1. Product Assembly Kit C. A. Collins

2. The Product A model assembly kit. A 1/72nd scale aircraft. Rated skill level 4 of 5. Its selection was inspired by the DFA tenets associated with assembly toys.

3. Product Assembly Drawing

4. Manual Assembly • Tools are required • Cut parts from ‘trees’ • Tweezers small parts • Glue & applicators • Paints & brushes • Magnifier glass • Speed & accuracy limited by physical skills of operators

5. Product DFA Analysis • The sum of parts totals 80 components • The product does not minimize parts • The small parts hamper assembly process • Gluing parts does not reduce skill or time • Low CAM and PAM indicate poor design

6. Product Design Changes • Design for simplicity; join fuselage & nose • Minimize small parts; probes, seats, etc. • Drop redundant parts; windshield, etc. • Snap fit parts to lessen skill and time.

7. Redesigned Assembly Drawing

8. Evaluation of the Redesign • The parts total only 18 for a 78% reduction • CAM&PAM improved to 9.69 high merits • Snap fit parts lowers skill level, lessens time • Has all DFA tenets for good assembly toys • Has improved hard assembly probability

9. Conclusions • Design the product so that it is easy to assemble manually – consequently it is highly probable that it will be easily assembled automatically. …Andreason