Design for manufacturing analysis on the Small Unmanned Ground Vehicle

Abstract

iRobot is responsible for delivering the Small Unmanned Ground Vehicle (SUGV) as part of the U.S. Army's Future Combat Systems (FCS) initiative. With increasing external competition and pressures, iRobot must deliver an innovative robot while reducing costs, improving quality, and shortening the product's time to market. Since 100% of iRobot's manufacturing is outsourced, the SUGV manufacturing team must optimize its mechanical design in order to help ensure a smooth handoff between its design team and its contract manufacturer. To achieve this goal, the SUGV manufacturing team utilized a Design for Manufacturability and Assembly (DFMA) analysis to simplify components, reduce assembly steps, and improve processes. This paper describes the benefits of DFMA and the tools and techniques used in conducting this analysis. By studying mechanical assemblies, reviewing design drawings with the engineers, and gathering best practices from other industries, this paper provides recommendations for design changes on the SUGV and organizational strategies that can help improve iRobot's product development process.