Design for assembly implementation of error analysis device for white goods with Boothroyd-Dewhurst approach

In addition to scientific experiments, laboratory equipments has expanded the range of usage in our homes by evolving into the equipment manufactured to measure and evaluate technical datas of white goods. White goods manufacturers have also started to use this equipment in after-sales services as well as in production-level tests. Relevant various equipments are used in after sales services to understand the causes of faults. Devices which depends on laboratory equipment standards are used in after-sale services in Arcelik A.S. In the pre-operation case, the service technicians are confronted with vaious difficulties related to equipments which are used for erro analysis. There are multiple devices for measuring different values, and these devices are carried and used separately. In addition, they can detect the problem by going to the customer's home at least three times. The study is about design for assembly implementation of new error analysis device for white goods. Aims of error detection devices are various. Energy measurement, temperature-time graph, voltage / current / power-time graphs can be shown among the purposes of these devices. As a result of reading the necessary technical values, it is becoming possible to solve the mistakes and give feedback to the production and research and development departments accordingly. Nowadays, production numbers have reached to high numbers. That is why quality of the service is so impartant. As a result ofthis, devices which service technicians use are in more important position. The development of a multipurpose device which the authorized services will use in the white goods product group has been examined and the structural design has been completed in this study. At the design stage, functionally similar products has been explained. As a result of this, It is decided that which functions will be used in the device, Service Informant. Primarily, the equipments used by sercive technicians and the equivalent products of these equipments have been examined. A temperature measuring device used to obtain temperature-time values was examined. Evaluations are carried out on existing or non-existing functions of them. Another device monitors the number of opening of the door, thus determining the effect of the user on the measurement accuracy during measurement processes. Also, the ability to remotely transfer these informations online to service personnel has emerged with this capability. Functional features of device have also been an important reference for new product design. Another product that obtains time dependent graphics of voltage/power/current is a separate device that is examined in terms of its functions likewise. Also, similar cardholder structures have been structurally examined and it is understood how to approach the emerging problems. After this stage, design criterias have been decided. The design criterias are very important for this study. The reason for this is that the standard of the device is naturally required and the design of the components in the device has a direct influence on the performance of the device. In this context, it has been decided how to construct structures under electrical and fire standards, and the light carrier parts. In addition, direction of microscript antennas create design criteria in structural parts. Relevant design criteria are determined by examining various standards. Standards and tests are crucial for design as a final product. These standards which are specified evaluate these standards, are a set of assessments that give approval to continue on the way to the final product. The standards that have to be fitted with the design objectives are subject to the same standards as the laboratory equipments. The details of this standard named IEC 61010 will be mentioned in detail. The standards can be eamined in two categories as electricity and fire standards. Electrical standards mention the requirements for gaps and live ends in devices. The test equipments referred to in this standard has been a reference to the details of the design of the device and the elecetrical connections. In addition, the conditions specified for flame sources in fire standards have a role in device design and material selection. There are light sources for the display group on the device. These light sources that are located in the display group are aesthetically supporting the device, allowing visual identification of the keys and indicators. For this reason, light carrier design criteria have emerged for light sources that are both homogeneous and visible for both functional purposes and aesthetic concerns. The layout of the electronic cards in the device and the criterion for the structural design details of the body in which they are places are antennas. The microstrip antennas in the cards have decisive guidelines for their direction or their location. These principles were also an important criterion for design process. These design criteria will be taken into account at every stage that will play a major role in the development and finalizing of the design. Since it is a series production project, it has to provide relevant standards. However, there is a design criterion that requires that the light carriers be functioning correctly on the interface, ensuring that the antennas are emitted within the context of the interrelationship of the electronic or mechanical components Electromechanical components and cards are defined after design criteria are determined. The constructions that have been decided on how to construct these parts in order to be able to combine them are designed in accordance with both the design criteria and the aesthetic concerns. Electromechanical components, cables, electronic cards, etc. other parts are designed in accordance with the standards and design principles. There are many design details such as electromechanical componenet connections, electrical connections, cable insulation, non-flammabiliy requirements, socket varying in the world. According to the electrical and fire standards, the plastic body design and many things to be careful in assembling the parts have to be taken into consideration likewise. The result is that the product, which is a series production project, has a lot of parts. In this context, it has become necessary to design for assembly implementation Certain consept designs have been put forward in order to determine how many pieces of designed structures can be combined. These concept designs have been examined according to certain criteria and various evaluations have been made in order to select the appropriate one As a result of these evaluations, concept design has emerged. It has been seen that the number of plastic parts and components in the concept design phase is considerably high. Because of the high production costs, literature revew of various assembly design approaches has been performed in order to reduce and facilitate assembly. Design for assembly approaches; the number of parts, suitability for ease of use and assembly, and the minimization of product cost. Increasing the montability helps to reduce the assembly time and reduce the part costs in production. This design tool is very important because it is suitable for both manual assembly and automation assemblies. The Hitachi installability evaluation methodology, the Lucas assembly design approach and the Bootroyd Dewhurts approach are significant samples in featured in the literature. The Bootroyd Dewhurst approach has been taken as the basis for this purpose between these approaches which have been investigated and evaluated. This method is similar to the other design goals. Unlike other methods, this method finds out the answers the questions by directing the concerns of design in the form of questions. The answers of these questions will determine the suitability of the design for assembly to be performed. With this approach, a new algorithm has been developed to analyze all factors which depends on the product spesificly. Each relation is evaluated according to this algorithm and the number of parts are reduced. Based on the Bootroyd Dewhurst approach, these algorithms have been prepared by directing them individually to each parts. With this algorithm, the answrs for each parts are evaluated and a "R Table" is executed. Depending on this table, "P, Q, T Tables" have been created and revisions have been made in parts in accordance with the design for assembly. While the assembly frame is being constructed, the design that is designed for assembly and the design for ease of assembly are regularyle queried and revised. This design for assembly implementation increases the assembly efficiency by %12. Prototyping studies has been done not only after the design has been completed but also to see if the solutions of the local problems can fulfill the function or to make the change and the function can be realized. Three different technologies have been used in this context. These technologies are FDM, SLS and Multijet technologies.When the design is finalized, there is an ergonomic, time saving, easy-to- install and serial- ready Service Informant device for service technicians to resolve errors easily. It is foreseen that the service technicians of the device will facilitate the life of the customers who need service.