Abstract
Reducing the time and cost involved in the product development is very important to stay competitive in the market. Design for Manufacturing and Assembly (DFMA) is a cost-reduction framework for designers to evaluate manufacturing aspects of a product design. A case study on an in-market food processor, this paper aims to demonstrate the significance of DFMA implementation on an Indian consumer product. Even though many DFMA case studies have been published till date, very few have dealt with the Indian consumer durables category. In this paper, various cost-reduction opportunities are identified in the design of a food processor manufactured by a reputed company in India. Using the DFMA study, design ideas are developed with an objective of reducing the overall manufacturing cost of the product. As a result of DFMA implementation, significant improvement in terms of the product’s architecture, assembly time and design efficiency is identified. Overall cost reduction of 0.25 USD (United States Dollar) was achieved and an improvement in the Design for Assembly (DFA) index from 15.99 to 19.93 is reported. This procedure utilized in this paper can be adopted for any consumer durable products of similar type and design improvements and cost reduction can be achieved.
Highlights
For a successful completion of any product in terms of schedule and cost is mainly dependent on how the lead time required to develop and produce the product can be minimized (Selvaraj, Radhakrishnan, & Adithan, 2009)
This paper provides the details about how Design for Manufacture and Assembly (DFMA) can be used for re-engineering the food processor used in the Indian market
Redesign of the food processor Being the first step of the DFMA analysis, existing assembly design was analysed with Design for Assembly (DFA) analysis
Summary
Anil, Kurain, and Arsha (2013) applied DFMA methodology on a connecting rod and reported that significant reductions in the part cost were possible All these case studies validate the importance and need for DFMA analysis in any product design process. The report further acknowledges the need for alternative ways of increasing profits on such products In such a scenario, DFMA studies on consumer durables product category will greatly help industries to reduce the manufacturing costs of their products and to improve their profit margin. 3. Redesign of the food processor Being the first step of the DFMA analysis, existing assembly design was analysed with DFA analysis.
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