UNIT 4,5,6 Question bank for Assignment

1. Explain with neat sketch about Retrieval CAPP system.

2. What is meant by a part family in Group Technology? Explain production flow
analysis.
3. Explain the working principle of computer /machine vision system with a neat sketch.
4. Explain about the integration of CAQC with CAD/CAM
5. What are the different types of manufacturing systems? Explain with characteristics
of each type of system
6. Write the Principles of Material handling systems.
7. Explain Opitz classification system.
8. Explain about Computer Aided Process Planning.
9. Explain about contact inspection methods.
10. Explain the need for automated inspection strategies in manufacturing plant.
11. What is a material requirement planning? Explain the various inputs to the MRP
system?
12. What are the functions of computer and human labor in CIMs manufacturing
systems?

1. Retrieval CAPP system.

2. Production Flow Analysis.

• Production flow analysis (PFA) is a method for identifying part families and
associated machine groupings that uses the information contained on process plans
rather than on part drawings.
• Work parts with identical or similar process plans are classified into part families.
These families can then be used to form logical machine cells in a group technology
layout.
• The procedure in production flow analysis must begin by defining the scope of the
study, which means deciding on the population of parts to be analyzed.
The procedure of Production flow analysis (PFA) consists of the following steps:
1. Data Collection. The minimum data needed in the analysis are the part number
and operation sequence, which is obtained from process plans.
2. Sortation of process plans. A sortation procedure is used to group parts with
identical process plans.
3. PFA Chart. The processes used for each group are then displayed in a PFA chart
as shown below.

4. Clustering Analysis. From the pattern of data in the PFA chart, related groupings
are identified and rearranged into a new pattern that brings together groups with
similar machine sequences.
3. Computer vision/Machine vision system:

1. Image acquisition and digitization

With camera focused on subject, viewing area is divided into a matrix of picture
elements (“pixels”)
a) Each pixel takes on a value proportional to the light intensity of that portion of
the scene and is converted to its digital equivalent by ADC
 In a binary system, the light intensity is reduced to either of two
values, white or black
 In a gray-scale system, multiple light intensities can be distinguished
b) Each frame is stored in a frame buffer (computer memory), refreshed 30 times
per second

2. Image processing and analysis :

a) Segmentation – techniques to define and separate regions of interest in the
image
 Thresholding – converts each pixel to a binary value (white or black)
by comparing the intensity level to a defined threshold value
 Edge detection – determines location of boundaries between an object
and its background, using the contrast in light intensity between
adjacent pixels at the boundary of an object
b. Feature extraction – determines an object’s features such as length, area, aspect
ratio

3. Interpretation:
For a given application, the image must be interpreted based on extracted features
Concerned with recognizing the object, called pattern recognition - common
techniques:
a) Template matching – compares one or more features of the image object with
a template (model) stored in memory
b) Feature weighting – combines several features into one measure by weighting
each feature according to its relative importance in identifying the object
 4. Integration of CAQC with CAD/CAM

 Automation in industries is intended to offer a batch oriented manufacturing. The

integration of the actions starting from design to the part coming out of the factory
leads to total automation. This closes the loop in a computer integrated manufacturing
System
 One of the serious factors in manufacturing quality assurance is to ensure that every
part coming off the production line is within design tolerance. The successful factory
constantly monitors quality at each step of design and manufacturing process
 In the shop, the coordinate measuring machine assists in this quality assurance
function. The productivity of the coordinate measuring machine can be enhanced by
interfacing with a CAD/CAM system
 Interfacing with the CAD/CAM database, the operator can use the off-line
programming capabilities of the CMM interface to process the input values for the
part geometry being measured. This removes the laborious manual data entry
techniques and reduces preparation time and increases accessibility of CMM for
inspection.
The CAD/CAM-CMM interface helps the programming efforts in the quality assurance
office where quick response to engineering changes can be made and current data to the
CMM can be provided.
Usually the CAD/CAM-CMM interface consists of a number of
modules :
I. CMM-Interface: This interface allows interacting with the CAD/CAM database to
generate a source file that can be converted to a CMM control data file.
II. Pre-CMM processor: The pre-CMM processor converts the language source file
generated by CMM Interface into the language of the specified Coordinate Measuring
Machine
III. . Post-CMM processor: The post-CMM processor creates wire frame surface model
from the CMM-ASCII output file. Comments are inserted into the ASCII-CMM
output file to control the creation of the CAD/CAM entities, which include points,
lines, arcs/circles, conics, splines and analytic surfaces.

6 Principles of Material handling systems.

 Orientation Principle: It encourages study of all available system relationships

before moving towards preliminary planning. The study includes looking at existing
methods, problems, etc.
 Planning Principle: It establishes a plan which includes basic requirements, desirable
alternates and planning for contingency.
 Systems Principle: It integrates handling and storage activities, which is cost
effective into integrated system design.
 Unit Load Principle: Handle product in a unit load as large as possible
 Space Utilization Principle: Encourage effective utilization of all the space available
 Standardization Principle: It encourages standardization of handling methods and
equipment.
 Ergonomic Principle: It recognizes human capabilities and limitation by design
effective handling equipment.
 Energy Principle: It considers consumption of energy during material handling.
  Ecology Principle: It encourages minimum impact upon the environment during
material handling.
 Mechanization Principle: It encourages mechanization of handling process wherever
possible as to encourage efficiency.
 Flexibility Principle: Encourages of methods and equipment which are possible to
utilize in all types of condition.
 Simplification Principle: Encourage simplification of methods and process by
removing unnecessary movements
 Gravity Principle: Encourages usage of gravity principle in movement of goods.
 Safety Principle: Encourages provision for safe handling equipment according to
safety rules and regulation
 Computerization Principle: Encourages of computerization of material handling and
storage systems
 System Flow Principle: Encourages integration of data flow with physical material
flow
 Layout Principle: Encourages preparation of operational sequence of all systems
available
 Cost Principle: Encourages cost benefit analysis of all solutions available
 Maintenance Principle: Encourages preparation of plan for preventive maintenance
and scheduled repairs
 Obsolescence Principle: Encourage preparation of equipment policy as to enjoy
appropriate economic advantage.

11. Need for automated inspection strategies in manufacturing plant.

 When we talk about automated inspection, we are usually referring to in-line 100%
inspection as opposed to off-line measurement room inspection. There are scenarios
that may be considered as automated off-line such as a programmable CMM.
 Whether dedicated inspection stations or process stations with inspection capabilities
there are clear advantages to automated 100% inspection over off-line sampling.
Labor savings and timeliness of detecting a process breakdown or product defect are
three examples.
 Another aspect of in-line automated inspection is that it is predominantly non-contact
to avoid wear. Sensor technologies described as laser triangulation, capacitive,
magnetic, eddy current, and 2D and 3D vision have all proven themselves in countless
applications.

Key Decisions

 When specifying an automated measurement station, there is a hierarchy of

automation elements and related decisions.

 At the bottom are the sensors, actuators, transport and fixturing.

 In the middle are the controls, interfaces, and software to connect the sensors and
analyze, visualize or archive the inspection results.
 And at the top are the strategies for handling rejected parts, maintaining the system
and managing failure modes.
 Decisions to not overlook:

As an example, with automated inspection some critical system life cycle level decisions
include:

1. System reliability monitoring methods

How do we know for certain at any time that the inspection system is operating
correctly? Not passing bad parts? How to achieve and keep 100% confidence in the
system?
2. System changes control procedures
How do we know if someone made a change to the system that might affect its
performance or capability? How do we confirm that a change does not adversely
affect the system performance or capability? Can we easily reverse a change? Can we
regression test program changes on archived data sets to assure the changes do not
adversely affect the system performance or capability?
3. System failure mode mitigation
What happens if the in-line inspection system goes down? Do we stop production? Do
we bypass the inspection? Does the system identify a malfunction to alert operators?
How to troubleshoot the problem? What is the offline backup plan?
4. Training and retaining key skills
When we outsource the inspection system design, integration, and installation how
much inside expertise do I need to effectively operate and maintain the system? Who
needs to be trained to work with the system? How do we maintain the expertise over
time and personnel changes?
5. Data management strategies
How much data does the system produce? Who needs the data and in what form?
What part/form of the data do we need to archive? Where do we archive the data? For
how long? How do we access and use the archived data?
6. Defective Material Handling Method
How do we handle rejected parts? How do they get marked, tracked, removed?
Rework and then reintroduce into the line to re-inspect? Rework and inspect offline?

11. Material Requirements Planning (MRP)

 Material Requirements Planning (MRP) is a computer-based production planning and

inventory control system. MRP is concerned with both production scheduling and
inventory control. It is a material control system that attempts to keep adequate
inventory levels to assure that required materials are available when needed.
 MRP is applicable in situations of multiple items with complex bills of materials
 MRP is not useful for job shops or for continuous processes that are tightly linked.

 The major objectives of an MRP system are to simultaneously:

1. Ensure the availability of materials, components, and products for planned

production and for customer delivery,

2. Maintain the lowest possible level of inventory,

3. Plan manufacturing activities, delivery schedules, and purchasing activities.

 MRP is especially suited to manufacturing settings where the demand of many of the
components and subassemblies depend on the demands of items that face external
demands.

The three major inputs of an MRP system are the

 master production schedule the product

 structure records and
 the inventory status records

Without these basic inputs the MRP system cannot function.

 The demand for end items is scheduled over a number of time periods and recorded
on a master production schedule (MPS). The master production schedule expresses
how much of each item is wanted and when it is wanted. The MPS is developed from
forecasts and firm customer orders for end items, safety stock requirements, internal
orders. MRP takes the master schedule for end items and translates it into individual
time-phased component requirements.
 The product structure records also known as bill of material records(BOM), contain
information on every item or assembly required to produce end items. Information on
each item, such as part number, description, quantity per assembly, next higher
assembly, lead times, and quantity per end item, must be available.
 The inventory status records contain the status of all items in inventory, including on
hand inventory and scheduled receipts. These records must be kept up to date, with
each receipt, disbursement, or withdrawal documented to maintain record integrity.

 MRP will determine from the master production schedule and the product
structure records the gross component requirements; the gross component
requirements will be reduced by the available inventory as indicated in the
inventory status records.