Case study: Application of Design for Automated Assembly methods in the development of an electronic product from early design to design freeze

Abstract

The paper discusses experiences from a concurrent product- and automated assembly process-development in a manufacturing company from early design to design freeze. The product is a compact product consisting of a plastic casing housing electronic components which is currently entering production. The company is a high-tech manufacturer operating in a high-cost country delivering safety products in a business to business market. The case study is based on project documentation, analyses of product and assembly concept, lab tests as well as dialogue with the manufacturer and the product designer. The main author was involved in the automated assembly process development and Design for Automatic Assembly (DFAA). The product and the automated assembly line were designed in parallel, throughout the entire product development process; from idea and concept development until the pre-production stages. In the early stages of the project the product was redesigned on a frequent basis, and each new design was evaluated for its automated manufacturability. In this process several DFAA methods were applied. The product designers also produced several prototypes by a plastic additive technology (3D printers) that were assembled in a prototype automated cell to assess product design and assembly solutions, and to reveal weaknesses that were not detected in the analysis. This paper compares the different DFAA methods used such as DFA2, as well as a custom DFAA review spreadsheet. Additionally, the paper discusses the interaction between product design and production process design, and effects on the outcome. Finally, the paper suggests design process improvements and guidelines.