Design for Quality, Manufacturing and Assembly

  • Course level: Beginner


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

Topics for this course

40 Lessons

Lecture 1 – Introduction to DfX

Lecture 2 – Introduction to Quality00:00:00
Lecture 3 – Introduction to Robustness00:00:00
Lecture 4 – Introduction to Six Sigma Concept00:00:00
Lecture 5 – Recap and clarifications of basic concepts00:00:00
Lecture 6 – Review of Six Sigma and Quality Loss Function (QLF)00:00:00
Lecture 7 – Types of QLF and SN Ratio00:00:00
Lecture 8 – Linking Quality and Robustness00:00:00
Lecture 9 – Design for Six Sigma – Stages, Design of Experiments00:00:00
Lecture 11 – Need for DoE and basic DoE methods00:00:00
Lecture 12 – Factorial Design00:00:00
Lecture 13 – Orthogonal Array- L4 and L8 example00:00:00
Lecture 14 – Setting up an Orthogonal Array00:00:00
Lecture 15 – Confounding OA & Resolution Table00:00:00
Lecture 16 – Confounding Logic & Randomization of Experiments00:00:00
Lecture 17 – Paper Helicopter Case Study – Part I00:00:00
Lecture 18 – Paper Helicopter Case Study – Part II00:00:00
Lecture 19 – Introduction To Injection Molding Process, Materials, Terminologies00:00:00
Lecture 20 – Estimation of Mold Cost for Injection Molding (Dixon & Poli’s Method)00:00:00
Lecture 21 – Estimation of Mold Cost for Injection Molding (Dixon & Poli’s Method) – Continued00:00:00
Lecture 22 – Mold Cost Estimation – Tutorial00:00:00
Lecture 23 – Design for Additive Manufacturing00:00:00
Lecture 24 – Demo00:00:00
Lecture 25 – Introduction to Sustainable Development and Sustainability Indicators – Part 100:00:00
Lecture 26 – Introduction to Sustainable Development and Sustainability Indicators – Part 200:00:00
Lecture 27 – Introduction to Design Process00:00:00
Lecture 28 – Accounting for Manufacturability and Assembly in Design – An Overview00:00:00
Lecture 29 – DfMA in Product Design00:00:00
Lecture 30 – General Design Guidelines for Manual Assembly00:00:00
Lecture 31 – Systematic DFA methodology00:00:00
Lecture 32 – Alpha symmetry, Beta symmetry00:00:00
Lecture 34 – Systematic DFA Case study – controller assembly00:00:00
Lecture 35 – DFA examples and discussion00:00:00
Lecture 36 – Xerox Producibility Index (XPI)00:00:00
Lecture 33 – Quantification of part size & thickness00:00:00
Lecture 37 – High Speed and Robotic Assembly00:00:00
Lecture 38 – Sheet Metal Working00:00:00
Lecture 39 – Overview of DoE Workflow00:00:00
Lecture 40 – DFA Software00:00:00
Lecture 41 – DFM Software & Case Studies00:00:00

Enrolment validity: Lifetime