Design Improvements by Using the Design for Assembly (DFA) Method in Elevator Production

Abstract

Aim The purpose of this research is to show the benefits to be obtained by redesigning production processes for small and medium-sized enterprises, which aim to grow but cannot progress due to traditional production understanding. Design & Methodology In this study, the production of semi-automatic door frames from elevator parts was investigated. First of all, a time study was applied to analyze the current process and the design efficiency value was calculated in the B&D DfA method. Then, three assembly processes were determined as the front plate, intermediate supports and head plate as the priority improvements. Finally, design improvements were made in these process steps and the design efficiency value of the door frame was calculated. The obtained design efficiency values were compared and the results were discussed. Originality The most important problem faced by small and medium-sized enterprises that want to grow is a product design and production organization. In this study, a way to solve the problems of these enterprises is shown. Findings According to the number of parts in the process groups; It has been revealed that there is 95% improvement in the front sheet, 100% improvement in intermediate supports and 64% improvement in head sheet preparation. In addition, according to the time spent in the transaction groups; Improvement (efficiency) was achieved by 79.8% in front sheet, 49.1% in spiraling, 100% in intermediate supports, 74% in head sheet preparation and 16.4% in handling operations. Conclusion In the improvement designs made within research scope, the TE value increased from 8.5% to 12.8%. Trial production of the improved design proposals presented in the research was validated.