Part Integration can save millions of $ to global OEMs for each set of components that can be integrated. However it is important to understand its pros and cons while implementing it as a technique in Product Design. If executed well - it offers several advantages:
- Lower part weight and overall process costs
- Enhanced reliability and higher MTBF
- Reduced assembly and secondary operations time
- Reduced energy consumtion and better eco footprint
- Optimum quality and functional control
- Reduced material handling and processing
- Easier to recycle at the end of life
- For the designer and OEM it often leads to Total Cost Out
- For the toolmaker it means lowering of total tooling costs
- Finally it adds to more predictable performance, amongst other advantages
Exceptions to consider:
- Combinations of extreme functional differences
- Integrations requiring over specification of primary material
- Emerging complexity of tooling and manufacturing due to integration of components & features.
- Situations where "critical parameters" vary dramatically such as thermal variations or point loads...
- Combinations where life expectancy of parts varies
- Where servicability costs increase due to integration.
If the designers understand such considerations in the process of conceptualizing and advanced design evaluations, a great design can evolve that benefits the manufacturer and end-user alike.
"Part Integration in Design" course is available at udemy.com. The course offers detailed methods, calculators and examples of part integration techniques.
© Copyright 2018. First Published by Pradeep Chowdhary
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The full course is also available at udemy.com starting Sept, 2018.
Approx. Duration: 2 hrs.
Level: Intermediate to Advanced