Boothroyd-Dewhurst yaklaşımı ile beyaz eşyalar için hata çözümleme cihazının montaja uygun tasarımı
Design for assembly implementation of error analysis device for white goods with Boothroyd-Dewhurst approach
Yazar: MEHMET TAYLAN ÇELİK
Danışman: YRD. DOÇ. DR. ZEYNEP PARLAR
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Makine Mühendisliği Ana Bilim Dalı / Konstrüksiyon Bilim Dalı
Derece: Yüksek Lisans, 2017
Konu: Makine Mühendisliği = Mechanical Engineering ; Mühendislik Bilimleri = Engineering Sciences

Özet:
Labaratuvar donanımları bilimsel deneylerin yanında, evlerimizde de kullanılan, belirli verileri ölçmek ve değerlendirmek amacıyla üretilen donanımlara evrilerek kullanım yelpazesini genişletmiştir. Beyaz eşya üreticileri de söz konusu bu donanımları üretim aşamasındaki testlerin yanı sıra satış sonrası hizmetlerde de kullanmaya başlamışlardır. Arçelik A.Ş. bünyesinde de laboratuvar donanımları standartlarına tabii ölçüm cihazları satış sonrası hizmetlerde kullanılmaktadır. Çalışma öncesi durumda servis teknisyenleri hata çözümlemesi için birden fazla cihaz kullanmakta ve müşterinin evine en az üç kere giderek problemi teşhis edebilmektedir. Çalışma kapsamında gözlemlenen bu probleme yönelik bir hata çözümleme cihazı tasarımı seri üretime uygun bir şekilde montaja uygun tasarım esaslarıyla gerçekleştirilmiştir.
Bahse konu hata çözümleme cihazlarının kullanım amaçları birbirinden farklıdır. Beyaz eşya enerji ölçümü, sıcaklık-zaman grafiğinin elde edilmesi, voltaj/akım/güç- zaman grafiklerinin elde edilmesi bu cihazların kullanım amaçları arasında gösterilebilir. Gerekli teknik değerlerin okunması sonucunda hataların çözümlenebilmesi, buna bağlı olarak üretim ve araştırma geliştirme departmanlarına geri bildirimler verilmesi mümkün hale gelmektedir. Üretim adetlerinin yüksek sayılara ulaştığı ve servis hizmetinin kalitesinin bu denli önem kazandığı günümüzde servis teknisyenlerinin kullandığı cihazlar görüldüğünden çok daha önemli bir pozisyonda bulunmaktadır. Sunulan çalışmada beyaz eşya ürün grubunda yetkili servislerin kullanacağı çok amaçlı bir cihazın geliştirilmesi incelenmiş ve seri üretime uygun olacak şekilde yapısal tasarımı tamamlanmıştır.
Tasarım aşamasında öncelikle bir piyasa araştırması gerçekleştirilmiş işlevsel olarak benzer ürünler incelenmiş, bu işlevlerden hangilerinin cihazda kullanılacağına karar verilmiştir. Bunun yanında hem bu cihazlar hem de benzer kart tutucu yapılara sahip elemanlar yapısal olarak incelenmiş ortaya çıkan problemlere nasıl yaklaşıldığı anlaşılmıştır. Bu aşamadan sonra tasarım kriterlerinin belirlenmesine geçilmiştir. Tasarım kriterleri söz konusu çalışma için oldukça fazla önem arz etmektedir. Bunun sebebi cihazın tabii olduğu standartları harfiyen sağlaması gerekliliği ve cihazdaki komponentlerin tasarımının cihazın performansına doğrudan etki etmesidir. Bu bağlamda cihadaz elektriksel ve yangın standartları kapsamında nasıl yapılar bulunması gerektiğine karar verilmiş ve ışık taşıyıcı parçalar tasarlanmış anten doğrutuları bu tasarım kriterlerine göre belirlenmiştir.
Tasarım kriterlerinin belirlenmesinin ardından elektromekanik komponentler ve kartlar tanımlanmıştır. Bu parçaların cihazla birleştirilebilmesi adına nasıl yapılar olması gerektiğine karar verilmiş yapılar gerek tasarım kriterlerine gerekse estetik kaygılara uygun olarak tasarlanmıştır. Bunun sonucunda seri üretim projesi olan ürünün oldukça fazla parça barındırdığı dikkat çekmiştir. Bu bağlamda montaja uygun tasarım yapma gerekliliği ortaya çıkmıştır. Tasarlanan yapıların kaç parçada birleştirilebileceği irdelenmiş belirli bir konsept tasarım ortaya atılmıştır.
Konsept tasarım aşamasında ortaya çıkan plastik parça ve komponent sayısının oldukça fazla olduğu görülmüştür. Seri üretim maliyetlerinin yüksek olması sebebiyle
bu parçalarda azaltmaya gitmek ve montaj kolaylığı sağlayabilmek amacıyla Bootroyd Dewhurst yaklaşımı esas alınmıştır. Bu yaklaşım kapsamında bir algoritma oluşturulmuştur. Her ilişki bu algoritmaya göre değerlendirilmiş ve parça azaltmaya gidilmiştir. Montaj kurgusu oluşturulurken de montaja uygun tasarım gereği montaj yönüne ve kolaylığına dikkat edilmiş tasarım düzenli olarak sorgulanmış ve revize edilmiştir. Montaja uygun tasarım uygulamasının montaj verimliliğini %12 arttırdığı ortaya çıkmıştır.
Tasarım son halini aldığında servis teknisyenlerinin hata çözümleyebilmesi için ergonomik zaman ve emek tasarrufu sağlayan, kolay montajlı ve seri üretime uygun Service Informant cihazı ortaya çıkmıştır. Cihazın gerek servis teknisyenlerinin gerekse servis hizmeti alan müşterilerin hayatını kolaylaştıracağı öngörülmektedir

Abstract:
In addition to scientific experiments, laboratory equipments has expanded the range of
usage in our homes by evolving into the equipment manufactured to measure and
evaluate technical datas of white goods. White goods manufacturers have also started
to use this equipment in after-sales services as well as in production-level tests.
Relevant various equipments are used in after sales services to understand the causes
of faults. Devices which depends on laboratory equipment standards are used in
after-sale services in Arcelik A.S. In the pre-operation case, the service technicians
are confronted with vaious difficulties related to equipments which are used for erro
analysis. There are multiple devices for measuring different values, and these devices
are carried and used separately. In addition, they can detect the problem by going to
the customer's home at least three times. The study is about design for assembly
implementation of new error analysis device for white goods.
Aims of error detection devices are various. Energy measurement, temperature-time
graph, voltage / current / power-time graphs can be shown among the purposes of these
devices. As a result of reading the necessary technical values, it is becoming possible
to solve the mistakes and give feedback to the production and research and
development departments accordingly. Nowadays, production numbers have reached
to high numbers. That is why quality of the service is so impartant. As a result ofthis,
devices which service technicians use are in more important position. The
development of a multipurpose device which the authorized services will use in the
white goods product group has been examined and the structural design has been
completed in this study.
At the design stage, functionally similar products has been explained. As a result of
this, It is decided that which functions will be used in the device, Service Informant.
Primarily, the equipments used by sercive technicians and the equivalent products of
these equipments have been examined. A temperature measuring device used to
obtain temperature-time values was examined. Evaluations are carried out on
existing or non-existing functions of them. Another device monitors the number of
opening of the door, thus determining the effect of the user on the measurement
accuracy during measurement processes. Also, the ability to remotely transfer these
informations online to service personnel has emerged with this capability. Functional
features of device have also been an important reference for new product design.
Another product that obtains time dependent graphics of voltage/power/current is a
separate device that is examined in terms of its functions likewise. Also, similar
cardholder structures have been structurally examined and it is understood how to
approach the emerging problems. After this stage, design criterias have been
decided.
The design criterias are very important for this study. The reason for this is that the
standard of the device is naturally required and the design of the components in the
device has a direct influence on the performance of the device. In this context, it has
been decided how to construct structures under electrical and fire standards, and the
light carrier parts. In addition, direction of microscript antennas create design criteria
in structural parts.
Relevant design criteria are determined by examining various standards. Standards
and tests are crucial for design as a final product. These standards which are
specified evaluate these standards, are a set of assessments that give approval to
continue on the way to the final product. The standards that have to be fitted with the
design objectives are subject to the same standards as the laboratory equipments. The
details of this standard named IEC 61010 will be mentioned in detail. The standards
can be eamined in two categories as electricity and fire standards. Electrical
standards mention the requirements for gaps and live ends in devices. The test
equipments referred to in this standard has been a reference to the details of the
design of the device and the elecetrical connections. In addition, the conditions
specified for flame sources in fire standards have a role in device design and material
selection.
There are light sources for the display group on the device. These light sources that
are located in the display group are aesthetically supporting the device, allowing
visual identification of the keys and indicators. For this reason, light carrier design
criteria have emerged for light sources that are both homogeneous and visible for
both functional purposes and aesthetic concerns.
The layout of the electronic cards in the device and the criterion for the structural
design details of the body in which they are places are antennas. The microstrip
antennas in the cards have decisive guidelines for their direction or their location.
These principles were also an important criterion for design process.
These design criteria will be taken into account at every stage that will play a major
role in the development and finalizing of the design. Since it is a series production
project, it has to provide relevant standards. However, there is a design criterion
that requires that the light carriers be functioning correctly on the interface, ensuring
that the antennas are emitted within the context of the interrelationship of the
electronic or mechanical components
Electromechanical components and cards are defined after design criteria are
determined. The constructions that have been decided on how to construct these parts
in order to be able to combine them are designed in accordance with both the design
criteria and the aesthetic concerns. Electromechanical components, cables,
electronic cards, etc. other parts are designed in accordance with the standards and
design principles. There are many design details such as electromechanical
componenet connections, electrical connections, cable insulation, non-flammabiliy
requirements, socket varying in the world. According to the electrical and fire
standards, the plastic body design and many things to be careful in assembling the
parts have to be taken into consideration likewise.
The result is that the product, which is a series production project, has a lot of
parts. In this context, it has become necessary to design for assembly implementation
Certain consept designs have been put forward in order to determine how many
pieces of designed structures can be combined. These concept designs have been
examined according to certain criteria and various evaluations have been made in
order to select the appropriate one As a result of these evaluations, concept design
has emerged.
It has been seen that the number of plastic parts and components in the concept design
phase is considerably high. Because of the high production costs, literature
revew of various assembly design approaches has been performed in order to reduce
and facilitate assembly. Design for assembly approaches; the number of parts,
suitability for ease of use and assembly, and the minimization of product cost.
Increasing the montability helps to reduce the assembly time and reduce the part
costs in production.
This design tool is very important because it is suitable for both manual assembly
and automation assemblies. The Hitachi installability evaluation methodology, the
Lucas assembly design approach and the Bootroyd Dewhurts approach are
significant samples in featured in the literature.
The Bootroyd Dewhurst approach has been taken as the basis for this purpose
between these approaches which have been investigated and evaluated. This method
is similar to the other design goals. Unlike other methods, this method finds out the
answers the questions by directing the concerns of design in the form of questions.
The answers of these questions will determine the suitability of the design for
assembly to be performed.
With this approach, a new algorithm has been developed to analyze all factors which
depends on the product spesificly. Each relation is evaluated according to this
algorithm and the number of parts are reduced. Based on the Bootroyd Dewhurst
approach, these algorithms have been prepared by directing them individually to each
parts. With this algorithm, the answrs for each parts are evaluated and a "R Table" is
executed. Depending on this table, "P, Q, T Tables" have been created and revisions
have been made in parts in accordance with the design for assembly. While the
assembly frame is being constructed, the design that is designed for assembly and the
design for ease of assembly are regularyle queried and revised. This design for
assembly implementation increases the assembly efficiency by %12.
Prototyping studies has been done not only after the design has been completed but
also to see if the solutions of the local problems can fulfill the function or to make the
change and the function can be realized. Three different technologies have been used
in this context. These technologies are FDM, SLS and Multijet technologies.When
the design is finalized, there is an ergonomic, time saving, easy-to- install and serial-
ready Service Informant device for service technicians to resolve errors easily. It is
foreseen that the service technicians of the device will facilitate the life of the
customers who need service.