Ny design för enklare montering : En fallstudie på värmefläkten Tiger P153

Sammanfattning: This bachelor thesis marks the end of the engineering program within innovation and product design. This study was conducted at Mälardalen university during the spring term of 2021. The demand of this study arose for the client, Systemair, who wanted to develop one of their existing products. The purpose of this development was to simplify the assembly by reducing the number of fasteners, this number was viewed as too great. Updates, for the chosen product, had basically been nonexistent since the 1990s and the construction did not make use of Design for Assembly. This led to the product taking more time to manufacture relatively similar products. The mission became to reduce the number of fasteners with kept or improved performance. Because Systemair is a profit driven company their products constantly need to be improved for the company to remain competitively advantageous. Development projects often lead to reduced costs and higher quality for the products. The purpose is to reduce the assembly time for a more effective assembly and reduced costs. Throughout this thesis a case study (Säfsten & Gustavsson, 2020) was conducted that followed the DFA-process explained by Tatikonda (Tatikonda, 1994). During the study, the steps reduce component costs and reduce assembly costs within DFM were also followed (Ulrich & Eppinger, 2012). From the step Identify to the step testing, Design Thinking was used (Dam & Siang, 2021). For planning the study and concept screening and scoring, steps from phases within Ulrich and Eppingers product development process were used (Ulrich & Eppinger, 2012). The results were shown through a Bill of Material for all improvements (Ulrich & Eppinger, 2012). Ulrich and Eppinger means that integrated product architecture leads to higher performance, components without the need to be assembled separately and controlling transferring to the manufacturing. According to Shetty and Ali there are questions that could be asked about specific components to see if they are combinable (Shetty & Ali, 2015). M. Dudek-Burlikowska and D. Szewieczek shows that human errors and assembly that relies on memory will be avoided with the help of Poka-Yoke (Dudek-Burlikowska & Szewieczek, 2009). The study started with familiarizing of the product to build an understanding of its design. Interviews were held with fitters from which six opportunities were identified that got presented and tested through functional prototypes. The original and the improved design were timed to measure the improvement timewise. Cost calculations were made for the improvements and were compared with the original design. The improvements then got evaluated with time- and efficiency points to show their level of Improvement. The new design is more assembly friendly and makes use of integrated components. Assembly friendliness leads to an effective assembly process according to Ulrich and Eppinger. The original design had 81 fasteners and after the redesign 29 were reduced, 36%. The assembly time got reduced by 7 minutes and 53 seconds, 28%. The product costs 49 SKR less to manufacture, 2,5%, since the assembly cost was reduced by 57 SKR and material costs increased with 8 SKR.