NATIONAL UNIVERSITY OF SCIENCE AND

TECHNOLOGY

FACAULTY OF EGINEERING
INDUSTRIAL AND MANUFACTURING ENGINEERING

NAME: MUSENGEYI WILLARD

STUDENT ID: N01522674T

COURSE: ADVANCED MANUFACTURING TECHNOLOGY

COURSE CODE: TIE 5216

LECTURER: ENG V. SIBANDA

ASSIGNMENT 1: A tin smith manually makes water containers, bath and cutlery washing
dishes. Visit a local dealer and identify a single product being manufactured. Develop a process
plan for the product manufacturing process.
Introduction

Traditional strip layout design is manual, highly experience based activity and therefore tedious,
time consuming and error-prone (Kumar, S. and Singh, R., 2008). The following is a sequence of
steps taken by local black smiths in the production of 25 litre containers. There is therefore a
need to include technology in the manufacturing process to increase productivity and lower lead
times

Marking out

The preliminary stage is sheet material marking out using measuring and cutting tools, after the
sheet is successfully marked it is then cut using metal cutting scissors.

Figure 1: tin pattern development

Hemming process

Hemming is the process in which the edge is rolled flush to itself and when hammered together
with another hemmed edge a join is produced. This method is used to join sheets by tin smith.

Figure 2: tin sheets joining process

Final hemming process

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A hem at the open end of the tin is made and a wire is wrapped inside to produce a round mouth
to avoid cutting and provision of support for the handle.

Figure 4: Tin mouth final hemming process

Proposed process plan for manufacture of 25 L tins

In sheet metal working operations process planning or strip layout often starts with the
determination of blank shape. Based on determined blank shape, further process planning
activities are performed to derive the total number and sequence of metal forming operations. In
order to manufacture tins, the blank shapes that are required are:

Determination of blank
shape

Sequencing of
operations

Tool selection

Determination of number of
workstations

End of process
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Determination of blank shape and dimensions

A blank shape is an important input for calculation of material requirements and cost so as to
ensure the feasibility of the forming process required to archive the final shape. To determine
blank shapes the cylinder is partitioned into its components to produce a rectangle and a circle.

Figure 5: partitioned parts of a tin (Salunkhe, S., Panghal, D., 2016)

To specify cutting die sizes a decision has to be made on the height of the 25 L and radius of the
base circle.
After determination of height(h) of the tin and the radius (r) the set of instructions are loaded into
the machine in which a stamping die with the required dimensions and profile is loaded. The
cutting thereafter is performed.
After cutting a circular base follows a different path with the rectangular sheet, the sheet goes
through station 2 for rolling followed by welding in station three. On station 4 the rolled
rectangular sheet is seamed together with the bottom circular base.

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A coating is applied in station 5 followed by heat curing from where the complete tins are
transferred to station 5 for manual inspection and sometimes insertion of handles if the design
requires that from the customer. The figure below shows the proposed machinery arrangements
of the planned manufacturing process.

Figure 6: proposed process plan for production of tins

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References
ElMaraghy, W., ElMaraghy, H., Tomiyama, T. and Monostori, L., 2012. Complexity in
engineering design and manufacturing. CIRP annals, 61(2), pp.793-814.
Poli, C., 2001. Design for manufacturing: a structured approach. Butterworth-Heinemann.
Kumar, S. and Singh, R., 2008. Automation of strip-layout design for sheet metal work on
progressive die. Journal of materials processing technology, 195(1-3), pp.94-100.