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Low Cost Automation Tutorial

#057 Concept of Reducing Mechanical Elements (Parts Count)

Category : Hints on designing
September24, 2010

One of the means to realize low cost but reliable LCA is to reduce the number of mechanical elements (parts count) used. The mechanical element reduction can be categorized in the following two ways.

(1) Design with fewer components

The following design thoughts and proceedings are the key.

Designing points for fewer mechanical elements
1. Reduction of repeated features such as mounting screws

-Design Points
a) Eliminate non-functional features
Ex. Number of mounting screws on a load bearing bracket.
See [Fig.1]
b) Eliminate inappropriate design features to save on machining process.
Ex. Reduction of machining by optimizing mounting screw placements on flanges.
See [Fig.2]
2. Utilization of integrated and pre-fabricated standard products

-Design Points
a) Require the use of standardized products for design processes
Ex. *MISUMI FA Mechanical Standard Components: Angle Plates, Gussets, Fabricated Sheet Metals, etc.
3. Eliminate or reduce adjustment elements (spacers and shims).

-Design Points
a) Designs that require no adjusting spacers.
If not possible, devise schemes to group the adjustment features together.

[Fig.1] Example of Eliminating Unnecessary Features

[Fig.2] Example of Eliminating Inappropriate Designs

In addition to the above points, it is important to acquire the following design practice points that reduce mechanical element machining costs.

Machining Cost Reduction Points
-Unification of bolt sizes used
-Unified machining direction
Reason: Machining labor costs and equipment depreciation costs are reduced by shortened setup change time.

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