Product manufacturability indicators are the most important component in assessing the quality characteristics of products, designs, parts, and so on. They allow you to create a comprehensive description of the effectiveness of technological products regarding the adaptability of the design to its use in specific conditions, for example, in production.
TKI: concept and features
The provisions that characterize the essence, content, composition and norms used in the selection of TCI, determine the standards of the Unified system of technological preparation of production. Today, testing of mechanisms for manufacturability is included in the wide functionality of technological preparation of production, which is provided and carried out at all stages of design preparation.
Indicators of manufacturability: GOST
According to GOST 14.205-83, TKI is nothing more than a set of those product design characteristics that are manifested in the ability to optimize resource (time, material, labor and other) costs in the process of production preparation in technical terms, manufacturing, further use and repair of structures in certain conditions related to organizational and technical.
Types of indicators
Technological indicators characterize the quality of structures, parts and other mechanisms. To date, seven varieties of these indicators are distinguished. It is advisable to consider them in more detail.
Indicators of technological rationality characterize the level of optimality of the structure and composition of the manufacture of parts, approved structural materials and shapes. We are talking about such factors as the complexity of the design of the product; her team; easily removable components; the availability of service points, the implementation of repairs; suitability; the balance of the parts during installation outside the company that is the manufacturer.
Succession Indicators
There is such an indicator of technological design as continuity. It defines both the technological and constructive continuity of the mechanism, the repeatability and variability of its components, as well as the structural parts of the product and relevant materials. Here, the novelty coefficients of the mechanism should be calculated; the use of unified structural components, for example, holes, threads and so on; repeatability and applicability of the material in the mechanism; repeatability of structural components and others.
Resource intensity and production processability
There are indicators of the manufacturability of the part that characterize the resource intensity (both private and complex). The first variety should include material consumption, labor intensity, energy intensity. The presented indicators determine labor costs, material, energy, time. All of them go to the creation and further operation of the mechanism.
Indicators of manufacturability of production determine the complexity of the mechanism in the production preparation of the technical plan, the complexity of the creation and installation of the product, the intensity of the creation, the energy intensity of the creation of the mechanism, the duration of this creation, the technological s / s of the mechanism in manufacture.
Performance Indicators
Another basic indicator of manufacturability depends on operating conditions. It is advisable to include the complexity of the mechanism under operating conditions; its complexity during maintenance, installation and dismantling; utilization complexity; material consumption of the mechanism in operational conditions; energy intensity in operating conditions; duration of maintenance; technological s / s in operation.
Indicators of general and repair manufacturability
The indicators of manufacturability in the repair plan determine the material consumption, the complexity and, of course, the energy consumption during repair work, the duration of these works, technological s / s.
As for indicators of general manufacturability, we are talking about a characteristic of the manufacturability of the mechanism in accordance with all stages of the life cycle. This includes the specific laboriousness of the structure, specific energy consumption and material consumption, specific technological s / s of a part or mechanism.
It should be noted that the use of specific indicators of manufacturability takes place when it is necessary to ensure comparability of characteristics and indicators of products of the same type. Such designs, as a rule, have different values of key parameters or implement different coefficient of utility.
Indicators by the number of properties
In accordance with the number of characteristics used, complex indicators of manufacturability, single (in other words, private) and group indicators are distinguished. Individuals describe one property, complex ones - several at once. Based on the totality of the presented types of indicators, it is customary to determine the quality of the structure.
Assessment Methods
We examined the calculation of technological indicators and their types. So it's time to start the assessment methods. The final decision regarding the choice of the most rational design option from among the possible is made solely on the basis of the quantitative assessment of manufacturability.
The most common and currently used methods are absolute assessment, relative and differential. The absolute indicator is calculated as K = (K (1) ... K (n). The relative manufacturability indicator can be calculated as K (v) = K / K (c).
It should be borne in mind that a qualitative assessment is based on engineering-visual techniques. It is carried out according to the technological and structural properties separately. That is why it is important to achieve the maximum level of TI. Qualitative assessment, as a rule, is made before quantitative. However, the methods are allowed to combine, which today is widely used in practice.
A qualitative assessment can be presented as “good” or “bad”, “possible” or “impossible”, in other words, the basis here is the analysis of the design for compliance with generally accepted standards and requirements. Recently, such a mechanism of qualitative characterization of technological and structural properties as the intensity scale has been used. That is, the transition to the assessment of quantity is made through the introduction of points.
Conditions to be provided
Having fully considered the types of indicators of product manufacturability and methods for their assessment, we can proceed to the main conclusions. After testing the product for manufacturability, one way or another, a number of conditions must be provided:
- As low as possible s / s and labor intensity regarding the manufacture of the product, structure or part.
- The lowest possible level of labor input and prices for repair work and product maintenance.
- The lowest possible level of material consumption of the structure, product.
It is important to note that today the issue of accuracy is an urgent issue. When solving it, the technologist is obliged to fully ensure the accuracy of manufacturing products that are required by the designer, and high profitability, productivity. The issue is quite sensitive, which is why modern manufacturers strive to recruit decent staff and constantly train him. Often, the accuracy of the product is achieved in one of two ways, which are fundamentally different from each other. The first of them involves trial measurements and passes, the second - automatic sizing through the use of customized machines. Naturally, in modern production, the second technique is increasingly used. The world is committed to automation.
Activities to improve manufacturability
In order for the manufacturability of the product, product or design to be as high as possible, it is necessary to plan and implement a number of measures, including:
- Increasing the serialization of products, products or their components through unification, standardization, as well as grouping in accordance with the design properties.
- The relative limitation of the nomenclature of the components of the product and the materials used.
- The use of those constructive techniques that are considered already mastered in production.
- Use of the most effective technological processes, as well as standard tools of technological equipment.
- The use of rational brands of materials.
- The use of rational grades of materials.
- The development and subsequent application of progressive design ideas that increase the accuracy of workpieces and use (at best) waste-free technology. Here we can talk about minimizing waste.
- The use of advanced techniques in order to make component products stronger.
- The use of those safety margins of mechanisms that are scientifically sound, as well as standard methods for calculating and testing products.
- Increasing the level of accessibility, suitability for control, ease of removability (if necessary), prefabrication, interchangeability, as well as product recovery.
- Limit the interchangeability of the components of a product as a result of repair work or maintenance.
- Limitation of requirements regarding the qualifications of employees performing repair work and structural maintenance.
Currently, an assessment of how technologically advanced a product is based on three types of indicators. Let's consider them in more detail. Firstly, these are the basic indicators of manufacturability. Their values are mandatory regulated by the corresponding directive papers on the product. Secondly, the performance of the designed product. They are achieved by testing the design, mechanism or products for manufacturability. Thirdly, indicators of the degree of manufacturability of the product, the values of which are regulated today by the corresponding policy papers that determine the production of the product.
It should be remembered that the variety of assessment is the most important factor that describes the methodology for comparing product options and the reasonable choice of the most optimal option among many others similar to the one chosen.