Brake and Clutch Pedal System Optimization Using Design for Manufacture and Assembly

This paper describes the application of the Design for Manufacture and Assembly (DFMA) method at Chrysler. Attention is focused on the development of the clutch and brake pedal and bracketry system of the PL project in the Small Car Platform. The Chrysler DFMA procedure including competitive evaluation and value engineering was utilized during the initial design phase involving product concept development from the original functional and manufacturing requirements. After the first laboratory tests, a number of key design and manufacturing concerns surfaced and led to a second cycle of DFMA analysis. The procedure permits major design functions and manufacturing and assembly process issues and criteria to be incorporated in the initial design stages. These DFMA factors include: (1) bracket and pedal forming complexity, (2) fabrication process for joining bracketry and pedal components, (3) system tolerance sensitivity and accumulation in the sub assemblies, (4) structural integrity, (5) material utilization, and (6) assembly process capability and repeatability. The successive optimization resulting from the DFMA process is described to highlight the essential steps.