Cost Reduction of A Diesel Engine Using The DFMA Method
Cost Reduction of A Diesel Engine Using The DFMA Method
Cost Reduction of A Diesel Engine Using The DFMA Method
THIRUMAVALAVAN SAMPATH, MECHANICAL SYSTEM DESIGN, INDIAN INSTITUTE OF INFORMATION TECHNOLOGY, DESIGN AND MANUFACTURING, CHENNAI.
Introduction
A study of manufacture and assembly costs
reduction in a diesel engine design of a company located in Curitiba that intends to make the engine economically feasible.
Problem statement
PROBLEMS FACED BY THE COMPANY:
Research methodology
To apply the DFMA in the engine X, it adopted the following guidelines: 1. To get the design details, engineering drawings, three dimensional models 3D, physical prototype or the own product; 2. To disassembly the ensemble observing the sequence and how each part is disassembled. To consider the sub-assemblies as spare parts, identifying each one of them; 3. To start the product re-assembly from the major part to the minor, writing the assembly time; 4. To calculate the design efficiency through the following formula: EP = 3 x NP/TM, EP: design efficiency NP: parts number TM: assembly time
chamber. Main components of the diesel engine. 1. cylinder block 2. injection pump 3. Cylinders 4. cylinder head 5. oil carter 6. Piston 7. connecting rod 8. crank shaft 9. Flywheel 10. Valves 11. camshaft
production time is approximately 5 hours and 35 minutes, and the production capacity correspond to one engine in each 7 minutes. The manufacture, assembly, test, and packing processes of the engine were studied, resulting in the following sequence: components received; inspection of components received; components available for the assembly line; engine assembly in the main line; dynamometer test in the engine during 31 minutes to verify: torque, power, noises, balancing lack, valves and leaking adjustment; items assembly for engine transport such as covers and drain plugs threaded in the final of assembly line; anti-corrosive fluid application in the engine; engine availability for transport to the customer.
applicability of the DFMA considering that components represent 66.23% of the total cost. Other costs are related to the transport, taxes, and other factors. To identify the relevant components to be analyzed, these components are listed according to its cost, from the highest to the minor. Afterwards, the components of the engine X were associated to the following subsystems:
rotating elements
injection
valves
cylinder
crankshaft
jackets
gears
pistons
shock absorber pulley flywheel main bearing connecting rods crankshaft seals
bolts
three questions were asked for each one, 1. is it necessary a relative movement between the parts? 2. is it necessary the specification of different materials for physical and/or chemical reasons? 3. must the component be dismountable to facilitate the maintenance?
alterations, according to DFMA guidelines. it was determined that the subsystem to be studied would be the Structural and Sealing, considering its representation of 37.915% in the total cost of the relevant components of the engine. Question 1 : 100 % negative answers Question 2: 73 % negative answers Question 3: 53 % negative answers Thus demonstrating the flexibility of design alterations.
the DFMA guidelines that are as follows: To project for a minor parts number; To develop modulate designs; To design multifunctional components; To design components of easy manufacture; To prevent or to reduce setting components (screws, rivets, bolts); To eliminate unnecessary adjusts and tolerances; To emphasize the standardization of components; To reduce the product parts number; To facilitate the manipulation and the assembly of the final parts; To simplify the product structure, reducing the assembly costs and other factors of this nature.
Reduction of 0.05% in the cylinder block cost and 0.03% in the cost of Structural and sealing subsystem.
Cost reduction of 0.29% in the cylinder block and 0.15% in the cost of Structural and sealing subsystem.
This modification results in a cost reduction of 0.18% in the cylinder block and 0.10% in the cost of Structural and sealing subsystem
Cost reduction of 0.29% in the cylinder block and 0.15% in the cost of Structural and sealing subsystem.
The design efficiency improved from 0.19 to 0.20 and the cost of Structural and sealing subsystem was reduced to 0.90%.
the design efficiency improved from 0.53 to 0.58 and the cost of Structural and sealing Subsystem was reduced in 0.53%.
Solution synthesis
total cost reduction in the subsystem: 1.94%