How can you reduce assembly time by minimizing the number of parts in a product?

1 Design for assembly (DFA)

Design for assembly (DFA) is a methodology that aims to optimize the design of a product for easy and efficient assembly. DFA involves analyzing the function, geometry, and material of each part, and eliminating, combining, or simplifying them whenever possible. DFA also considers the assembly sequence, orientation, alignment, and handling of the parts, and strives to reduce the number of tools, fasteners, and operations required. By applying DFA principles, you can reduce the assembly time and cost, as well as the weight, size, and complexity of the product.

3 Benefits of reducing parts

Reducing the number of parts in a product has many benefits for both the designer and the customer. For instance, fewer parts lead to faster and easier assembly, lower manufacturing costs, higher reliability and performance, and greater customer satisfaction. This is because fewer parts mean less time and effort spent on assembling, inspecting, and testing the product, as well as less material, inventory, transportation, and labor costs. In addition, fewer parts result in less friction, wear, noise, vibration, and failure points, as well as better fit, function, and aesthetics. Ultimately, fewer parts mean less maintenance, repair, and replacement costs for customers as well as more user-friendly, ergonomic, and safe products.

4 Challenges of reducing parts

Reducing the number of parts in a product is not always easy or feasible. There may be trade-offs between part count and other design criteria, such as potentially compromising the functionality, performance, or quality of the product, or increasing the difficulty or cost of manufacturing or disassembly. Additionally, constraints from existing designs or standards may limit the number of parts. Resistance from stakeholders is another challenge to consider, as customers, suppliers, and manufacturers may have different preferences, expectations, or incentives.

5 Tips and techniques for reducing parts

Reducing the number of parts in a product requires a variety of tips and techniques, depending on the type, function, and context of the product. For instance, you can eliminate any part that does not contribute to the product’s function, performance, or quality. Additionally, you could combine multiple parts that have similar or complementary functions, geometries, or materials. Alternatively, you can simplify complex parts by reducing their shape, size, or detail. Standardizing similar parts and minimizing fasteners are also viable options. You can use fewer or simpler fasteners such as screws, bolts, nuts, washers, pins, clips, or rivets; or replace them with snap-fits, press-fits, hinges, tabs, or slots.

6 Examples of reducing parts

To illustrate how to reduce the number of parts in a product, here are some examples of products that have been redesigned with fewer parts, and the results they achieved. A hand dryer, for instance, was reduced from 17 parts to 4 parts, reducing the assembly time from 10 minutes to 30 seconds and the manufacturing cost by 40%. Similarly, a bicycle was redesigned with 19 parts instead of 42, cutting the assembly time from 2 hours to 15 minutes and reducing the weight by 30%. Additionally, a coffee maker was reduced from 68 parts to 12 parts, resulting in a 3-minute assembly time and a 50% reduction in energy consumption.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?