Professional Documents
Culture Documents
CERTIFICATE
This is to certify that project report entitled GROUP TECHNOLOGY (CODING SYSTEM) submitted by KHAPANDI JITENDRA R. (06ME004) and KAWA KAUSHIK M. (06ME019) towards the partial fulfillments of the requirements for semester 7th of bachelor in Mechanical Engineering of V.V.P. Engineering college, Rajkot the record of work carried out by them under our supervision and guidance. The work submitted has in our opinion reached a level for being accepted for examination the results embodied in this major project work to the best of our knowledge have not been submitted to any other university of institution for award of any degree or diploma.
ACKNOWLEDGEMENT
By these words I am feeling very lucky for the opportunity that has been given to me for working with PROF. RUPA P. ACHARYA who has been always Supportive and helpful to my work during the seminar work of the 7th semester MECHANICAL ENGINEERING. I acknowledge his assistance and Encouragement extended by his for giving us information clearing Doubts, Obligatory.
I has inflated pleasure to offer my sincere respect to Prof. JIGNASA P. MEHTA (H.O.D.) for providing us with all the necessary facilities and timely centralization during the period I stay with him.
INDEX
INTRODUCTION PART FAMILIES PART FAMILY CONCEPT METHOD FOR DEVELOPING PART FAMILIES PROCESS LAYOUT PARTS CLASSIFICATION AND CODING CODING SYSTEM STRUCTURE SPECIAL SYMBOL CODES PRINCIPLES OF CODING SELECTION OF CODING SYSTEMS SOME OF THE IMPORTANT SYSTEMS
o
o DCLASS System
o o o
INTRODUCTION
Group technology is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in design and manufacturing. Group technology (GT) is a manufacturing philosophy where similar objects are identified and grouped together to take advantage of their similarities in design and manufacturing. Group Technology is the realization that many problems are similar and that, by grouping similar problems, a single solution can be found to a set of problems, thus saving time and effort. The technique of identifying and bringing together related or similar parts in a production process in order to utilize the inherent economy of flow production methods. Parts with similar characteristics are grouped into families. Families may be based on similarities in design attributes such as geometric shape and size, or manufacturing attributes such as sequence of processing steps required, jigs, fixtures, and tooling.
PART FAMILIES
Group Technology is a manufacturing concept in which similar parts are grouped together in parts groups families.
1.
2.
In the manufacturing processed required to produce them (differ design) GT exploits the part similarities by utilizing similar processes and tooling to produce them.
The cubical parts which are not very similar anymore; however, they also form a production family and can be made on the same multi-axis machining center.
The dissimilar parts requiring at least one common process, which is to drill four holes. In this case, the other processes needed to shape the part would have to be done with different machine tools. These parts are typical for companies producing a wide spectrum of products.
Two completely identical designed parts, one made from plastic and the other from steel. The manufacturing processes would be injection molding for the plastic reel and turning for the metal reel. In this case we have a common design family; however, the production processes are unrelated.
If the parts were to be manufacturing according to group technology considerations, the plant would have to be realigned. The production process assumes a flow line operation with machine tools located in the flow line where they are needed. It can readily be seen that intra-plant transportation is minimized. Setup operations and tool changes are also reduced.
PROCESS LAYOUT
By grouping parts into families, manufacturing personnel can cut down significantly on the amount of materials handled and movement wasted in producing them by grouping manufacturing machines into specialized work cells instead of arranging them according to function figure shows a processtype layout for batch production in a machine shop. The process machine tools are arranged by function. During the machining of given part, the work piece must be moved between sections, with perhaps the same section being visited several times. This results in a significant amount of material handling, a large in-process inventory, usually more setups than necessary, long manufacturing lead times, and high cost. Figure shows a production shop of equivalent capacity, but with the machines arranged into cells. Each cell is organized to specialize in the manufacture of a particular part family. Advantages are gained on the form of reduced work piece handling, lower setup times, less inprocess inventory, and shorter lead time.
1. Process-layout
HYBRID CODE
It is the mixture of both monocode and polycode systems. Mixed code retains the advantages of both systems. Most coding systems use this code structure. The first digit for example, might be used to denote the type of part, such as gear. The next five position might be reserved for a short attribute code that would describe the attribute of the gear. The next digit (7th digit) might be used to designate another subgroup, such as material, followed by another attribute code that would describe the attributes.
A code created by this manner would be relatively more compact than a pure attribute code while retaining the ability to easily identify parts with specific characteristics
hieroglyphically, which can best characterized by the symbolic therbligs, created by Frank and Lillian Gilbreths or of more recent vintage, the flow chart codes for tracking the handling of data within a system. During their study of work and time-and motion, they used an epitomized hieroglyphic code symbols to represent a fundamental motions such as reach, grasp, think, etc. The hieroglyphic code symbols described by the therbligs codes pictorially represent the action they describe. For example, the activity of planning can be represented by planning therbligs symbol by a person with his finger at his brow, denoting a thinking pose. Like wise, in the flow chart symbols, the operation performed on a lathe machine can be represented by a circle. Sometimes a code used in a special symbol codes can have a little or no meaning in their shape or character or the code and the information it represents. The common flow chart symbols established and developed by The American Society of Mechanical Engineers (ASME) show in the table below is a good example of such codes.
(ASME) Symbol Activity
Combined Activity
Principles of Coding
As in the case of classification, an industrial coding has also its own principles. These includes
1.
No code should exceed five characters without a break in the string. That means when the code number becomes shorter it becomes easy to handle and, fewer errors committed. Identity codes should of fixed length and pattern. If we use varying-length codes within a given class of materials it will proliferate error rates and require justification in handling (right or left) to the longest code in use. All-numeric codes produce fewest errors.
2.
3.
4.
Alphanumeric combination codes are acceptable if the alpha field is fixed and used to break a string of numbers.
Form code: describes the primary design attributes of a part Supplementary code: describes manufacturing related attributes Secondary code: more detail of manufacturing attributes
Basic Structure of the Opitz Parts Classification and Coding System
DCLASS System
It is a decision-making and classification system. It is a tree-structured system that generates codes for components, material, processes, machines, and tools. Each branch of the system represents a condition in which a code is formed at the junction of each branch. The complete code is obtained by taking multiple passes in the decision tree. Sample of DCLASS code representation
Basic form: Basic shape (1), Shape element (2 & 3), Location of the shape element (4) Supplementary design and mfg. information: Number of outside diameters (19), Number of inside diameters or specific shape (20), Rotational grooves or knurls (21), Close tolerance diameters (22), Splines (23), Gears (24), Sprockets (25), Pitch diameter/diameter pitch (26), Number of teeth
KK3 SYSTEM:-
service
Some of the well-known tangible and intangible benefits of implementing GT: 1. Engineering design
Reduction in new parts design Reduction in the standardization number of drawings through
Reduction of number of similar parts, easy retrieval of similar functional parts, and identification of substitute parts
3. Specification of equipment, tools, jigs, and fixtures Standardization of equipment Implementation of cellular manufacturing systems
Significant reduction in up-front costs incurred in the release of new parts for manufacture
4. Manufacturing: process planning Reduction in setup time and production time Alternative routing leading to improved part routing
Reduction in number of machining operations and numerical control (NC) programming time
5. Manufacturing: production control Reduced work-in-process inventory Easy identification of bottlenecks Improved material flow and reduced warehousing costs Faster response to schedule changes
Improved usage of jigs, fixtures, pallets, tools, material handling, and manufacturing equipment
6. Manufacturing: quality control Reduction in number of defects leading to reduced inspection effort Reduced scrap generation Better output quality
Increased accountability of operators and supervisors responsible for quality production, making it easier to implement total quality control concepts.
7. Purchasing Coding of purchased part leading to standardized rules for purchasing Economies in purchasing possible because of accurate knowledge of raw material requirements Reduced number of part and raw materials
Form used to select the external shape attributes for the rotational work part.
Form used to select the external shape attributes (this is the case for a rotational work-part with two outer diameter)
Form used to select the internal shape attributes for the rotational work part.
Form used to select the internal shape attributes (this is the case for a rotational work-part with one internal diameter)