Short answer

Integrate DFMA software and FEA into the design process to proactively identify and implement cost reductions and performance enhancements for manufactured products.

Field
Modelling
Source
Designs (2020)
Method
Case study with computational modelling and simulation.
Evidence
Strong effect

Applying Design for Manufacturing and Assembly (DFMA) software modelling to an existing conveyor system can significantly reduce manufacturing costs and improve design efficiency. This modelling research insight is drawn from a 2020 study published in Designs. Using Case study with computational modelling and simulation., researchers explored how this design variable affects real-world outcomes. The key design takeaway: Integrate DFMA software and FEA into the design process to proactively identify and implement cost reductions and performance enhancements for manufactured products.

Study
ModellingHigh ImpactStrong effect

DFMA modelling reduces conveyor system manufacturing costs by 29%

Applying Design for Manufacturing and Assembly (DFMA) software modelling to an existing conveyor system can significantly reduce manufacturing costs and improve design efficiency.

Designs · 2020

01

Key Findings

  • 01Manufacturing cost reduction of 29% was achieved with the redesigned conveyor system.
  • 02Design efficiency increased from 1.7% to 5% after redesign.
  • 03Finite element analysis confirmed the structural integrity of the new design.
02

Application

Design takeaway

Integrate DFMA software and FEA into the design process to proactively identify and implement cost reductions and performance enhancements for manufactured products.

How to apply

Before finalizing a product design, use DFMA software to analyze the number of parts, assembly time, and potential manufacturing complexities. Use FEA to test critical components under expected loads.

Project actions

  • 01When redesigning a product, consider using software to simulate manufacturing and assembly.
  • 02Quantify the benefits of your design changes, such as cost savings or time reduction.
03

Method & Evidence

AimHow can DFMA software modelling be utilized to redesign an existing side-flexing Table Top Chain (TTC) conveyor system to achieve significant manufacturing cost reduction and enhance design efficiency?
MethodCase study with computational modelling and simulation.
ProcedureThe existing TTC conveyor system design was analyzed using DFMA 9.3 software. The insights gained were used to create a redesigned model, which was then optimized using the Pugh controlled convergence method. Finally, the structural integrity of the optimized design was validated through finite element analysis using SolidWorks 2019.
ContextManufacturing engineering, specifically conveyor system design for the food industry.

Variables

IVDFMA software modelling and redesign process.
DVManufacturing cost, design efficiency.
CVType of conveyor system (side-flexing TTC), company context (reputed company in Saudi Arabia), specific DFMA software version (9.3), FEA software (SolidWorks 2019).
04

Strengths & Limitations

Strengths

  • +Quantifiable results for cost reduction and design efficiency.
  • +Validation of structural integrity through FEA.
  • +Application of a recognized engineering methodology (DFMA).

Limitations

The accuracy of the results depends heavily on the quality of the input data and the software used. Real-world manufacturing can introduce variables not captured in simulations.

Reliability & validity

The study's validity is supported by the use of established software (DFMA, SolidWorks) and a recognized methodology (DFMA, FEA). Reliability is enhanced by the quantitative nature of the findings (percentage cost reduction, efficiency increase).

Think critically

To what extent can the cost savings identified through DFMA modelling be fully realized in actual production, considering potential variations in manufacturing environments and supply chains?

05

Design Principles

"Employ computational modelling and simulation early in the design process to optimize for manufacturing cost and assembly efficiency."

This research demonstrates a quantifiable benefit of using digital tools for product redesign. By simulating manufacturing and assembly processes, designers can identify cost-saving opportunities and optimize designs before physical prototyping, leading to more efficient product development cycles and improved market competitiveness.

06

What This Means for Your Design

Using computer programs to plan how to build something can help designers find ways to make it cheaper to build and easier to put together.

How to use in your project

  • 1.Reference this study when discussing the use of simulation software (like DFMA or FEA) to justify design decisions and improvements in your design project.
07

Add to My Project

08

Quick Cite

Paragraph starter

The application of Design for Manufacturing and Assembly (DFMA) methodology, as demonstrated by Butt and Jedi (2020), provides a robust framework for optimizing product designs. Their case study on a conveyor system revealed that utilizing DFMA software for analysis and redesign led to a significant 29% reduction in manufacturing costs and an increase in design efficiency from 1.7% to 5%. This highlights the potential of computational modelling to identify cost-saving opportunities and streamline production processes, validating the use of such tools in achieving practical design improvements.

09

Source

Designs

Redesign of an In-Market Conveyor System for Manufacturing Cost Reduction and Design Efficiency Using DFMA Methodology

journal · 2020

View source

Questions About This Research

What does the research say about dfma modelling reduces conveyor system manufacturing costs by 29%?
Integrate DFMA software and FEA into the design process to proactively identify and implement cost reductions and performance enhancements for manufactured products. Evidence: Designs (2020).
Why does "DFMA modelling reduces conveyor system manufacturing costs by 29%" matter for design?
This research demonstrates a quantifiable benefit of using digital tools for product redesign. By simulating manufacturing and assembly processes, designers can identify cost-saving opportunities and optimize designs before physical prototyping, leading to more efficient product development cycles and improved market competitiveness.
How can designers apply this research?
Integrate DFMA software and FEA into the design process to proactively identify and implement cost reductions and performance enhancements for manufactured products.
What were the main findings?
Manufacturing cost reduction of 29% was achieved with the redesigned conveyor system.. Design efficiency increased from 1.7% to 5% after redesign.. Finite element analysis confirmed the structural integrity of the new design.
What research method was used?
Case study with computational modelling and simulation..
How strong is the evidence?
Evidence strength is rated Strong effect, based on a 2020 journal from Designs.
What should I do differently in my next project?
Before finalizing a product design, use DFMA software to analyze the number of parts, assembly time, and potential manufacturing complexities. Use FEA to test critical components under expected loads.
What are the limitations?
The study focused on a specific type of conveyor system and may not be directly generalizable to all manufacturing equipment. The cost savings are specific to the manufacturing context in Saudi Arabia.