universiti teknikal malaysia universiti teknikal malaysia melaka . design improvement of solar grass

Download UNIVERSITI TEKNIKAL MALAYSIA UNIVERSITI TEKNIKAL MALAYSIA MELAKA . DESIGN IMPROVEMENT OF SOLAR GRASS

Post on 02-Jan-2020

0 views

Category:

Documents

0 download

Embed Size (px)

TRANSCRIPT

  • UNIVERSITI TEKNIKAL MALAYSIA MELAKA

    DESIGN IMPROVEMENT OF SOLAR GRASS CUTTER USING DFMA METHODOLOGY

    Thesis submitted in accordance with requirement of the Universiti Teknikal Malaysia

    Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

    (Manufacturing Design) with Honours.

    by

    ISMAIL BIN RASHID

    FACULTY OF MANUFACTURING ENGINEERING

    2011

  • i

    ABSTRACT

    This project describe about the implementation of redesign the solar grass cutter by

    using the application of Design for Manufacturing and Assembly (DFMA)

    methodology. The scope based on the existing solar grass cutter and the appropriate

    of DFMA methodology. The method used for gaining the data is from the resembled

    the existing solar grass cutter. From the data achieved, it can be classified into

    several categories to be studied. Data would be analyzed by using Lucas Hull method

    to verify the design efficiency, handling ratio and fitting ratio to achieve. The tools

    that used is TeamSET software. The new proposed design of solar grass cutter

    drawn by using SolidWorks software based on TeamSET result achieved. Result

    shown that the design efficiency for new design solar grass cutter obtained better

    percentage rather than the existing design. From the study, the total part, handling

    ratio, fitting ratio and cost of existing design is reduced. Eventually, the improvement

    of new design solar grass cutter finally will be able to meet user requirements and

    satisfactions.

  • ii

    ABSTRAK

    Projek ini menghuraikan tentang pelaksanaan dalam mereka bentuk semula mesin

    pemotong rumput solar dengan menggunakan aplikasi perisian DFMA (Design for

    Manufacturing and Assembly). Skop projek adalah memfokuskan mesin pemotong

    rumput solar yang sedia ada dan sesuai dengan kaedah DFMA. Kaedah yang di

    gunakan untuk memperoleh data ialah dengan menganalisis mesin pemotong rumput

    solar yang sedia ada. Data yang diperoleh dapat diklasifikasikan ke dalam beberapa

    kategori untuk dikaji. Data dianalisis dengan menggunakan kaedah Lucas Hull bagi

    menentukan kecekapan reka bentuk, nisbah pengendalian dan nisbah perhimpunan

    sebagai pencapaian objektif projek. Perkakas perisian yang digunakan ialah perisian

    TeamSET. Reka bentuk mesin pemotong rumput baru di lukis dengan menggunakan

    perisian SolidWorks berdasarkan hasil yang didapati dari analisis TeamSET.

    Keputusan yang di peroleh membuktikan yang kecekapan reka bentuk untuk mesin

    pemotong rumput yang direka bentuk semula memperolehi peratusan lebih baik

    daripada reka bentuk yang sedia ada. Daripada kajian itu, jumlah bahagian, nisbah

    pengendalian, nisbah perhimpunan dan kos reka bentuk juga dapat dikurangkan.

    Akhirnya, peningkatan mesin pemotong rumput baru ini dapat memenuhi keperluan

    dan kepuasan pengguna.

  • iii

    DEDICATION

    To my beloved Mum

    Rahimah Binti Abdul Rahman

    To my beloved wife

    Hasaniah Binti Yahya

    For the rest of the families, my brothers and sisters,

    Thanks for your encouragement, support and motivation.

  • iv

    ACKNOWLEDGEMENTS

    Bismillahirrahmaanirrahiim…

    Alhamdullilah, grateful to Allah for giving me the strength to finish this final year

    project completely beside gaining valuable experiences and knowledge throughout

    completing this thesis, this experiences and knowledge may assist me to develop my

    personal skill in the future.

    Special thanks are addressed to my supervisor, En Taufik for his guidance, advices, idea,

    and his patience to me in accomplishing this project, a special debt of gratitude towards

    him. To my beloved mother, brothers and sisters, and my wife, thank you so much.

    Without their continue support and encouragement, I could not have gone further than

    where I have. Not forgetting En. Zolkarnain Bin Marjom and my friends for their help,

    co-operation, opinion and advice.

    Lastly to the names that I forgot to mention, you know who you are, thank you so much

    from the bottom of my heart.

    May Allah repay all your kindness…

  • v

    TABLE OF CONTENTS

    ABSTRACT i

    ABSTRAK ii

    DEDICATION iii

    ACKNOWLEDGEMENT iv

    TABLE OF CONTENTS v

    LIST OF TABLE viii

    LIST OF FIGURE ix

    LIST OF EQUATION x

    LIST OF ABBREVIATIONS xi

    CHAPTER 1 INTRODUCTION

    1.1 Project background 1

    1.2 Problem statements 2

    1.3 Objectives of the project 3

    1.4 Scopes of the project 3

    CHAPTER 2 LTERATURE REVIEW

    2.1 Introduction 4

    2.2 Designs for Assembly (DFA) Overview 5

    2.3 Drives for DFA Implementation 6

    2.3.1 Global market changes 6

    2.3.2 Consequences of component oriented design 7

    2.4 Assembly Methods and Processes 8

    2.4.1 Manual assembly 8

    2.4.2 Automated Assembly 9

    2.4.2.1 Automatic /Dedicated Assembly 9

    2.4.2.2 Robotic /Flexible Assembly 10

  • vi

    2.5 Lucas Hull DFA Method 10

    2.6 Designs for Assembly (DFA) Guideline 14

    2.7 Solar cell (Photovoltaic, PV) 15

    2.14.1 History of Photovoltaic (PV) 16

    2.14.2 Environmental Benefits of PV 17

    CHAPTER 3 METHODOLOGY

    3.1 Introduction 18

    3.2 Methodology 18

    3.3 Project Planning 19

    3.3.1 Gantt Chart 20

    3.4 Project Flowchart 21

    3.4.1 The detailed explanations of the flowchart 23

    CHAPTER 4 RESULT AND ANALYSIS

    4.1 Introduction of analysis 28

    4.2 Draw design using SolidWork software 29

    4.2.1 Detail drawing of existing design 29

    4.2.2 Detail drawing of redesign 30

    4.3 Analysis using TeamSET software 31

    4.3.1 DFA analysis for existing design 32

    4.3.1.1 Flow chart of existing design 33

    4.3.1.2 Flow chart of handling part existing design 34

    4.3.1.3 Flow chart of main part existing design 35

    4.3.1.4 TeamSET analysis for existing design 36

    4.3.2 DFA analysis for redesign 37

    4.3.2.1 Flow chart of redesign 38

    4.3.2.2 Flow chart of handling part redesign 38

    4.3.2.3 Flow chart of main part redesigns 39

    4.3.2.4 TeamSET analysis for existing design 40

  • vii

    4.4 Material and process selection 41

    4.4.1 Container box 41

    4.4.2 Strap 42

    4.4.3 Blade 43

    CHAPTER 5 DISCUSSION

    5.1 Comparison of existing design with redesign 44

    5.2 Safeguard for prevent from heating 46

    CHAPTER 5 CONCLUSION AND FUTURE WORKS

    6.1 Conclusion 47

    6.2 Future works 48

    REFERENCES 49

    APPENDICES

    Appendix A 51

    Appendix B 54

  • viii

    LIST OF TABLES

    3.1 : Gantt Chart 20

    3.2 : Example of table for nine dimensions of quality 27

    4.1 : Quantity list of existing design 31

    4.2 : Quantity list of a redesign 37

    5.1 : Comparison of existing design with redesign 45

  • ix

    LIST OF FIGURE

    2.1 : Design Changes vs. Cost 6

    2.2 : Cost comparison between different assembly methods relative with

    volume of production 8

    2.3 : Annual production volume for each type assembled 9

    2.4 : Example of assembly sequence flow chart 11

    2.5 : Nine questions for consideration on an example part 12

    2.6 : Photovoltaic cell 16

    3.1 : Flowchart for research methodology 22

    3.2 : Exploded drawing existing product 24

    3.3 : Detailed drawing existing product 24

    4.1 : View of existing design 29

    4.2 : View of redesign 30

    4.3 : A flow chart of existing design 33

    4.4 : A flow chart of handling part existing design 34

    4.5 : A flow chart of main part existing design 35

    4.6 : TeamSET analysis for existing design 36

    4.7 : A flow chart of redesign 38

    4.8 : A flow chart of handling part redesign 38

    4.9 : A flow chart of main part redesign 39

    4.10 : TeamSET analysis for redesign 40

    4.11 : Drawing of container box 41

    4.12 : Drawing of strap 42

    4.13 : Drawing of blade 43

    5.1 : Part for safeguard 46

    6.1 : Shows the comparison between existing product and redesign 47

  • x

    LIST OF EQUATION

    1 : Design Efficiency 12

    2 : Handling Ratio 14

Recommended

View more >