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Purpose: In the case study presented, the DFA (Design for Assembly) technique is applied to an automotive fuel intake cover of a currently produced vehicle in order to simplify the current product design. Design/methodology/approach: DFMA and Lucas methodology, which is used in this study, can be adopted not only for the development phase of new products, but also for already developed products, reducing the number of components and the costs. Findings: The Lucas methodology approach for the DFMA has been applied in a successful way to improve a fuel intake cover. Research limitations/implications: Only a prototype part was tested. More specimens must be tested to validate final design. Practical implications: The application of this technique allowed a product cost saving of 10%, a tooling saving of 5%, and a significant product simplification without losing its original functionality.

Nowadays quality and efficiency in the process is no longer a question of competition among automakers. Another factor that has been highlighted in the automotive industry and has become a strategic is the sustainability. Processes considered “green” can generate value for the company with less environmental impact, and they are seen favorably by both market and customers. The process to be examined is widely used by automakers to manufacture their bodies in white, the resistant spot welding process. Considering that, this process generates a considerable impact in the environment mainly for the generation of gases, some manufacturers in recent years has replaced it by the clinching process, which also performs the union of sheet metal, but for metal forming. The process of spot welding generates dust, fumes and pollutants gases, which will be transported to the external environment somehow.