Integration of computer simulation in design for manufacturing and assembly

Abstract

As a reason for competitiveness, the process of product development evolves using, in some situations, improvement methods, e.g. design for manufacturing and assembly (DFMA). In the framework of the product development process, it is desirable that engineers and managers have a systemic view of the effects that changes in local processes will have on the overall performance of the entire production system. This vision of such effects can be achieved with computer simulation. This study aims at assessing how DFMA can be integrated with computer simulation and the benefits from the alternatives identified by such method during production and assembly. Using the electronic voting machine printer as object of study, options to improve design by means of DFMA principles are identified. Five models were developed to represent the current assembly process and two models following the implementation of the changes proposed by the DFMA. The sale price is confidential (exclusive product of the Brazilian government). The company provided data in assembly costs. The results show the production increase in assembly time (9.94%) and average daily sales ($415).

Keywords:

• DFMA
• product development
• simulation

Notes on contributors

Carlos Eduardo Sanches da Silva has obtained his DSc degree in Industrial Engineering from Federal University of Santa Catarina, Brazil (2001) and master's degree in Industrial Engineering from Federal University of Itajubá (1994). He completed his graduation in Mechanical Engineering from Federal University of Itajubá (1990) and Economy at Faculty of Economics of Sul de Minas (1989). Since 1994 he is a professor of Industrial Engineering at Federal University of Itajubá, Brazil. In 2007/2008, he was visitor at Texas University (TX, USA). His research interests are optimisation of the product development, quality system and project management.

Eduardo G. Salgado completed his graduation in Production Engineering with emphasis in Mechanical from Federal University of Itajubá (2005), master's degree in Production Engineering from Federal University of Itajubá (2008) and PhD in Mechanical Engineering from São Paulo State University (UNESP) (2011). Since 2009 he is an adjunct professor at Federal University of Alfenas (UNIFAL-MG). He was awarded the Early Career Researcher Mentoring Award by the International Foundation for Production Research in 2013. He has experience in Production Engineering, mainly in the following areas: management of the development process of products, reverse engineering, rapid prototyping, innovation management, total quality management and ISO 9001.

Carlos Henrique Pereira Mello completed his graduation in Mechanical Engineering with emphasis in Production Management from Federal University of Itajubá (1994), master's degree in Production Engineering from Federal University of Itajubá (1998) and PhD in Industrial Engineering at Polytechnic School of São Paulo University (USP) (2005) . Since 2006 he is an adjunct professor at Federal University of Itajubá (UNIFEI). He has experience in Production Engineering, mainly in the following areas: product development process management, Scrum, innovation management and open innovation.

Eduardo da Silva Oliveira is a graduate in Industrial Engineering from Federal University of Itajubá (2005). He has entered for master’s degree in Industrial Engineering at Federal University of Itajubá. His research interest is developing projects in the area of product development (2006-2007). He is a professor at public high school since 2008.

Fabiano Leal is a professor of design and measurement of work at Federal University of Itajubá (UNIFEI/Brazil). He got graduated in Mechanical Engineering (2000); he completed his master’s degree in Industrial Engineering from Federal University of Itajubá (2003) and PhD in Mechanical Engineering at São Paulo State University - UNESP (2008). His research interests includes discrete event simulation and process modelling.

Acknowledgements

CAPES (Pro-Engineering – PE024/2008 process; PRODOC – 102059), the FAPEMIG and CNPq (processes 478509/2012-0, TEC-PPM-00058-13 and 304628/2012-3). Special thanks to SISVOO (especially those involved in this study) and interviewees.