Tesis doctoral de Gabriela Estrada Cadena
The main hypothesis of this research is that it is possible to prevent assembly failures or defects in products since early stages of product design; based on common practices observed in industries and literature, assembly issues are commonly eliminated until they are experienced in later stages such as manufacturing process and operation of product when manufacturing process, machines, equipment, tooling etc were already defined and implemented. assembly failures are efficiently eliminated by using poka-yoke or error-proofing technique. This work proposes to develop poka-yoke design requirements and comply with them since early product design stages in order to designs features to prevent assembly failures. This approach makes designers to think in poka-yoke solutions when they are designing the product by first time, this practice helps to prevent later redesigns. this research respond to these questions -¿it is possible to design the product in a poka-yoke way since early designs stages, in order to prevent redesigns in later stages?; How can be possible to anticipate to potential assembly issues before they occur and how designers can think and develop poka-yoke design solutions?. It is possible to capture knowledge from different designers about poka-yoke design solutions in order to use them in future new product development projects? this thesis propose solutions for these questions, the first activity was to investigate in literature, industries and assembly issues posted in recall web pages to collect the greater quantity of assembly issues and classify them based in the life system phase where they occur. the different assembly issues were analyzed in order to know the causes associated to product design that influences the occurrence of these issues. Eleven design characteristics in a product referred as cx were identified. the analysis of design characteristics- cx that influence the occurrence of assembly issues in addition with the examples reviewed about design solutions helped to figure out how designers can design products since early design stages oriented to prevent assembly issues. To comply with this purpose seventeen poka-yoke assembly design requirements referred as rx were defined. after develop the poka-yoke assembly design requirements it was proposed a new dfx called design for poka-yoke assembly. , this approach consisted in four parts: i) product design method for poka-yoke assembly-dfpya. ii) dfpya as part of design process. iii) dfpya method to evaluate rx priorities. iv) moka methodology to capture dfpya knowledge. these four parts of dfpya methodology were programmed in ms access software this program works as a guide to designers during each design stage in order to implement dfpya in a new product development project. the program starts with two options: i) dfpya new product: it was designed to be used since task clarification stage; this option starts asking several questions to designers in order to identify potential assembly issues that could occurs in the new product being developed; after response questions a dfpya matrix is automatically generated, this matrix indicates the connections among dfpya clusters such as: ax-assembly issues, rx-poka-yoke requirements, sx-system phases, dx-design stages and tx-type of design decisions. ii) dfpya product redesign. In this option icare forms are captured in dfpya knowledge management then based on this knowledge captured; designers can access to dfpya product redesign and select which specific assembly issues they desire to prevent in a product. dfpya software was used in a case study in an industry that develops and manufactures mechanical products. The results of case study show that dfpya helped to identify ten potential assembly issues which were prevented by designing the product in a poka-yoke way.
Datos académicos de la tesis doctoral «Design strategies oriented to prevent product assembly failures. a methodology to design for poka-yoke assembly-dfpya«
- Título de la tesis: Design strategies oriented to prevent product assembly failures. a methodology to design for poka-yoke assembly-dfpya
- Autor: Gabriela Estrada Cadena
- Universidad: Politécnica de catalunya
- Fecha de lectura de la tesis: 28/07/2010
Dirección y tribunal
- Director de la tesis
- Joaquim Lloveras Macia
- Tribunal
- Presidente del tribunal: fernando Romero subiron
- ricard Gonzalez cinca (vocal)
- (vocal)
- (vocal)