Society provides complete technical services and membership benefits through a number of associations. Each serves a special interest area. Members may join these associations in addition to SME. The associations are: Association for Finishing Processes of SME (AFP/SME) Computer and Automated Systems Association of SME (CASA/SME) Machine Vision Association of SME (MVA/SME) ~ North American Manufacturing Research Institute of SME (NAMRUSME) Robotics International of SME (RVSME) Composites Manufacturing Association of SME (CMA/SME) Association for Electronics Manufacturing of SME (EM/SME) Machining Technology Association of SME (MTA/SME) Networking and Communications in Manufacturing Group of SME Members and Chapters-The Society and its associations have 80,000 member in 73 countries, most of whom are affiliated with SME’s 300-plus senior chapters. The Society also has some 8000 student members and more than 150 student chapters at colleges and universities. Publications -T he Society is involved in various publication activities encompass- ing handbooks, textbooks, videotapes, and magazines. Current periodicals include: Manufacturing Engineering Manufacturing Insights (a video magazine) SME Technical Digest SME News Journal of Manufacturing Systems vii Certification -T his SME program formally recognizes manufacturing managers, engineers , and technologists based on experience and knowledge. The key certification requirement is successful completion of a two-part written examination covering (1) engineering fundamentals and (2) an area of manufacturing specialization. Educational Programs -T he Society sponsors a wide range of educational activi- ties, including conferences, clinics, in-plant courses, expositions, publications and other educationah-aining media, professional certification, and the SME Manufactur- ing Engineering Education Foundation. viii CONTENTS VOLUME VI-DESIGN FOR MANUFACTURABILITY Symbols and Abbreviations ....................................................... xi Design for Manufacturability ..................................................... 1. 1 Concurrent Engineering ......................................................... 2-1 Management Involvement in DFM ................................................ 3-1 Team Building and Training ..................................................... 4-1 Justification of DFM ........................................................... 5-1 Quality Tools in DFM .......................................................... 6-1 Computer-aided Technologies .................................................... 7-1 Design for Assembly .......................................................... 8-1 : Preliminary Design Issues ....................................................... 9-1 General Product Design ........................................................ 10-1 Machining ................................................................... 11-1 Forming ..................................................................... 12-1 Finishing and Coating ......................................................... 13-1 Fastening and Joining .......................................................... 14-1 Materials .................................................................... 15-1 Design for Electronics Assembly ................................................. 16-1 Appendix A-DF'M Case Studies ................................................ A-1 Appendix B-DFM Products and Services ......................................... B-1 Index ....................................................................... 1-1 ix SYMBOLS AND ABBREVIATIONS The following is alist of symbols and abbreviations in general use throughout this volume. Supplementary ancUorderived units, symbols, and abbreviations that are peculiar to specific subject matter are listed within chapters. CIM-11 Computer-integrative management (of the A-B manufacturing enterprise) CL fdes Cutter location files ABC Activity-based costing CMI Continuous measurable improvement AI Artificial intelligence CMM Coordinate measuring machine AIS Automated infrastructure support CMPP Computer managed process planning AMA American Management Association CNC Computer numerical control ANOVA Analysis of variation COB Chip on board ANSI American National Standards Institute COQ Cost of quality APICS American Production and Inventory Control CQI Continuous quality improvement Society CRP Cost reduction potential AQS Advanced quality system CSG Constructive solids geometry ASIC Application-specific integrated circuits CSM Continuous strand mat ASM American Society for Metals CTS Carpal tunnel syndrome ASME American Society of Mechanical Engineers DFA Design for assembly ASQ Assured quality level DFD Design for disassembly ASQC American Society for Quality Control DFM Design for manufacturability (manufacture, ASTD American Society for Training and manufacturing) Development DFM/A Design for manufacttrrability/assembleability ASTM American Society for Testing and Materials DFQ Design for quality ATE Automatic test equipment DFP Direct fiber placement ATG Automated-test generation DFR Design for reliability ATPG Automated-test pattern generation DFT Design for test AVA Added-value analysis DFS Design for serviceability BIST Built-in self test DFX Design for X (anything) BOM Bill of materials DIP Dual in-line package BON Bed-of-nails fixture DNC Direct numerical control BP Best practices DOD Department of Defense BPM Ballistic particle manufacturing DOE Design of experiments B-rep Boundary-representation DOM Drawn over mandrel BTAP Board-1evel test access port DPI Design producibility index Bump Inner-1ead bondhtg DRF Datum reference frame ECM Electrochemical machining C-D-E ECO Engineering change order EDI Electronic data interchange CA Cyanoacrylates EDM Electrical discharge machining CAD/CAM Computer-aided design/computer-aided EM Electrochemical metallizing manufacturing en Enable CAE Computer-aided engineering EPS Expanded polystyrene foam CAM Computer-aided manufacturing Eq. Equation CAPP Computer-aided process planning ES Expert systems CAT Computer-aided test CBT Computer-based training F-G-H-l-J-K CCB Change Control Board CE Concurrent engineering FAST Function analysis system technique CFC Chlorofluorocarbon FDM Fused deposition modeling CIB Computer-integrated business FEA Failure effect analysis (also, Finite element CIE Computer-integrated enterprise analysis) CIM Computer-integrated manufacturing FF Flip-flop CIME Computer-integrated manufacturing enterprise FGI Finished goods inventory CIM-I Computer-interfaced manufacturing FIA Forging Industry Association
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