Standardization and
Interchangeability
Prof. V N A Naikan
IIT Kharagpur
Standardization
- Market gap or opportunity identification
- Conceptual design
- Detailed technical design
- Parts list: Minimum variety of components, processes, tools.
- As much as possible use all standard parts only
- Non-standard parts only for supporting the main design
- Non-standard parts, in general, should not fail
Standardization
Standardization is the process of establishing standards or units of
measure by which extent, quality, quantity, value, performance,
etc., may be compared and measured.
• Standards are the base of mass production
• There are only certain specific sizes made and sold
• Standards are carefully established specification for products,
components and materials
• Standardization produce maximum variety of products using
minimum variety (standardized) of materials, parts, tools and
processes
• More economic products
• Easily maintainable
• Non-standard products are only custom made
Standardization Involves
• Classification
• Coding
Helps easier, accurate, faster, and economic
management of components and parts during
various stages of design, procurement,
manufacturing, marketing, and service of
products.
Classification
Classification:
• Necessary for NPD
• Grouping items together by
their common features and
subdividing them by special
features.
Bearings
• Ball bearings
• Roller bearings
• Journal bearings
Classification…
Gears
• Spur Gear
• Helical Gear
• Herringbone Gear
• Bevel Gear
• Hypoid Gear
Classification…
• Resisters
– Carbon Composition Resistor.
– Thermistor.
– Wire Wound Resistor.
– Metal Film Resistor.
– Carbon Film Resistor.
– Variable Resistor.
– Varistor
– Light Dependent Resistor
Classification…
• Screws
Coding
• Using letters and numbers for identifying each
part
• Coding Helps :
– Identify and locate identical items
– Facilitate use of standard items in new designs
– Identify substitutes incase of stock-outs
– Help developing group technology in manufacturing
– To improve parts location in the store
– Computerization requires parts coding
Example for Coding
Example : IS classifies the grinding wheel as follows.
Grade of Grinding wheel: C54G6U
C 54 G 6 U
Silicon Medium Soft dense vetrified
carbide grain size grade structure bond
Abrasive
Advantages of Standardization
1. Design department
- fewer specification, drawing parts list, less mistakes,
less skill requirement
2. Manufacturing department
- lower unit costs, find easier substitutes, vendor selection
3. Marketing department
4. Production planning
5. Production control
6. Purchase and stock control
7. Q C
8. Works study
9. Supervision
10. Costing
Disadvantages
Reduction in choice
Changes in public taste may affect sales
immediately
Difficult to introduce new models with rigid setups
Helps big companies in mass production scenerio
Standards once set, difficult to change,
obstacle to progress!
International Standards
• ISO after second W.W. II
• Most industrialized countries are members
• ISO does not issue independent standards of its own but
make recommendations to induce in National standards
• Exporting requires acceptance and implementation of ISO
standards
National Standards
India IS
UK BS
Germany DIN
US ASO, MIL- STD
Simplification
- Closely related to standardization
- Reducing the variety of products/components
- Manufacture fewer parts, varieties, and changes
- Removes the superfluous varieties
- Product, assembly, design become less complex & less
difficult
- Lesser confusion
- Availability of suitable standards helps simplification
Some concerns of Simplification
• How simplification will affect customer
demand & volume of sales?
• Does market competition permit
simplification or it encourage products
diversification ?
• More varieties need flexible manufacturing
systems
• Trade off is required
Advantages of Simplification
- Manufacturing operations simplified
- Quick delivery & better service
- Less inventory
- Fewer parts less cost, better management
- Better quality
- Product prize reduction
Specialization
Standardization & simplification lead to Specialization
Specialized company: - bearings
- sparks-plugs
Specialized man power: - produces a small part of a product
- proficient in one activity
- higher skill level is achieved
Less flexible
Result in monotony
Can be applied to: (1) Products
(2) Processes
(3) Individuals
(4) Jobs
(5) Equipment
Interchangeability
Great invention of industrial revolution
Necessary for mass production
S, S, & S interchangeability
Any standardized component will assemble correctly
with any mating standard component both being
chosen at random
All parts of a given specification must be identical
Reduces cost - easier assembly - no need of
retrofitting / alterations
Faster, easier to repair/replacement of parts
Achieving Interchangeability
- Specify appropriate component tolerances (from standards)
to suit the type of fit required
- Unilateral tolerance
- Bilateral tolerance
- Select manufacturing process to make components within
specified tolerance (Process Capability)
- Inspection & QC must ensure achieving tolerance
- An interchangeable system is also known as a limit
system or a system of limits & fits
Fits
Kind of engagement between two mating parts
Fits
Clearance Transition Interference
push light shrink or
sliding running driving or
keying
press fit force fit
Types of Fits
Clearance Fit
When a shaft & journal are assembled a clearance occurs
Largest shaft is smaller than smallest journal
Sliding Fit
Sliding contact
Die & punch
Reciprocating parts
Running Fit
Shaft on journal bearing
Types of Fits….
Interference Fit
Always interference of mating parts
Diameter of smallest shaft > diameter of biggest hole
Driving or press fit :
Semi permanent fit
Need light hammering to assemble
Example : keying a pulley on a shaft
Shrink or Force Fit :
Permanent fit
Need great pressure to assemble
Example : Fixing a crank on a locomotive wheel
Types of Fits….
Transition Fit
~ Between clearance & interference fits
~ When assembled mating parts, either
clearance or interference occurs
Example : smallest shaft could be clearance fit with largest hole &
largest shaft has interference fit with smallest hole
Push fit & Light keying fit
results when assembling is done with the help of light hand
pressure
Example : plugs, fitting dowels/pins in a hole etc
Allowance
~ the variation given for the purpose of providing different classes of fits
Ex: Hole dimension – shaft dimension
Shaft basis keep shaft diameter constant, vary hole diameter
Hole basis keep hole diameter constant vary shaft diameter
modern
easier fixed drills of standard diameter are available
adjusting shaft diameter is easier compared to hole
HL
Shaft IFT
Basic
Hole S
Size
S TF
LL
CF
Allowance
End