The Significant Improvement on The Design of Pedestrian Traffic Light Using Boothroyd Dewhurst Design for Assembly (DFA) Method: A Case Study

M. N. Ahmad; N. Adeera; M. H. Osman Mazran; M. Khalid

Authors

M. N. Ahmad Department of Manufacturing Engineering Technology, Faculty of Engineering Teknologi Universiti Teknikal Malaysia Melaka, 76100 Melaka, Malaysia.
N. Adeera Department of Manufacturing Engineering Technology, Faculty of Engineering Teknologi Universiti Teknikal Malaysia Melaka, 76100 Melaka, Malaysia.
M. H. Osman Mazran Department of Manufacturing Engineering Technology, Faculty of Engineering Teknologi Universiti Teknikal Malaysia Melaka, 76100 Melaka, Malaysia.
M. Khalid Department of Manufacturing Engineering Technology, Faculty of Engineering Teknologi Universiti Teknikal Malaysia Melaka, 76100 Melaka, Malaysia.

Keywords:

Design for Assembly (DFA), cost reduction, Boothroyd Dewhurst, assembly time

Abstract

Design for Assembly (DFA) is a tool for the industry to minimize the assembly cost by optimizing the assembly process and reducing the number of parts. In this paper, the pedestrian traffic lights from PPK Technology Sdn Bhd are selected as the case study sample. The Boothroyd Dewhurst DFA method is used to improve the design and reduce the cost of the pedestrian traffic lights. The Solidworks software is used to generate the CAD models, which are further analyzed using the Boothroyd Dewhurst DFA software tool. The result from this study shows that the assembly time decreased from 758.45 seconds to 318.80 seconds per product. The significant result shows that the assembly cost reduction is from RM1175.60 to RM207.20. From the result, it has been proven that this Boothroyd Dewhurst DFA method was able to improve the design in terms of design efficiency, product assembly time, and cost reduction. This method can be applied in the manufacturing industry in order to improve their design effectiveness.