Design Strategies

1. Design Strategies Design for XXX

2. Design for XDesign Strategies • 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.

3. Design for XDesign Strategies • 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.

4. Design for XDesign Strategies • 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.

5. Design for XDesign Strategies • 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.

6. Design for XDesign Strategies • 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).

7. Design for XDesign Strategies • 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.

8. Design for XDesign Strategies • 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.

9. Design for XDesign Strategies • 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.

10. Design for XDesign Strategies • 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.

11. Design for XDesign Strategies • 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.

12. Design for XDesign Strategies • 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.

13. Design for XDesign Strategies • 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

14. Design for XDesign Strategies • 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.

15. Design for XDesign Strategies • 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.