Research Article
Year 2023,
Volume: 26 Issue: 1, 377 - 385, 27.03.2023
Abstract
The purpose of this research is to show the benefits to be obtained by redesigning production processes for small and medium-sized enterprises, which aim to grow but cannot develop due to runaway production. In this study, an exemplary approach is presented using the principles of Design for Assembly (DFA) in an enterprise aiming to grow in the elevator industry. Within the scope of the research, the doorframe assembly process of the semi-automatic elevator door, which is the most produced in the elevator industry, was examined. According to this; Design improvement studies were carried out in the assembly processes of the side profiles, head plate, forehead plate, floor plate and their subparts used in the production of the case. In the design improvement, the B&D design efficiency measurement principles were used. As a result of the improvements; The semi-automatic door frame, which is 98 pieces in its current design, has been reduced to 55 pieces with the new design. With the reduction in the number of parts and design changes, the total assembly time was reduced by 33.8% in assembly time. As a result of the improvements, the Design Efficiency has been increased from 8.5% to 12.8%.
References
- [1] Molloy O., Warman E.A. and Tilley S., “Design for manufacturing and assembly: concepts, architectures and implementation”, Springer, US, (2012).
- [2] Uslu Divanoglu S., Tas U. ve Pak E., “Application of Methodology of Kaizen in Assembley Line in a Production Facility in Automotive Sector”, Politeknik Dergisi, 24(4):1533-1541,(2021).
- [3] Boothroyd G., Dewhurst P. and Knight W.A., “Product design for manufacture and assembly”, 2nd ed. Marcel Dekker, New York, US, (2002).
- [4] Desai, A., Mital, A., “Facilitating design for assembly through the adoption of a comprehensive design methodology”, International Journal of Industrial Engineering, 17(2): 92 – 102, (2010).
- [5] Imrak C.E., Salman O., “Design of elevator cabin doors suitable for assembly”, 2nd National Design, Manufacturing and Analysis Congress, Balıkesir, Turkey, 272 – 280 (2010). (In Turkish).
- [6] Imrak C.E., Kocaman M., “Design optimisation of elevator car for double deck system”, 9th Int. Congress Machines, Technologies, Materials MTM2012, The Scientific-Technical Union of Mechanical Engineering, Bulgaria, 99 – 102, (2012).
- [7] Cabello Ulloa M.J., Remirez Jauregui A., Zulaika Munain I., Areitioaurtena Oiartzun M., Retolaza Ojanguren I., Campos Insunza M,A. and Martínez Noguera F., “New integrative approach to existing design for assembly (DfA) metodologies: application on elevator components”, DS 92: Proceeding of the Design 2018 15th Design Conference, The Design Society a Worldwide Community, Dubrovnik, Croatia, 215-224, (2018).
- [8] Favi C., Germani M. and Mandolini M., “Design for manufacturing and assembly vs. design to cost: toward a multi-objective approach for decision-making strategies during conceptual design of complex products”, Procedia CIRP, 50: 275 – 280, (2016).
- [9] Suresh P., Ramabalan S. and Natarajan U., “Integration of DFE and DFMA for the sustainable development of an automotive component”, International Journal of Sustainable Engineering, 9(2): 107-118, (2016).
- [10] Gao S., Low S.P. and Nair K., “Design for manufacturing and assembly (DfMA): a preliminary study of factors influencing its adoption in Singapore”, Architectural Engineering and Design Management, 14(6): 440-456, (2018).
- [11] Remirez A., Ramos A., Retolaza I., Cabello M., Campos M. and Martinez F., “New design for assembly methodology adapted to large size products: application on a solar tracker design”, Procedia CIRP, 84: 468–473, (2019).
- [12] Ezpeleta I., Justel D., Bereau U. and Zubelzu J., “DFA-SPDP, a new DFA method to ımprove the assembly during all the product development phases”, Procedia CIRP, 84: 673–679, (2019).
- [13] Gao S., Jin R. and Lu W., “Design for manufacture and assembly in construction: a review”, Building Research & Information, 538 – 550, (2019).
- [14] Naga Malleswari V., SurendraBabu B. and Praneeth C., “Redesigning of electric plug for assembly time reduction using DfA”, Advances in Applied Mechanical Engineering, Lecture Notes in Mechanical Engineering, Springer, Singapore, 1179 – 1187, (2020).
- [15] Çetin H., Arcaklıoğlu E. ve Çetin R., “Soğuk haddehane montaj sürecinin verimliliğinin artırılması”, Politeknik Dergisi, 23(4): 1245-1253, (2020).
- [16] Aydınlı M., “Design for assembly practise in machine production”, MSc Thesis, Pamukkale University, Institute of Science, Denizli, Turkey, (2020). (In Turkish).
- [17] Adam A., Shukor A.I.A., “Evaluation of design efficiency using boothroyd dewhurst method for pcb drilling machine products”, International Journal of Simulation: Systems. Science & Technology, 19(5): 35 – 41, (2018).
- [18] Koç Ö., Top N., Eldem C., Gökçe H. ve Şahin İ. “Ergonomics assessment and redesign of helicopter transmission assembly fixture using digital human models”, Politeknik Dergisi, 24(3): 1197-1203, (2021).
Year 2023,
Volume: 26 Issue: 1, 377 - 385, 27.03.2023
Abstract
The purpose of this research is to show the benefits to be obtained by redesigning production processes for small and medium-sized enterprises, which aim to grow but cannot develop due to runaway production. In this study, an exemplary approach is presented using the principles of Design for Assembly (DFA) in an enterprise aiming to grow in the elevator industry. Within the scope of the research, the doorframe assembly process of the semi-automatic elevator door, which is the most produced in the elevator industry, was examined. According to this; Design improvement studies were carried out in the assembly processes of the side profiles, head plate, forehead plate, floor plate and their subparts used in the production of the case. In the design improvement, the B&D design efficiency measurement principles were used. As a result of the improvements; The semi-automatic door frame, which is 98 pieces in its current design, has been reduced to 55 pieces with the new design. With the reduction in the number of parts and design changes, the total assembly time was reduced by 33.8% in assembly time. As a result of the improvements, the Design Efficiency has been increased from 8.5% to 12.8%.
References
- [1] Molloy O., Warman E.A. and Tilley S., “Design for manufacturing and assembly: concepts, architectures and implementation”, Springer, US, (2012).
- [2] Uslu Divanoglu S., Tas U. ve Pak E., “Application of Methodology of Kaizen in Assembley Line in a Production Facility in Automotive Sector”, Politeknik Dergisi, 24(4):1533-1541,(2021).
- [3] Boothroyd G., Dewhurst P. and Knight W.A., “Product design for manufacture and assembly”, 2nd ed. Marcel Dekker, New York, US, (2002).
- [4] Desai, A., Mital, A., “Facilitating design for assembly through the adoption of a comprehensive design methodology”, International Journal of Industrial Engineering, 17(2): 92 – 102, (2010).
- [5] Imrak C.E., Salman O., “Design of elevator cabin doors suitable for assembly”, 2nd National Design, Manufacturing and Analysis Congress, Balıkesir, Turkey, 272 – 280 (2010). (In Turkish).
- [6] Imrak C.E., Kocaman M., “Design optimisation of elevator car for double deck system”, 9th Int. Congress Machines, Technologies, Materials MTM2012, The Scientific-Technical Union of Mechanical Engineering, Bulgaria, 99 – 102, (2012).
- [7] Cabello Ulloa M.J., Remirez Jauregui A., Zulaika Munain I., Areitioaurtena Oiartzun M., Retolaza Ojanguren I., Campos Insunza M,A. and Martínez Noguera F., “New integrative approach to existing design for assembly (DfA) metodologies: application on elevator components”, DS 92: Proceeding of the Design 2018 15th Design Conference, The Design Society a Worldwide Community, Dubrovnik, Croatia, 215-224, (2018).
- [8] Favi C., Germani M. and Mandolini M., “Design for manufacturing and assembly vs. design to cost: toward a multi-objective approach for decision-making strategies during conceptual design of complex products”, Procedia CIRP, 50: 275 – 280, (2016).
- [9] Suresh P., Ramabalan S. and Natarajan U., “Integration of DFE and DFMA for the sustainable development of an automotive component”, International Journal of Sustainable Engineering, 9(2): 107-118, (2016).
- [10] Gao S., Low S.P. and Nair K., “Design for manufacturing and assembly (DfMA): a preliminary study of factors influencing its adoption in Singapore”, Architectural Engineering and Design Management, 14(6): 440-456, (2018).
- [11] Remirez A., Ramos A., Retolaza I., Cabello M., Campos M. and Martinez F., “New design for assembly methodology adapted to large size products: application on a solar tracker design”, Procedia CIRP, 84: 468–473, (2019).
- [12] Ezpeleta I., Justel D., Bereau U. and Zubelzu J., “DFA-SPDP, a new DFA method to ımprove the assembly during all the product development phases”, Procedia CIRP, 84: 673–679, (2019).
- [13] Gao S., Jin R. and Lu W., “Design for manufacture and assembly in construction: a review”, Building Research & Information, 538 – 550, (2019).
- [14] Naga Malleswari V., SurendraBabu B. and Praneeth C., “Redesigning of electric plug for assembly time reduction using DfA”, Advances in Applied Mechanical Engineering, Lecture Notes in Mechanical Engineering, Springer, Singapore, 1179 – 1187, (2020).
- [15] Çetin H., Arcaklıoğlu E. ve Çetin R., “Soğuk haddehane montaj sürecinin verimliliğinin artırılması”, Politeknik Dergisi, 23(4): 1245-1253, (2020).
- [16] Aydınlı M., “Design for assembly practise in machine production”, MSc Thesis, Pamukkale University, Institute of Science, Denizli, Turkey, (2020). (In Turkish).
- [17] Adam A., Shukor A.I.A., “Evaluation of design efficiency using boothroyd dewhurst method for pcb drilling machine products”, International Journal of Simulation: Systems. Science & Technology, 19(5): 35 – 41, (2018).
- [18] Koç Ö., Top N., Eldem C., Gökçe H. ve Şahin İ. “Ergonomics assessment and redesign of helicopter transmission assembly fixture using digital human models”, Politeknik Dergisi, 24(3): 1197-1203, (2021).
There are 18 citations in total.
Details
| Primary Language | English |
|---|---|
| Subjects | Engineering |
| Journal Section | Research Article |
| Authors | |
| Publication Date | March 27, 2023 |
| Submission Date | November 1, 2021 |
| Published in Issue | Year 2023 Volume: 26 Issue: 1 |
Cite
Cited By
Design Optimization of PM Synchronous Motor: Rail Mounted Belt Drive Elevator Systems
IEEE Transactions on Industry Applications
https://doi.org/10.1109/TIA.2023.3311781
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