Design for Quality, Manufacturing and Assembly

COURSE OUTLINE : In the context of product design, it is very important to appreciate the limitations of a design from manufacturing and assembly perspective and to produce high quality products at low cost. This course will introduce methods that can provide guidance to design teams in simplifying product structure to reduce manufacturing and assembly costs, quantify improvements and how robust design concepts can be used for ensuring quality. This course aims at introducing the need to account for variability, mathematically represent it, formulate it and control it. Concepts such as quality, robustness, six sigma and orthogonal array will be discussed

Lecture 1 - Introduction to DfX.
Lecture 2 - Introduction to Quality.
Lecture 3 - Introduction to Robustness.
Lecture 4 - Introduction to Six Sigma Concept.
Lecture 6 - Review of Six Sigma and Quality Loss Function (QLF).
Lecture 9 - Design for Six Sigma - Stages, Design of Experiments.
Lecture 8 - Linking Quality and Robustness.
Lecture 7 - Types of QLF and SN Ratio.
Lecture 5 - Recap and clarifications of basic concepts.
Lecture 11 - Need for DoE and basic DoE methods.
Lecture 10 - INTRODUCTION TO DESIGN OF EXPERIMENTS.
Lecture 12 - Factorial Design.
Lecture 13 - Orthogonal Array- L4 and L8 example.
Lecture 14 - Setting up an Orthogonal Array.
Lecture 15 - Confounding OA & Resolution Table.
Lecture 16 - Confounding Logic & Randomization of Experiments.
Lecture 17 - Paper Helicopter Case Study - Part I.
Lecture 18 - Paper Helicopter Case Study - Part II.
Lecture 19 - Introduction To Injection Molding Process, Materials, Terminologies.
Lecture 20 - Estimation of Mold Cost for Injection Molding (Dixon & Poli's Method).
Lecture 21 - Estimation of Mold Cost for Injection Molding (Dixon & Poli's Method) - Continued.
Lecture 22 - Mold Cost Estimation - Tutorial.
Lecture 23 - Design for Additive Manufacturing.
Lecture 24 - Demo.
Lecture 25 - Introduction to Sustainable Development and Sustainability Indicators - Part 1.
Lecture 26 - Introduction to Sustainable Development and Sustainability Indicators - Part 2.
Lecture 27 - Introduction to Design Process.
Lecture 28 - Accounting for Manufacturability and Assembly in Design – An Overview.
Lecture 29 - DfMA in Product Design.
Lecture 30 - General Design Guidelines for Manual Assembly.
Lecture 31 - Systematic DFA methodology.
Lecture 32 - Alpha symmetry, Beta symmetry.
Lecture 34 - Systematic DFA Case study – controller assembly.
Lecture 35 - DFA examples and discussion.
Lecture 36 - Xerox Producibility Index (XPI).
Lecture 33 - Quantification of part size & thickness.
Lecture 37 - High Speed and Robotic Assembly.
Lecture 38 - Sheet Metal Working.
Lecture 39 - Overview of DoE Workflow.
Lecture 40 - DFA Software.
Lecture 41 - DFM Software & Case Studies.