Design for Quality, Manufacturing and Assembly

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About Course

Design for Quality, Manufacturing, and Assembly

In the context of product design, it’s critical to recognize a design’s limitations in terms of production and assembly, as well as to generate high-quality products at a cheap cost.

This course will cover strategies for guiding design teams in reducing product structure to decrease manufacturing and assembly costs, quantifying benefits, and demonstrating how robust design concepts may help. quantifying improvements and demonstrating how solid design concepts may be utilized to ensure quality.

This course will teach you how to account for variability, express it mathematically, formulate it, and control it. Quality, robustness, six sigma, and orthogonal array are some of the concepts that will be explored.

Course Outline

Week 1: Introduction, course objectives, and quality debate

Week 2: Quality Loss Function and Measuring Quality Robustness and six-sigma notions are discussed.

Week 3: Measuring robustness: Signal to Noise Ratio and SNR-based issue formulation Discussions on experiment design

Week 4: Optimal combinations, orthogonal arrays, linear graphs, triangular tables Case studies are used to illustrate a point.

Week 05: Design for Manufacturing: over-the-top design, the most influential phase of design, injection molding and sheet metal working best practices

Week 6: Additive manufacturing design, single point, and multipoint tools

Week 07: Xerox producibility index (XPI) approach, Boothroyd Dewhurst method, the theoretical minimum number of parts

Week 08: Manual assembly dos and don’ts, assembly time calculation, and design for robotic assembly considerations Design for long-term use

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Course Content

Lecture 1 – Introduction to DfX

  • Lecture 2 – Introduction to Quality
    00:00
  • Lecture 3 – Introduction to Robustness
    00:00
  • Lecture 4 – Introduction to Six Sigma Concept
    00:00
  • Lecture 5 – Recap and clarifications of basic concepts
    00:00
  • Lecture 6 – Review of Six Sigma and Quality Loss Function (QLF)
    00:00
  • Lecture 7 – Types of QLF and SN Ratio
    00:00
  • Lecture 8 – Linking Quality and Robustness
    00:00
  • Lecture 9 – Design for Six Sigma – Stages, Design of Experiments
    00:00
  • Lecture 10 – INTRODUCTION TO DESIGN OF EXPERIMENTS
    00:00
  • Lecture 11 – Need for DoE and basic DoE methods
    00:00
  • Lecture 12 – Factorial Design
    00:00
  • Lecture 13 – Orthogonal Array- L4 and L8 example
    00:00
  • Lecture 14 – Setting up an Orthogonal Array
    00:00
  • Lecture 15 – Confounding OA & Resolution Table
    00:00
  • Lecture 16 – Confounding Logic & Randomization of Experiments
    00:00
  • Lecture 17 – Paper Helicopter Case Study – Part I
    00:00
  • Lecture 18 – Paper Helicopter Case Study – Part II
    00:00
  • Lecture 19 – Introduction To Injection Molding Process, Materials, Terminologies
    00:00
  • Lecture 20 – Estimation of Mold Cost for Injection Molding (Dixon & Poli’s Method)
    00:00
  • Lecture 21 – Estimation of Mold Cost for Injection Molding (Dixon & Poli’s Method) – Continued
    00:00
  • Lecture 22 – Mold Cost Estimation – Tutorial
    00:00
  • Lecture 23 – Design for Additive Manufacturing
    00:00
  • Lecture 24 – Demo
    00:00
  • Lecture 25 – Introduction to Sustainable Development and Sustainability Indicators – Part 1
    00:00
  • Lecture 26 – Introduction to Sustainable Development and Sustainability Indicators – Part 2
    00:00
  • Lecture 27 – Introduction to Design Process
    00:00
  • Lecture 28 – Accounting for Manufacturability and Assembly in Design – An Overview
    00:00
  • Lecture 29 – DfMA in Product Design
    00:00
  • Lecture 30 – General Design Guidelines for Manual Assembly
    00:00
  • Lecture 31 – Systematic DFA methodology
    00:00
  • Lecture 32 – Alpha symmetry, Beta symmetry
    00:00
  • Lecture 34 – Systematic DFA Case study – controller assembly
    00:00
  • Lecture 35 – DFA examples and discussion
    00:00
  • Lecture 36 – Xerox Producibility Index (XPI)
    00:00
  • Lecture 33 – Quantification of part size & thickness
    00:00
  • Lecture 37 – High Speed and Robotic Assembly
    00:00
  • Lecture 38 – Sheet Metal Working
    00:00
  • Lecture 39 – Overview of DoE Workflow
    00:00
  • Lecture 40 – DFA Software
    00:00
  • Lecture 41 – DFM Software & Case Studies
    00:00

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