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Kec150051 Dfma Plug

The document analyzes the manual assembly process of electrical parts and proposes design changes to reduce costs. It details the original and new designs, listing parts, manual tasks, times, and costs. Charts compare the original and new designs, showing the new design reduces total manual time and cost by over 25%.

Uploaded by

Tay le Yong
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53 views6 pages

Kec150051 Dfma Plug

The document analyzes the manual assembly process of electrical parts and proposes design changes to reduce costs. It details the original and new designs, listing parts, manual tasks, times, and costs. Charts compare the original and new designs, showing the new design reduces total manual time and cost by over 25%.

Uploaded by

Tay le Yong
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as XLSX, PDF, TXT or read online on Scribd
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DFA Worksheet

Old Design
0 1 2 3 4 5

# of times the
operation is two-digit manual two-digit
carried out manual handling time manual
Part Part ID # consecutively handling code per part insertion code
Main Screw 1 1 10 1.5 92
Front Casing 2 1 30 1.95 06
Wire Set Screw *3 3 3 11 1.8 92
Earth Pin 4 1 20 1.8 01
Live Pin 5 1 30 1.95 03
Neutral Pin 6 1 20 1.8 01
Cable Grip Lef 7 1 31 2.25 01
Cable Grip Right 8 1 31 2.25 01
Internal Screw Thread 9 1 16 2.57 13
Back Casing 10 1 30 1.95 00
Fuse 11 1 10 1.5 30
Re-Orienting the casing n/a 1 0 98

New Design
0 1 2 3 4 5

# of times the
operation is two-digit manual two-digit
carried out manual handling time manual
Part Part ID # consecutively handling code per part insertion code
Front Casing 1 1 30 1.95 30
Wire Set Screw *3 2 3 11 1.8 92
Earth Pin 3 1 20 1.8 01
Live Pin 4 1 30 1.95 03
Neutral Pin 5 1 20 1.8 01
Cable Grip 6 1 30 1.95 03
Back Casing 7 1 30 1.95 00
Fuse 8 1 10 1.5 30

Sketch of Proposed Design Changes


6 7 8 9

estimation of
manual operation operatrion theoretical
insertion time time, sec, (2) x cost, cents, minimum # of
per part [4+6] 0.4 * (7) parts, 0/1
5 6.5 2.6 0
5.5 7.45 2.98 1
5 20.4 8.16 0
2.5 4.3 1.72 1
3.5 5.45 2.18 1
2.5 4.3 1.72 1
2.5 4.75 1.9 0
2.5 4.75 1.9 0
6 8.57 3.428 1
1.5 3.45 1.38 1
2 3.5 1.4 1
9 9 3.6 n/a
TM CM NM
82.42 32.968 7

EM : 25.479252609 %

6 7 8 9

estimation of
manual operation operatrion theoretical
insertion time time, sec, (2) x cost, cents, minimum # of
per part [4+6] 0.4 * (7) parts, 0/1
2 3.95 1.58 1
5 20.4 8.16 0
2.5 4.3 1.72 1
3.5 5.45 2.18 1
2.5 4.3 1.72 1
3.5 5.45 2.18 1
1.5 3.45 1.38 1
2 3.5 1.4 1
TM CM NM
50.8 20.32 7

EM : 41.338582677 %
10

Notes: Why is it theoretical part

Need for disassembly

Insulate from other pin; need to be a conductor


Insulate from other pin; need to be a conductor
Insulate from other pin; need to be a conductor

Metal screw thread to prevent wear and tear


Need for disassembly
Different material
n/a

10

Notes: Why is it theoretical part


Need for disassembly

Insulate from other pin; need to be a conductor


Insulate from other pin; need to be a conductor
Insulate from other pin; need to be a conductor
Different material (Rubber for flexibility)
Need for disassembly
Different material

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