i
Panel’s Verification
I / We* hereby confirm that I/we have examined and aware of the contents of this report and
in my/our opinions that this report qualify to be awarded with Bachelor Degree of Mechanical Engineering (Design & Innovation)
due to its reasonable scope and quality.
Signature : ………
First Panel’s Name : ……… Date : ………
Signature : ………
Second Panel’s Name : ……… Date : ………
ii
OPTIMIZATION ON MANUFACTURING AND ASSEMBLY OF THE EXISTING OUTDOOR SWING
CHEN SIEW TEEN
This report is used to fulfill
part of the requirement in order to be awarded with
Bachelor Degree of Mechanical Engineering (Design & Innovation)
Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka
iii
“I hereby confirm that this report is solely written by me except those paragraphs and summaries
that have been stated with citation”
Signature : ……….
iv
ACKNOWLEDGEMENT
Here, I would like to acknowledge with appreciation to all those people who helped me numerously during completing this project.
In this great opportunity, I would like to convey my sincere thank you to Mr. Mohd Nazim Abdul Rahman, who is my supervisor for giving me a chance to do the final seminar project. Under his guidance and encouragement, I was able to complete my project with successfully. I also feel thankful to Mr. Mohd Nazim Abdul Rahman for sharing his experience and giving me a lot of knowledge more in mechanical engineering subjects especially works for my topic. Thanks for your guidance and cooperation.
Besides that, I would like to express my appreciation to my classmates and housemates for being kind and helpful to me until the project done. They share the journals, books, sources that they get from library and internet; I will appreciate our friendship forever.
v ABSTRACT
vi ABSTRAK
vii
TABLE OF CONTENT
CHAPTER TITLE PAGE
SUPERVISOR’S VERIFICATION MIDDLE PAGE DECLARATION ACKNOWLEDGEMENT i ii iii iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENT vii
LIST OF TABLE xi
LIST OF FIGURE LIST OF SYMBOL
LIST OF ABBREVIATIONS LIST OF APPENDIX
xiii xvii xviii xix
CHAPTER I INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 5
1.3 Objective 6
1.4 Scope 1.5 Conclusion
6 6
CHAPTER II LITERATURE REVIEW 7
2.1 Outdoor Swing
2.1.1 Materials of Outdoor Swing 2.1.1.1 Plastic Swing
viii
2.1.1.2 Metal Swing 2.1.1.3 Wooden Swing
2.1.1.3.1 Cedar Swing 2.1.1.3.2 Redwood Swing
9 10 11 11 2.2 DFMA
2.2.1 History of DFMA
2.2.2 Principle and Guideline of DFMA 2.2.3 Benefits of DFMA
2.2.4 DFM 2.2.5 DFA
12 13 15 18 20 22
CHAPTER III METHODOLOGY 24
3.1 Introduction 24
3.2 Design Process
3.2.1 Problem Statement 3.2.2 Needs
3.2.3 Engineering Design Specification 3.2.4 Conceptual Design
3.2.5 Select the Best Design 3.2.6 Configuration Design 3.2.7 Parametric Design 3.2.8 Detail Design
25 26 26 27 27 28 29 29 29
CHAPTER IV ENGINEERING DESIGN SPECIFICATION 31
4.1 Introduction 31
4.2 Customer Needs
4.2.1 Questionnaire Method 4.2.2 Result from Questionnaire 4.2.3 Customer Requirements 4.2.4 Engineering Characteristic 4.2.5 House of Quality
4.2.6 EDS for an Outdoor Swing
32 33 34 36 38 39 41
ix
CHAPTER V CONCEPTUAL DESIGN 44
5.1 Introduction 44
5.2 Product Decomposition 5.3 Morphology
5.3.1 First Concept 5.3.2 Second Concept 5.3.3 Third Concept 5.3.4 Fourth Concept 5.3.5 Fifth Concept 5.4 Concept Evaluation
5.4.1 Weighted Rating Method
45 46 48 49 50 51 52 53 53
CHAPTER VI CONFIGURATION DESIGN 57
6.1 Introduction
6.2 Product Architecture 6.3 Existing Swing Description 6.3.1 Existing Swing Diagram 6.4 Concept Description
6.4.1 Concept Swing Diagram
57 59 60 64 65 69
CHAPTER VII PARAMETRIC DESIGN 70
7.1 Introduction
7.2 Solidwork Simulation Analysis 7.2.1 Structure Analysis Result 7.2.2 Screw Analysis Result 7.3 Manual Calculation
7.4 Comparison of Manual and Analysis Result 7.5 DFMA Manual Analysis for Existing Swing 7.5.1 Assembly flow chart
7.5.2 The Process and Material Selection 7.5.3 Theoretical Part
7.5.4 Alpha and Beta Symmetric 7.5.5 Handling and Insertion Time
x
7.6 DFMA Software Analysis of Existing Swing 7.6.1 Design for Manufacturing
7.6.2 Design for Assembly
7.7 DFMA Manual Analysis for Concept Swing 7.7.1 Assembly Flow Chart
7.7.2 The Process and Material Selection 7.7.3 Theoretical Part
7.7.4 Alpha and Beta Symmetric 7.7.5 Handling and Insertion Time
7.8 DFMA Software Analysis for Concept Swing 7.8.1 Design for Manufacturing
7.8.2 Design for Assembly 7.9 Result
98 98 100 103 105 106 114 115 116 118 118 120 123
CHAPTER VIII DETAIL DESIGN 126
8.1 Introduction
8.2 Detail Drawing for Existing Swing 8.3 Detail Drawing for Concept Swing
126 127 130
CHAPTER IX DISCUSSION 133
9.1 Comparison Existing Swing and Concept Swing 9.2 Comparison of DFMA Manual and Software
Analysis
133 135
CHAPTER X CONCLUSION AND RECOMMANDATION 136
10.1 Conclusion 10.2 Recommandation
136 137
REFERENCES 138
xi
LIST OF TABLE
NO. TITLE PAGE
4.2.3 Customer needs for outdoor swings (Source: Karl. T. U. & Steven D. E. 2003)
37
4.2.4 The relative of customer needs and metric for outdoor swings (Source: Karl. T. U. & Steven D. E. 2003)
38
4.2.5 House of quality 40
4.2.6 Engineering design specification for an outdoor swing 41
5.4.1 Weighted decision matrix for an outdoor swing (Source: Chang R. Y. & Niedzwiecki M. E. 1995)
55
6.3 Existing swing description 61
6.4 Concept swing description 66
7.2.1 Structure analysis result apply with 2000N load 72
7.2.2 Screw analysis result apply with 2000N load 76
xii
7.5.3 Theoretical part & non-theoretical part for existing swing 94
7.5.4 Alpha & Beta of existing swing 95
7.5.5 Analyze Handling and Insertion Time for existing swing 97
7.6.1 Total costing per part of each part 99
7.7 Explore view parts for concept swing 103
7.7.3 Theoretical part & non-theoretical part for concept swing 114
7.7.4 Alpha & Beta of concept swing 115
7.7.5 Analyze Handling and Insertion Time for concept swing 117
7.8.1 Totals Costing per part of each part 119
xiii
LIST OF FIGURE
NO. TITLE PAGE
3.2 Design process 25
3.2.4
4.2.2
Design concept = physical concept + part decomposition (Source: Henry W. S., (1999))
Histogram of comparison between nursery, customer and playground equipment company
27
34
5.2
5.3
5.3.1
Outdoor swing decomposition part
Morphology chart
First concept
46
47
48
5.3.2 Second concept 49
5.3.3 Third concept 50
5.3.4 Fourth concept 51
5.3.5
5.4.1
Fifth concept
Objective tree for design of an outdoor swing
52
xiv
5.4.1 Objective tree for design of an outdoor swing 54
6.3 Existing swing 60
6.3.1 Existing swing diagram 64
6.4 Concept swing 65
6.4.1 Concept swing diagram 69
7.2.1 Stress on the structure 73
7.2.1 Displacement on the structure 74
7.2.1 Strain for the structure 74
7.2.1 Factor of safety for the structure 75
7.2.2 Stress on the screw 77
7.2.2 Displacement on the screw 77
7.2.2 Strain for the screw 78
7.2.2
7.5
Factor of safety for the screw
Explore view of existing swing
78
83
7.5.1 Assembly process flow for existing swing 84
7.5.2 Process flow for rail 86
xv
7.5.2 Process flow for hanger hole 88
7.5.2 Process flow for hanger 89
7.5.2 Process flow for shackle 90
7.5.2 Process flow for chain 91
7.5.2 Process flow for seat hanger 92
7.5.2 Process flow for seat 93
7.6.1 DFM software concurrent costing totals 98
7.6.2 Executive summary for DFA 100
7.6.2 Total analysis for DFMA 101
7.6.2 DFMA summary result 102
7.7
7.7.1
Explore view of concept swing
Assembly process flow for concept swing
104
105
7.7.2 Process Flow for Structure 107
7.7.2 Process Flow for Hanger Hole 108
7.7.2 Process flow for hanger 109
xvi
7.7.2 Process Flow for Chain 111
7.7.2 Process Flow for Quick Link 112
7.7.2 Process Flow for Seat 113
7.8.1 DFM concurrent costing totals 118
7.8.2 Executive summary for DFA 120
7.8.2 Total analysis for DFMA 121
7.8.2 DFMA summary result 122
8.2 Exploded view for existing swing 128
8.2 Assembly dimension of existing swing 129
8.3 Exploded view for concept swing 131
8.3 Assembly dimension of concept swing 132
9.1 Structure comparison 133
9.1 Seat hanger and quick link comparison 134
xvii
LIST OF SYMBOLS
σ = Stress
δ = Displacement M = Moment r = Radius
ȓ = Radius from the vertex center R = Reaction load
A = Area F = Force e = Span length
E = Modulus of elasticity P = Concentrated load
y = Distance of axis to extreme fiber L = Length
xviii
LIST OF ABBREVIATIONS
DFMA = Design for manufacturing and assembly DFA = Design for assembly
DFM = Design for manufacturing BDI = Boothroyd Dewhurst Inc ECN = Engineering change notice CE = Concurrent engineering
EDS = Engineering design specification PDS = Product design specification QFD = Quality Function Deployment CAD = Computer aided design
xix
LIST OF APPENDIX
NO. TITLE PAGE
A Conceptual design references 143
B Gantt chart for PSM I 146
C Gantt chart for PSM II 147
D Rail for existing swing 148
E Stand for existing swing 149
F Hanger for existing and concept swing 150
G Shackle for existing and concept swing 151
H Chain for existing and concept swing 152
I Seat hanger for existing swing 153
J Seat for existing swing 154
K Structure for concept swing 155
xx
M Seat for concept swing 157
1 CHAPTER I
INTRODUCTION
1.1 BACKGROUND
The wave of modernization that is prevalent in our lives is also affecting our children’s lifestyles, most kids are fascinated with video games and indoor entertainment they are no longer sociable.
This is where children’s outdoor swings would fill in the missing link. As a parent one must understand that an outdoor experience is something that will develop the growth of a child's social awareness and behavior. It all starts in interactions with neighbors and classmates for those who are already going to school. However prior to coming to school a child’s mind should already be prepared to interact with other children and one way of doing this is to engage your child into outdoor activities. Children’s outdoor swings are great for all ages, it is a tool to capture the attention of your children and make them realize the significance of interaction between people.
2
encourages or improves social well being. Although everything that happens around us are all dependent on the state of the mind it is important to consider the enjoyment provided of our sense of touch, hearing, and sight. These senses are important and it contributes to the basic requirements of our social development. The virtual entertainment provided by computers, video games and televisions are merely virtual, they are a good motivation to practice our mental state but they are unreal and you cannot feel them, you just see it but it is more like an abstract you would not feel it at all. The children’s outdoor swings will not only entertain but also put your child’s cardio vascular system to work; it will become a form of an exercise that your child will appreciate. (Source: http://ezinearticles.com/?Childrens-Outdoor-Play-Sets&id=4053741)
Design for Manufacturing (DFM) and design for assembly (DFA) are the integration of product design and process planning into one common activity. Designing for manufacturing and assembly (DFMA) can define as a process for improving product design for easy to manufacture and low cost assembly, focusing on functionality and on assimilability concurrently.
The goal of DFMA is to design a product that is easily and economically manufacture and assembly. On the other words is to improve the design of the assembly, to reduce the adhesion such as welding operation necessary to end up with a finished product. The most common methods of improvements are reducing the number of times the part has to be reoriented, and eliminating any excess material without sacrifice the product quality (Source: John W. P. & Sanchez J., (2001)).
3
Designing parts for use in a flexible automation system can have profound results on the overall effectiveness of the system. While simply attempting to automate the assembly of existing designs is possible, the resulting operation is often prone to error and continual failure. More than often, the root of many of the problems can be traced back to the parts and assembly procedures being used.
In the past, design and manufacture tasks have been performed independently. In this scenario, the designer designs a product and ‘‘tosses it over the wall’’ to the manufacturer to produce. There is no interaction between the designer and manufacturer and often what results is a design that is difficult to produce using automation. What is required is collaboration between all aspects of the engineering staff, beginning with product conception all the way through delivery. By tapping into the expertise of all engineering areas (design, automation, manufacturing and etc), an equally functional and high quality design will result, but it will be much easier to reliably manufacture in an automated system. In practice, this approach is often difficult to implement, especially if the product designers are employed by one sub-contractor, the machine builders by another, and the raw components manufactured by a third. However, time spent by all involved parties in mutual consultation at the design phase will far outweigh and inconveniences.
4
types of small changes to a design can have a major impact on the quality and ease of automated manufacture.
Engineering design is a process of developing a system, component, or process to meet desired needs. It is a decision making process in which basic sciences, mathematic, and engineering technologies are applied to convert resources optimally to meet a stated objective. Engineering design had usually been complete purely based on the process-planning department and then to the manufacturing department. These activities were completed in a sequential manner with no feedback given to the designer. Sometimes the designed product is extremely difficult to manufacture and the manufacturing cost is unnecessarily high. To solve this problem, two approaches are used to help the designer reducing the product cost after a design is completed. They are value engineering and producibility engineering. (Source: Boothroyd, G. et. al., (2002))
