DESIGN FOR XXX Design Strategies

Design for X Design Strategies 6/1/ Part shape strategies: adhere to specific process design guidelines if part symmetry is not possible, make parts very asymmetrical design "paired" parts instead of right and left hand parts. design parts with symmetry. use chamfers and tapers to help parts engage. provide registration and fixturing locations. avoid overuse of tolerances.

Design for X Design Strategies 6/1/ Standardization strategy use standard parts standardize design features minimize the number of part types minimize number of total parts. standardize on types and length of linear materials and code them. consider pre-finished material (pre-painted, pre-plated, embossed, anodized). combine parts and functions into a single part.

Design for X Design Strategies 6/1/ Assembly strategies 1 design product so that the subsequent parts can be added to a foundation part. design foundation part so that it has features that allow it to be quickly and accurately positioned. Design product so parts are assembled from above or from the minimum number of directions. provide unobstructed access for parts and tools make parts independently replaceable. order assembly so the most reliable goes in first; the most likely to fail last.

Design for X Design Strategies 6/1/ Assembly strategies 2 make sure options can be added easily ensure the product's life can be extended with future upgrades. use sub-assemblies, especially if processes are different from the main assembly. purchase sub-assemblies which are assembled and tested.

Design for X Design Strategies 6/1/ Fastening strategies 1 use the minimum number of total fasteners use fewer large fasteners rather than many small fasteners use the minimum number of types of fasteners make sure screws should have the correct geometry so that auto-feed screwdrivers can be used. design screw assembly for downward motion minimize use of separate nuts (use threaded holes). consider captive fasteners when applicable (including captive nuts if threaded holes are not available).

Design for X Design Strategies 6/1/ Fastening strategies 2 avoid separate washers and lockwashers (make it be captivated on the bolt or nut so it can still spin with respect to the fastener) use self-tapping screws when applicable. eliminate fasteners by combining parts. minimize use of fasteners with snap-together features. consider fasteners that push or snap on. specify proper tolerances for press fits.

Design for X Design Strategies 6/1/ Assembly motion strategies fastened parts are located before fastener is applied. assembly motions are simple. Assembly motions can be done with one hand or robot. assembly motions should not require skill or judgment. products should not need any mechanical or electrical adjustments unless required for customer use. minimize electrical cables; plug electrical sub-assemblies directly together. minimize the number of types of cable.

Design for X Design Strategies 6/1/ Automation handling strategies 1 design and select parts that can be oriented by automation design parts to easily maintain orientation use parts that will not tangle when handled in bulk. use parts what will not shingle when fed end to end (avoid disks). use parts that not adhere to each other or the track. specify tolerances tight enough for automatic handling. avoid flexible parts which are hard for automation to handle.

Design for X Design Strategies 6/1/ Automation handling strategies 2 make sure parts can be presented to automation. make sure parts can be gripped by automation. parts are within machine gripper span. parts are within automation load capacity. parting lines, spruces, gating or any flash do not interfere with gripping.

Design for X Design Strategies 6/1/ Quality and test strategies product can be tested to ensure desired quality sub-assemblies are structured to allow sub-assembly testing testing can be performed by standard test instruments test instruments have adequate access. minimize the test effort spent on product testing consistent with quality goals. tests should give adequate diagnostics to minimize repair time.

Design for X Design Strategies 6/1/ DF Maintenance strategies 1 provide ability for tests to diagnose problems make sure the most likely repair tasks are easy to perform. ensure repair tasks use the fewest tools. use quick disconnect features ensure that failure or wear prone parts are easy to replace with disposable replacements provide inexpensive spare parts in the product. ensure availability of spare parts.

Design for X Design Strategies 6/1/ Maintenance strategies 2 use modular design to allow replacement of modules. ensure modules can be tested, diagnosed, and adjusted while in the product. sensitive adjustment should be protested from accidental change. the product should be protected from repair damage. provide part removal aids for speed and damage prevention. protect parts with fuses and overloads

Design for X Design Strategies 6/1/ Maintenance strategies 3 protect parts with fuses and overloads ensure any sub-assembly can be accessed through one door or panel. access over which are not removable should be self- supporting in the open position. connections to sub-assemblies should be accessible and easy to disconnect. make sure repair, service or maintenance tasks pose no safety hazards. make sure sub-assembly orientation is obvious or clearly marked.

Design for X Design Strategies 6/1/ Maintenance strategies 4 make sure sub-assembly orientation is obvious or clearly marked. provide means to locate sub-assembly before fastening. design products for minimum maintenance. design self-correction capabilities into products design products with self-test capability. design products with test ports design in counters and timers to aid preventative maintenance. specify key measurements for preventative maintenance programs include warning devices to indicate failures.