Design for Manufacturing Assembly of Electric Scooter

Conducted an extensive literature review focusing on electric scooters and their components, identifying areas for redesign using Design for Manufacture and Assembly (DFMA) principles.

Applied DFMA principles to redesign key components of the electric scooter, including the Deck, Stand, Handle Gripper, Mudguard, Wheel Rim, Brake Lever, Brake Disc, Brake Calipers, Handle, and Forks.

For each of the above components, redesigned models were created using SolidWorks. Functional parameter verification was conducted through finite element analysis (FEA).

Material selection for each part was carried out using Ansys Granta. The optimal materials were chosen based on their performance, cost-effectiveness, and suitability for the manufacturing process. The selected materials offer advantages over previous options, such as lower cost per part and enhanced manufacturability.

Ansys Granta was also utilized to determine the best manufacturing processes for each part, ensuring efficiency and cost savings compared to prior methods.

A part cost estimator was employed to calculate price variations for production runs ranging from 0 to 100,000 units.

The total assembly time for each part of the scooter was calculated, considering insertion time, handling time, and inspection time. The total assembly time was approximately 402 seconds (around 6 minutes and 42 seconds), as determined using DFMA formulas from the "Product Design for Manufacture and Assembly" book.

A Bill of Materials (BOM) was created for all parts used in the electric scooter, and the assembly cost was calculated based on the time required for assembly.

The total production cost for one electric scooter was determined to be $186.51. This figure was derived by summing the part cost, handling cost, insertion cost, and inspection cost. Compared to a selling price of $440, the difference accounts for profit margins and supply chain considerations in the manufacturing process.

Project Report