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
Course Content
Lecture 1 – Introduction to DfX
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Lecture 2 – Introduction to Quality
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Lecture 3 – Introduction to Robustness
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Lecture 4 – Introduction to Six Sigma Concept
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Lecture 5 – Recap and clarifications of basic concepts
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Lecture 6 – Review of Six Sigma and Quality Loss Function (QLF)
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Lecture 7 – Types of QLF and SN Ratio
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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
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Lecture 12 – Factorial Design
00:00 -
Lecture 13 – Orthogonal Array- L4 and L8 example
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Lecture 14 – Setting up an Orthogonal Array
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Lecture 15 – Confounding OA & Resolution Table
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Lecture 16 – Confounding Logic & Randomization of Experiments
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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
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Lecture 34 – Systematic DFA Case study – controller assembly
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Lecture 35 – DFA examples and discussion
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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
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Lecture 39 – Overview of DoE Workflow
00:00 -
Lecture 40 – DFA Software
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Lecture 41 – DFM Software & Case Studies
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