final report of the project

1. Product Design for Manufacturing
Title of the Project: DFMA Study of an Emergency Lamps
Faculty In-charge: Prof. Darius Gnanaraj S
SUBMITTED BY,
A. Rammohan 15BME0094
K. Lohith 15BME0067
Sushil Manda 15BME0727
Under the guidance of:
PROF. Prof. Darius Gnanaraj S

2. CERTIFICATE
This is to certify that the project work entitled “DFMA Study of an
Emergency Lamps” that is being submitted by group members-
15BME0094, 15BME0067, 15BME0727 for product design for
manufacturing is a record of bonafide work done. The contents of this
Project work, in full or in parts, have neither been taken from any
other source nor have been submitted for any other CAL course.
Place: Vellore
Date: 12-11-2018

3. AKNOWLEDGEMENT
We take this momentous opportunity to express our heartfelt
gratitude, ineptness and regards to our sir Prof.
Darius Gnanaraj S, School of Mechanical Engineering, VIT
University for providing us an opportunity to present our project. The
topic we have chosen has provided us with a lot of knowledge. It was an
enriching learning experience. This project provided us with an
opportunity and experiences of working in a group. We believe
that these experiences are going to take us a long way in the future. We
are grateful to our professor for providing us with this
opportunity.
Thank You

4. ABSTRACT
This work presents a study of manufacture and assembly costs
reduction in an emergency lamp model manufactured in an industry.
The study presents a brief literature review about product
development and technological resources to support product design,
emphasizing a review about the DFMA (Design for Manufacturing
and Assembly) method. The paper presents a detailed description of
how delimited the most critical subsystem of the engine was,
considering the cost and the application of DFMA guidelines for the
delimited subsystem. The results show an increase in the design
efficiency of the selected assembly. Community needs that are not
primary but important in everyday life are lights for lighting. State
electricity company (PLN) is experiencing limitations in supplying
electricity for this puIDRose. Therefore, emergency lights
(emergency lights) are already marketed in the community, which
limited function only illuminate a very limited space. Therefore, we
developed the design of energy saving lamps using "Light Emitting
Diode" (LED) which can illuminate the whole house as well as
functioning as mobile phone charger (HP). The method used is
Design for Manufacture and Assembly (DFMA), with the result of
design development the percentage increase in assembly efficiency
(E) is 0.01071 - 0.00645 = 0.00426 or = 39.76%. The decrease in
material costs is INR 234,000 - INR 214,000 = INR 20,000 or =
8.54%. Development design is received because of more assembly
efficiency than the initial design. Power usage on previous products
with series and designs of the original product can last only 4-5 hours
non-stop, while the development of the design can survive 9-10 hours
2x more energy efficient.

5. INTRODUCTION
DFA is the method of design of the product for ease of assembly.
‘Optimization of the part/system assembly’ DFA is a tool used to assist the
design teams in the design of products that will transition to productions at a
minimum cost, focusing on the number of parts, handling and ease of
assembly. DFM is the method of design for ease of manufacturing of the
collection of parts that will form the product after assembly. ‘Optimization of
the manufacturing process’ DFA is a tool used to select the most cost-effective
material and process to be used in the production in the early stages of product
design. Design for Manufacturing (DFM) and Design for Assembly (DFA) are
now commonly referred to as a single methodology - Design for Manufacturing
and Assembly (DFMA).
Advantages of DFMA:
● Quantitative method to assess design
● Communication tool with other engineering disciplines and departments.
● Greater role for other groups while still in the “engineering” phase such as
Manufacturing.
● Since almost 75% of the product cost is determined in the “engineering”
phase, it gives a tool to attack those hidden waste areas before committing to a
design.
In this particular case of an emergency lamps:
Power supply lamps are supplied by the state electricity company (PLN).
Lately is often faced by our society is a rotating power outage. This is due to
the lack of electricity supply from PLN that is not in accordance with the needs
of consumer electricity. Problem inhibiting the activity of damage power
plants, especially in terms of lighting or lighting. Based on RI.NO.43th
Presidential Decree 1991 on the conversion of electrical energy then public
company Negara (PLN) as the provider and processing energy has made
energy saving movement. One of the research activities to realize the
conversion and energy savings, especially in terms of lighting design is the
development of energy-saving lamps by using "Light Emitting Diode" (LED).
Society still many who do not know and understand about the cost of energy
saving lamps (LHE). People tend to choose cheap lights and easily obtainable
in the market, but the reality is not energy efficient, i.e. light type of
incandescent.

6. METHODOLOGY
The Boothroyd-Dewhurst Method:
This method started in 1977 and has been used in industries
extensively since. The primary idea behind it is to reduce costs by
reducing the number of parts, assembly time and manufacturing time
by optimizing the design.
In this method the ideality of a design is calculated by asking the
following questions:
1. During operation of the product, does the part move relative to all
other parts already assembled?
2. Must the part be of a different material than the parts already
assembled? [Only fundamental reasons associated with material
properties are acceptable.]
3. Must the part be separate from all parts already assembled
(because otherwise necessary assembly/disassembly of other parts
would be impossible)?
After analysis, design efficiency is calculated using
DE = ((3 x NM)/TM), where NM is the TM 3×NM theoretical
minimum number of parts, TM is the manufacturing time.

7. PREVIOUS
RESEARCHES
A research has been conducted by Krist (2010) whose explain about
design and manufacture of light emitting diode packages for general
lighting. By exploiting the opportunities of energy-saving lamp
needs, the idea came up to develop product design on emergency
lamp (emergency) that already exist. Lights that will be developed
are emergency lights that are still less efficient in terms of cost and
assembly time and system usage is still by manual (on / off manual).
The resultant lamp has a design with greater cost efficiency and
assembly time than previous lights. Hopefully the resultant light
development researchers are beneficial to the wider community.

8. DFMA STUDY
Here the main objective is to reduce the total number of components and
thus reducing the total assembly time of the product. This is done by
reducing the size and lights used in the emergency lamps.
1) The lamps which were big in size, had more components and used
incandescent lights.
The number of initial design components.
Constituent components Amount
Box (unit) 1
Cover(unit) 1
Screw (unit) 14
Pcb(unit) 1
Component circuit(unit) 1
Transformer ct (unit) 1
Cable (meter) 2
Lamp output(unit) 1
Clinch(unit) 1
Accu 12 v(unit) 1
LED Indicator (unit) 2
Saklar(unit) 1
Total 27

9. Assembly time of one product.
No Assembly of each part Time (min) Time (sec)
1 Install components box 10 600
2 Installation of pitingan 10 600
3 Assemble components to the
pcb board
20 1200
4 Installing pcb to box 5 300
5 Installation of transformer to
box
5 300
6 Install the battery / battery to
the box
6 360
7 Installation of the switch 7 420
8 Connecting cables to all
components on the box
15 900
9 Installation of indicator light
to box
5 300
10 Installation of neon output to
the box
5 300
11 Pair bolts and nuts in each
component
3 180
12 Installation of lamp cover 2 120
Total 93 5580
Production assembly efficiency analysis:
From the assembly efficiency calculation, the starting product has an
assembly efficiency of 0.00645. This means that the initial product
manufacturing process with a total of 12 parts and totals assembly time of
5580 seconds, resulting in assembly efficiency of 0.00645
Cost analysis of product:
Material costs in the original design Have total cost has total component
price INR. 234.000.

10. 1) Now for the improved version of emergency lights(Assessment of
Product Development assembly):
Assembly time of one product.
No Assembly of each part Time (min) Time (sec)
1 Lamp Box Assembly 5 300
2 Installation of transformer CT 4 240
3 Installation of MP2PI relay 7 420
4 Installation of condenser 5 300
5 Installation of led indicator 3 180
6 Installing ic7805 to USB socket 5 300
7 Installation of diodes into USB
sockets
3 180
8 Installation of USB sockets to the
box
10 600
9 Installation of resistors to USB
sockets
3 180
10 Installing all components in the box 15 900
11 Installation of the fuse 3 180
12 Installing 12v / 5a battery 5 300
13 Install Plavon led panel output 2 120
Total 70 4200

11. Number of Components of Product Development.
Constituent components Total
Analog switch(unit) 1
Led indicator (unit) 2
Cable (meter) 1
Relay mp 2pi (unit) 1
Switch (unit) 1
Condenser 470uf / 50v(unit) 2
Ic 7805 (unit) 1
Resistor 1k (unit) 2
Sockets usb (unit) 1
Accu 12v/5a (unit) 1
Travo ct (unit) 1
LED Ceiling panel(unit) 1
Diodes (unit) 1
Paint (tin) 1
Box power supply (unit) 1
Box power supply (unit) 1
Total 19

12. RESULTS
Development efficiency of assembly:
From the assembly efficiency calculation, the Development product has
an assembly efficiency of 0.01071, meaning that the development
process of the Development product with the number of components 15
and the total assembly time is 4200 seconds, resulting in assembly
efficiency of 0.01071.
Analyse the cost of development design:
The material costs of the overall innovation design are required for
innovative products that have a price of INR.214.000
Based on the calculation Percentage increase in assembly efficiency (E)
is 0.01071 - 0.00645 = 0.00426 or = 39.76%. The percentage decrease
in material costs is INR 234,000 - INR 214,000 = INR 20,000. Or =
8.54% And the innovation design is received due to greater assembly
efficiency than the old design.

13. Conclusion
Design Development can work automatically when the current source
is disconnected (die) and Design Development can also be used for all
rooms without having to move the products other than as a source of
lighting at the time of the blackout design Development also has the
function of mobile phone charge with universal output (USB).
Product design the development that has greater assembly efficiency
and the cost incurred is also low in comparison with the initial design
i.e. Percentage Improved assembly efficiency (E) is 0.01071 - 0.00645
= 0.00426 or = 39.76%. The decrease in material costs is INR 234,000
- INR 214,000 = INR 20,000 or = 8.54%. Development design is
received because of more assembly efficiency than the initial design.
Power usage on the previous product with series and design of the
original product only last 4-5 hours non-stop while the product owned
by Product Development with series and design of product
development can survive 9-10 hours 2x more energy efficient.

14. REFERENCES
1) [1] G. Boothroyd and P. Dewhurst, Boothroyd Dewhurst, Inc.
Marcell Dekker, Inc. “Product Design for Manufacture and
Assembly”, 1989
2) http://iopscience.iop.org/article/10.1088/1742-6596/953/1/012235
3) http://iopscience.iop.org/article/10.1088/1742-6596/953/1/012235
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7) David Stienstra, Rose-Hulman, “Introduction to Design for (Cost
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