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Assembly Automation and Product Design Second Edition MANUFACTURING ENGINEERING AND MATERIALS PROCESSING A Series of Reference Books and Textbooks SERIES EDITOR Geoffrey Boothroyd Boothroyd Dewhurst, Inc. Wakefield, Rhode Island 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Computers in Manufacturing, U. Rembold, M. Seth, and J. S. Weinstein Cold Rolling of Steel, William L. Roberts Strengthening of Ceramics: Treatments, Tests, and Design Applications, Harry P. Kirchner Metal Forming: The Application of Limit Analysis, Betzalel Avitzur Improving Productivity by Classification, Coding, and Data Base Standardization: The Key to Maximizing CAD/CAM and Group Technology, William F. Hyde Automatic Assembly, Geoffrey Boothroyd, Corrado Poli, and Laurence E. Murch Manufacturing Engineering Processes, Leo Alting Modern Ceramic Engineering: Properties, Processing, and Use in Design, David W. Richerson Interface Technology for Computer-Controlled Manufacturing Processes, Ulrich Rembold, Karl Armbruster, and Wolfgang Ülzmann Hot Rolling of Steel, William L. Roberts Adhesives in Manufacturing, edited by Gerald L. Schneberger Understanding the Manufacturing Process: Key to Successful CAD/CAM Implementation, Joseph Harrington, Jr. Industrial Materials Science and Engineering, edited by Lawrence E. Murr Lubricants and Lubrication in Metalworking Operations, Elliot S. Nachtman and Serope Kalpakjian Manufacturing Engineering: An Introduction to the Basic Functions, John P. Tanner Computer-Integrated Manufacturing Technology and Systems, Ulrich Rembold, Christian Blume, and Ruediger Dillman Connections in Electronic Assemblies, Anthony J. Bilotta Automation for Press Feed Operations: Applications and Economics, Edward Walker 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Nontraditional Manufacturing Processes, Gary F. Benedict Programmable Controllers for Factory Automation, David G. Johnson Printed Circuit Assembly Manufacturing, Fred W. Kear Manufacturing High Technology Handbook, edited by Donatas Tijunelis and Keith E. McKee Factory Information Systems: Design and Implementation for CIM Management and Control, John Gaylord Flat Processing of Steel, William L. Roberts Soldering for Electronic Assemblies, Leo P. Lambert Flexible Manufacturing Systems in Practice: Applications, Design, and Simulation, Joseph Talavage and Roger G. Hannam Flexible Manufacturing Systems: Benefits for the Low Inventory Factory, John E. Lenz Fundamentals of Machining and Machine Tools: Second Edition, Geoffrey Boothroyd and Winston A. Knight Computer-Automated Process Planning for World-Class Manufacturing, James Nolen Steel-Rolling Technology: Theory and Practice, Vladimir B. Ginzburg Computer Integrated Electronics Manufacturing and Testing, Jack Arabian In-Process Measurement and Control, Stephan D. Murphy Assembly Line Design: Methodology and Applications, We-Min Chow Robot Technology and Applications, edited by Ulrich Rembold Mechanical Deburring and Surface Finishing Technology, Alfred F. Scheider Manufacturing Engineering: An Introduction to the Basic Functions, Second Edition, Revised and Expanded, John P. Tanner Assembly Automation and Product Design, Geoffrey Boothroyd Hybrid Assemblies and Multichip Modules, Fred W. Kear High-Quality Steel Rolling: Theory and Practice, Vladimir B. Ginzburg Manufacturing Engineering Processes: Second Edition, Revised and Expanded, Leo Alting Metalworking Fluids, edited by Jerry P. Byers Coordinate Measuring Machines and Systems, edited by John A. Bosch Arc Welding Automation, Howard B. Cary Facilities Planning and Materials Handling: Methods and Requirements, Vijay S. Sheth 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. Continuous Flow Manufacturing: Quality in Design and Processes, Pierre C. Guerindon Laser Materials Processing, edited by Leonard Migliore Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Robert E. Stein Handbook of Manufacturing Engineering, edited by Jack M. Walker Metal Cutting Theory and Practice, David A. Stephenson and John S. Agapiou Manufacturing Process Design and Optimization, Robert F. Rhyder Statistical Process Control in Manufacturing Practice, Fred W. Kear Measurement of Geometric Tolerances in Manufacturing, James D. Meadows Machining of Ceramics and Composites, edited by Said Jahanmir, M. Ramulu, and Philip Koshy Introduction to Manufacturing Processes and Materials, Robert C. Creese Computer-Aided Fixture Design, Yiming (Kevin) Rong and Yaoxiang (Stephens) Zhu Understanding and Applying Machine Vision: Second Edition, Revised and Expanded, Nello Zuech Flat Rolling Fundamentals, Vladimir B. Ginzburg and Robert Ballas Product Design for Manufacture and Assembly: Second Edition, Revised and Expanded, Geoffrey Boothroyd, Peter Dewhurst, and Winston Knight Process Modeling in Composites Manufacturing, edited by Suresh G Advani and E. Murat Sozer Integrated Product Design and Manufacturing Using Geometric Dimensioning and Tolerancing, Robert Campbell Handbook of Induction Heating, edited by Valery I. Rudnev, Don Loveless, Raymond Cook and Micah Black Re-Engineering the Manufacturing System: Applying the Theory of Constraints, Second Edition, Robert Stein Manufacturing: Design, Production, Automation, and Integration, Beno Benhabib Rod and Bar Rolling: Theory and Applications, Youngseog Lee Metallurgical Design of Flat Rolled Steels, Vladimir B. Ginzburg Assembly Automation and Product Design: Second Edition, Geoffrey Boothroyd Assembly Automation and Product Design Second Edition Geoffrey Boothroyd Boothroyd Dewhurst, Inc. Wakefield, Rhode Island Boca Raton London New York Singapore A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the academic division of T&F Informa plc. Published in 2005 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2005 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S. Government works Printed in the United States of America on acid-free paper 10 9 8 7 6 5 4 3 2 1 International Standard Book Number-10: 1-57444-643-6 (Hardcover) International Standard Book Number-13: 978-1-57444-643-2 (Hardcover) Library of Congress Card Number 2005041949 This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data Boothroyd, G. (Geoffrey), 1932Assembly automation and product design / Geoffrey Boothroyd. -- 2nd ed. p. cm. -- (Manufacturing engineering and materials processing ; 66) Includes bibliographical references and index. ISBN 1-57444-643-6 (alk. paper) 1. Assembly-line methods--Automation. I. Assembling machines. I. Title. II. Series TS178.4.B66 2005 670.42'7--dc22 2005041949 Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com Taylor & Francis Group is the Academic Division of T&F Informa plc. and the CRC Press Web site at http://www.crcpress.com Preface Portions of this book are based on a book published in 1968 under the title Mechanized Assembly by G. Boothroyd and A.H. Redford. In a later further edition, titled Automatic Assembly by G. Boothroyd, C. Poli, and L.E. Murch, the original material developed at the University of Salford in England was updated with work carried out at the University of Massachusetts. In those days, it was felt that manufacturing engineers and designers wished to learn about automatic assembly as it appeared to provide a means of improving productivity and competitiveness. Since 1978, I developed a subject that holds much greater promise for productivity improvement and cost reduction, namely, design for assembly (DFA). The DFA method has become widely used and has helped numerous companies introduce competitive product designs. This text, therefore, includes detailed discussions of design for assembly, and the subject of assembly automation is considered in parallel with that of product design. The first step in considering automation of assembly should be careful analysis of the product design for ease of automatic assembly. In addition, analysis of the product for ease of manual assembly should be carried out in order to provide the basis for economic comparisons of automation. Indeed, it is often found that if a product is designed appropriately, manual assembly is so inexpensive that automation cannot be justified. Thus, a whole chapter is devoted to design for manual assembly. Another chapter is devoted to design for high-speed automatic and robot assembly, and a third chapter deals with electronics assembly. This second edition includes, as an appendix, the popular Handbook of Feeding and Orienting Techniques for Small Parts published at the University of Massachusetts. This edition also includes the original data and coding systems for product design for high-speed automatic and robot assembly also developed at the University of Massachusetts. Finally, numerous problems have been added and worked solutions to all the problems are available. The book is intended to appeal to manufacturing and product engineers as well as to engineering students in colleges and universities. I wish to thank Dr. A.H. Redford for his kind permission to use material published in our original book, Mechanized Assembly, and to Drs. C.R. Poli and L.E. Murch for permission to include much of the material from the Handbook of Feeding and Orienting Techniques for Small Parts, which we coauthored. Finally, thanks go to Dr. P. Dewhurst for his contributions to our work on product design for robot assembly. Geoffrey Boothroyd The Author Geoffrey Boothroyd is Professor Emeritus of Industrial and Manufacturing Engineering at the University of Rhode Island in Kingston. The author or coauthor of more than 100 journal articles, he is also the coauthor or coeditor of several books, including Fundamentals of Machining and Machine Tools, Second Edition (with W.A. Knight), Automatic Assembly (with C. Poli and L.E. Murch), and Applied Engineering Mechanics (with C. Poli) (all titles published by Marcel Dekker.). Additionally, Professor Boothroyd serves as coeditor for the Taylor & Francis series Manufacturing Engineering and Materials Processing. A Fellow of the Society of Manufacturing Engineers, he is a member of the National Academy of Engineering, among other professional societies. Professor Boothroyd received Ph.D. (1962) and D.Sc. (1974) degrees in engineering from the University of London, England. His numerous honors and awards include the National Medal of Technology and the SME/ASME Merchant Medal.