CASE STUDY

DFMA APPLIED TO INDUSTRIAL COMPRESSORS

Visualizações: 189

Authors

DOI:

https://doi.org/10.56579/rei.v7i5.2052

Keywords:

Compressores, DFMA, Eficiencia, Custo, Manutenção

Abstract

The compressor market has experienced continuous growth, driven by increasing demand from sectors such as refrigeration, HVAC, automation, and transportation. These machines are essential in systems involving the pressurization of gases and fluids, playing a strategic role in various industrial processes. In this context, the pursuit of more efficient and sustainable solutions has fostered significant technological advancements. The application of the Design for Manufacturing and Assembly (DFMA) methodology stands out as a promising approach in compressor development. DFMA aims to optimize the design, with an emphasis on design simplification, cost reduction, and increased efficiency in manufacturing and assembly processes. One of the main benefits of this methodology lies in facilitating maintenance throughout the product’s life cycle. The incorporation of preventive maintenance strategies, as well as easy access to critical components, helps reduce unplanned downtime and system inactivity. Structural complexity has been decreased, with fewer components subject to wear, resulting in more reliable equipment, lower production costs, and reduced maintenance time. Thus, integrating DFMA principles into compressor design presents a significant opportunity to enhance production and maintenance efficiency, as well as competitiveness, in the global industrial landscape.

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Author Biographies

Welton Conceição Araújo, Senai SP University Center

Student of the Graduate Program in Industrial Mechanical Projects at the SENAI SP University Center.

Leandro Cardoso da Silva, SENAI SP University Center and Faculty of Technology

I hold a Ph.D. in Mechanical Engineering from the University of São Paulo, a Master’s degree in Materials Engineering from Mackenzie Presbyterian University, and a Bachelor’s degree in Mechanical Production Engineering from Nove de Julho University Center. I have extensive experience as a professor in both in-person and distance learning (EaD) education, teaching since 2011 in undergraduate programs in Engineering and Technology, in both modalities, as well as in postgraduate (lato sensu) programs. My academic work is strongly linked to the field of Production Engineering, with an emphasis on product development, additive manufacturing, manufacturing processes, and engineering applied to Industry 4.0.
I teach courses such as DFMA (Design for Manufacturing and Assembly), DOE (Design of Experiments), Finite Element Method (FEA), Computational Fluid Dynamics (CFD), Materials Science, Strength of Materials, Production Planning and Control, Quality Management, Logistics, Supply Chain Management, Production Simulation, Manufacturing Processes, and Operations Research, among others.
Throughout my career, I also worked for 14 years in the automotive industry, in multinational companies, focusing on product and process development of critical components such as engine suspension systems, gear shift mechanisms, pedal assemblies, and exhaust and air intake systems. Currently, I am a professor and researcher at Centro Universitário Senai-SP and FATEC, where I contribute to the training of professionals and the advancement of applied engineering through teaching, research, and innovation projects.

Lucas Almeida Willenshofer, SENAI SP University Center

Bachelor’s degrees in Control and Automation Engineering and Electrical Engineering from ENIAC College, and a Master’s degree in Mechanical Engineering from the Federal Institute of São Paulo. During his master’s program, he developed the dissertation titled “Fault Detection in Bearings Based on Convolutional Neural Networks Using Low-Cost MEMs Accelerometers.”
An experienced professional in the fields of Industrial Automation, Electrical Engineering, and Information Technology (IT), he has worked as a professor in courses of Electrical Engineering, Mechanical Engineering, Control and Automation Engineering, and Computer Engineering at ENIAC College, as well as in subjects related to Industrial Maintenance, Building Maintenance, and Project Development at SENAI-SP.
He has extensive experience in connectivity and communication, mastering protocols such as RS232, UART, SPI, I2C, Bluetooth, and WiFi, integrating hardware and smartphone applications to develop connected solutions with remote access. His experience includes project validation, assembly of test rigs, and performance of structural and functional tests to ensure system reliability.
He works with data acquisition, including reading, storage, processing, and transmission of information — essential for real-time monitoring systems. He also develops IoT platforms, both locally and in the cloud, covering design, dashboard creation, API integration, and data visualization for efficient monitoring.
Additionally, he implements online task automation systems using services such as WebHooks, automated email sending, and trigger logic, integrating firmware for sensor reading, logic processing, data transmission, and reception in the cloud, with remote display.
In the field of industrial networks, he designs local, centralized, and distributed architectures using different transmission media (twisted pair, optical fiber, wireless) and topologies such as star, bus, and hybrid, as well as standards such as LAN, WAN, and PAN.
He specializes in network infrastructure, developing projects that include servers, routers, and controllers, with emphasis on the use of protocols such as TCP/IP, Modbus, Profibus, and Profinet for communication in industrial environments. His work combines a practical and innovative approach, training students and developing solutions that integrate automation, connectivity, and infrastructure, aligned with the demands of Industry 4.0.
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Edgard Gonçalves Cardoso, SENAI SP University Center

Mechanical Production and Occupational Safety Engineer. Technician, Technologist, and MBA in Business Management. Technician, Specialist, Master’s, and Ph.D. candidate in Energy. Technologist and postgraduate in Industrial Maintenance. Specialist in Project Management, People Management, Special and Inclusive Education and Technology, Teacher Training, and Society. Holds solid experience in the areas of maintenance, education, energy, administration, and risk management. Mechatronics Laboratory Technician at the Federal University of ABC and Undergraduate and Postgraduate Professor at SENAI-SP. Worked at companies such as Arno S.A., Crisflex Technical Rubber Products, Fatec, Facens, and Scania Latin America. Director and Secretary at the Association of Engineers and Agronomists of Mauá (ASSEAM). Lean Mentor and Black Belt in Lean Six Sigma. Co-author of three books in the field of industrial maintenance and one in the area of energy/waste. Member of Technical Committees of ABNT and of the Deliberative Council of ABRAMAN. Eucharistic Minister and Minister of Worship and the Word in the Roman Catholic Apostolic Church. Student of Catholic Doctrine Theology.
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Manuel Patricio da Silva Bisneto, SENAI SP University Center

Ph.D. in Nanoscience and Advanced Materials from the Industrial Academic Doctoral Program (DAI) at the Federal University of ABC – UFABC (2019–2024). Master’s degree in Mechanical and Aeronautical Engineering with an emphasis on production from the Aeronautics Institute of Technology (ITA), 2018. Thesis Topic: Preliminary Proposal of the Design for High-Speed Machining Method – defense presented in March 2017. Postgraduate (specialization) in Production Engineering (2014) from Uninter. Undergraduate thesis topic: Ergonomics and Design in a Hospital Device. Holds a degree in Production Process Technology from the State University of São Paulo – UNESP, 2002.

University professor with experience in Mechanical and Production Engineering, skilled in planning, execution, and management of groups, as well as in the development of new products and processes from concept to end-of-life, focusing on innovation and continuous improvement. Promotes an innovation culture as a business model and in the aggregation of knowledge and value for the customer.

Experienced in preparing budgets for innovation projects; participation in projects across various sectors such as oil and gas, auto parts, machinery and equipment, healthcare, among others, involving multiple stakeholders and companies, always focused on innovation and processes that add value to the customer. Experienced in submission, monitoring, and approval of funding projects (from business model development) for national industrial innovation.

Works as a consultant in Integrated Product Development (IPD), using tools such as PFEMEA, DFEMEA, DFA, DFM, among others. Consultant in Lean Manufacturing for companies of all sizes. Uses simulation software for analysis and validation of proposed changes. Develops products with multidisciplinary and design teams, conducts research for the development of mechanical devices and systems, and creates 3D modeling. Demonstrates leadership, teamwork, and dynamism in the development of general projects related to the field.

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Published

2025-10-29

How to Cite

Araújo, W. C., Silva, L. C. da, Willenshofer, L. A., Cardoso, E. G., & Silva Bisneto, M. P. da. (2025). CASE STUDY: DFMA APPLIED TO INDUSTRIAL COMPRESSORS. Interdisciplinary Studies Journal, 7(5), 01–21. https://doi.org/10.56579/rei.v7i5.2052

Issue

Vol. 7 No. 5 (2025): JOURNAL OF INTERDISCIPLINARY STUDIES

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ARTICLES

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