A simplified approach to design for assembly

The basic principles of design for assembly (DfA) are well established. This paper presents a short review of the development of DfA approaches before presenting a new tool in which these principles are packaged for use in teams, both in an industrial and an educational context. The fundamental consideration in the design of this tool is to encourage wide team participation from across an organisation and is thus physical rather than software-based. This tool builds on the process developed by Appleton whilst at the University of Cambridge. In addition to the traditional analysis of component fitting, feeding and fixing, this process also encourages the team to explore how this relates to the overall assembly flow and specifically the achievement of throughput targets. The novel approach is an improvement to established methods and encompasses an original assessment tool and its delivery process that includes custom designed post-it notes and simple check lists for scoring. The process is demonstrated in a single case study in an Indian firm.