Design for Manufacturing: A Guide for Elevators

Elevators are complex machines that require a blend of engineering expertise and practical manufacturing considerations. While functionality and safety are paramount, designing an elevator for efficient and cost-effective production is equally crucial for its success. This guide delves into the key principles of Design for Manufacturing (DfM) for elevators, providing valuable insights for engineers, designers, and manufacturers alike.

Principles of Design for Manufacturing (DfM)

Before diving deeper into the specifics of DfM for elevators let's have a look at the 5 key principles of DfM.

1. Process:

Choosing the right manufacturing process: Selecting the most appropriate and cost-effective manufacturing method based on the product's design and material requirements.

Streamlining the number of operations: Minimizing the number of individual steps and processes needed to manufacture the product, reducing complexity and cost.

Considering manufacturability during design: Designing the product with the chosen manufacturing process in mind, avoiding features or geometries that are difficult or expensive to produce.

2. Design:

Simplicity: Favoring simpler designs with fewer parts and features whenever possible, as complex designs often require more intricate manufacturing techniques and increase production time.

Standardization: Utilizing standardized components and materials across different product variations whenever feasible, reducing the need for custom parts and simplifying production logistics.

Modular design: Breaking down the product into smaller, self-contained modules that can be easily assembled, facilitating pre-fabrication and future upgrades.

3. Material:

Selecting readily available materials: Choosing materials that are easily obtainable, minimizing procurement lead times and potential supply chain disruptions.

Considering material properties: Understanding the properties of the chosen material, such as machinability, formability, and recyclability, to ensure compatibility with the selected manufacturing process and promote sustainable practices.

Optimizing material usage: Minimizing material waste through efficient design and fabrication techniques, reducing costs and environmental impact.

4. Assembly:

Employing simple and reliable joining methods: Utilizing well-established joining techniques like welding, bolting, or riveting, as complex assembly methods can be time-consuming and prone to errors.

Designing for ease of assembly: Ensuring components can be easily accessed and assembled, minimizing the need for specialized tools or complex handling procedures.

Considering future disassembly and maintenance: Designing the product with disassembly and future maintenance in mind, facilitating repairs and replacements when needed.

5. Testing and Quality Control:

Integrating testing throughout the process: Implementing thorough testing procedures at various stages of production to identify potential defects early on and ensure consistent quality.

Designing for testability: Designing the product to allow for easy and efficient testing of its functionality and performance.

Continuous improvement: Utilizing feedback from testing and production to refine the design and manufacturing process for future iterations, ensuring ongoing quality and cost optimization.

By adhering to these principles, designers and engineers can create products that are not only functional and reliable but also cost-effective, efficient to manufacture, and maintainable throughout their lifecycle.

Understanding DfM for Elevators

DfM is a proactive approach to product development that integrates manufacturing concerns throughout the design process. By considering manufacturing limitations and capabilities from the outset, DfM aims to:

• Reduce manufacturing costs: Simplifying designs, optimizing material usage, and minimizing assembly complexity can significantly decrease production expenses.
• Enhance product quality: DfM practices often lead to improved product quality by minimizing the risk of errors, facilitating thorough testing, and ensuring consistent production.
• Shorten lead times: Streamlining the manufacturing process through DfM can accelerate delivery times and meet customer demands efficiently.

Key DFM Considerations in Elevator Design

Now, let's explore specific DfM considerations applicable to the various components and aspects of elevator design:

1. Modular Design

Benefits: Breaking down the elevator system into smaller, standardized modules simplifies assembly, facilitates pre-fabrication in controlled environments, and allows for easier customization and future upgrades.

Examples: Standardized car frames, pre-wired control panels, and modular hoistway components promote efficient production and on-site installation.

2. Standardization of Components

Benefits: Utilizing readily available, standardized components across different elevator models reduces the need for custom parts, minimizing production complexity and cost.

Examples: Standardizing door types, motors, and control systems across various capacity and speed requirements can streamline production and improve supply chain efficiency.

3. Material Selection

Benefits: Choosing readily available, high-quality materials that are easy to fabricate, assemble, and maintain reduces production costs and simplifies maintenance processes.

Examples: Selecting pre-finished steel panels for car walls and laser-cut sheet metal for brackets can decrease fabrication time and improve material handling.

4. Joining and Assembly

Benefits: Employing simple, reliable, and well-understood joining methods like welding, bolting, and riveting minimizes assembly time, reduces the risk of errors, and facilitates on-site installation.

Examples: Utilizing standardized welding techniques for car frames and pre-drilled components for bolting simplifies assembly and ensures consistent quality.

5. Accessibility and Maintainability

Benefits: Designing elevators with easy access for maintenance and component replacement improves serviceability, reduces downtime, and minimizes lifecycle costs.

Examples: Implementing easy-to-remove access panels for control systems and readily accessible lubrication points for critical components facilitates preventative maintenance and simplifies repair processes.

6. Testing and Quality Control

Benefits: Integrating rigorous testing procedures at various stages of production ensures compliance with safety regulations, identifies potential issues early on, and leads to consistent product quality.

Examples: Implementing load testing of car frames, pre-testing of control systems, and conducting rigorous safety inspections during and after assembly ensure adherence to stringent safety standards.

Additional Considerations

Software and Control Systems: Utilizing readily available and well-established software platforms for elevator control systems streamlines development, reduces programming complexity, and facilitates easier integration with different components.

Sustainability: DfM principles can embrace sustainability by considering factors like material recyclability, energy efficiency during operation, and minimizing waste generation during production.

Conclusion

By adopting an integrated DfM approach, elevator designers and manufacturers can achieve a balance between functionality, safety, cost-effectiveness, and ease of production. Through careful consideration of the principles outlined above, elevator production can be optimized, leading to high-quality, reliable, and cost-effective products that meet market demands effectively.

It is important to note that DfM is a continuous process requiring ongoing collaboration and communication between designers, engineers, and manufacturing teams. By fostering a culture of innovation and continuous improvement, companies can ensure their elevator designs remain competitive, efficient, and deliver exceptional value throughout their lifecycle.

Resources

Free sample engineering bundle for an Elevator Balustrade with standard dimensions.

National Center for Manufacturing Science and Technology (NCMST): The NCMST website offers a wealth of resources on DfM, including case studies, best practices, and educational materials. https://www.ncms.org/

Elevator World: This industry magazine publishes articles and reports on various aspects of the elevator industry, including design, manufacturing, and technology advancements. You may find articles specific to DfM in elevator design within their archives. https://elevatorworld.com/

American Society of Mechanical Engineers (ASME): The ASME provides various resources on design and manufacturing, including standards and guidelines relevant to DfM principles. While not specific to elevators, their resources can offer valuable insights applicable to the broader context. https://www.asme.org/

International Organization for Standardization (ISO): The ISO publishes a range of standards related to design and manufacturing, including ISO 14001 for environmental management and ISO 9001 for quality management. These standards can guide DfM practices for sustainability and quality control considerations, respectively. https://www.iso.org/home.html

By exploring these resources, you can gain a deeper understanding of DfM principles and their practical applications in various industries, including the elevator sector.

*originally posted in Elevator Plans