This project demonstrated the importance of assembly efficiency in a manufactured product. It began in February 2016, and ended in May 2016. The new design had improved assembly efficiency and reduced labor and production costs.
Problem: When a product is designed, there are two considerations which are of the utmost importance: Ergonomics and Cost. This is due to the fact that almost anything manufactured is meant for human usage or more appropriately, human-centered usage.
Many manufactured products are designed to aid during a emergency situations. However, sometimes, they have unwanted parts which make their assembly and hence manufacturing a lengthy task. The idea is to eliminate unwanted parts or merge multiple parts and increase assembly efficiency and decrease the cost.
Goal: The aim of this project was to redesign a 7-in-1 multi-tool using Boothroyd and Dewhurst Design for Assembly Method (DFA / BDI), and Hitachi Assembly Evaluation Method (AEM). The purpose is to eliminate unnecessary parts, increase the ease in assembly, decrease the material cost and increase the design and assembly efficiencies.
Tools: Solidworks, Rhinoceros, Reverse Engineering, Tool Design, Design for Manufacturing, Design for Assembly, Cost benefit analysis
Impact: After disassembling, analyzing, reassembling, and brainstorming about the product. The project proposes a new design which reduces the total parts from 39 to 23. The new design is estimated to decrease the total assemble time from 325.86 seconds to 159.45 seconds. The new design is also estimated to save labor production cost of $2.08 per unit and material cost of $3.38 per unit. The part count design efficiency is increased from 46% to 83%. In BDI analysis, the assemble efficiency is increased from 36% to 43%, and the design efficiency is increased from 17% to 36%. In AEM analysis, the assemble efficiency is increased from 65% to 67%, and the design efficiency is increased from 30% to 56%.
The BodyGard® 7-in-1 Emergency Tool is a key-chain rescue tool that combines an automatic glass breaker, a seat belt cutter, sonic alarm, bright LED flashlight with both a high beam and low beam and an emergency flasher in a device small enough to fit on a key chain or in a pocket. In addition to these safety devices, the BodyGard 7-in-1 offers a digital tire pressure gauge and a thermometer. For convenience, the product from hence forth will also be known as multi-tool. The tool was invented by Bennett S. Rubin and Richard C. Adamany. The product, is made in China and has pending patent — US patents 7,557,720 and D575,182.