UNIT -I INTRODUCTION OF CIM PART-A 1. Define CIM. CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency 2. What are the elements of CIM? The applications of CIM can be divided into two broad categories 1, Business functions 2. Product design 3. Manufacturing planning 4 Manufacturing control 3. Define manufacturing planning. The information and documentation that constitute the product design flows into the manufacturing planning function. The information- processing activities in manufacturing planning include process planning, master scheduling, requirements planning, and capacity planning 4. Define manufacturing control. Manufacturing control is concemed with managing and controlling the physical operations in the factory to implement the manufacturing plans, Manufacturing control functions are shop floor control, inventory control, and quality control. 5. Define concurrent Engineering (Nov/Dec 2016) Concurrent engineering refers to an approach used in product development in which the functions of design engineering, manufacturing engineering, and other functions are integrated to reduce the elapsed time required to bring a new product to market Also called simultaneous engineering, it might be thought of as the organizational counterpart to CAD/CAM technology. 6. Define automation. Automation is generally defined as the process of having machines follow a predetermined sequence of operations with little or no human labour, using specialized equipment and devices that performs and control manufacturing processes7. What are the functions of automated manufacturing system? Automating manufacturing systems operate in the factory on the physical product, They perform operations such as processing, assembly, inspection, or material handling, in some cases accomplishing more than one of these operations in the same systems 8. Define production rate. The production rate for an individual processing or assembly operation is usually expressed as an hourly rate, that is, parts or products per hour. Let us consider how this rate is determined for the three types of production: job shop production, batch production, and mass production 9. What are the levels of automation? * Device level *Machine level * Cell or system level * Plant level + Enterprise level 10. Define JIT. The ideal just-in-time production system produces and delivers exactly the required number of each component to the downstream operation in the manufacturing sequence just at the time when that component is needed. Each component is delivered “just in time." 11. What are the benefits of automation? © Toreduce labour cost © Tomitigate the effects of labour shortages © Toreduce or eliminate routine and clerical takes ¢ To improve worker safety. To increase the labour productivity 12. What are the objectives of JIT? © Zero defect *Zero setup time * Zero inventories Zerohandling * Zero breakdowns * Zero lead time 13. What are the elements of JIT? © Reduce or eliminate setup time Reduce manufacturing and purchasing lot sizes Reduce production and delivery lead times© Preventive maintenance © Stabilize and level the production schedule with uniform plant loading © Flexible workspace 14, What are the types of production? ¢ Low production; Quantities in the range of 1 to 100 units per year © Medium production: Quantities in the range of 100 to 10,000 units annually. High production, Production quantities are 10,000 to millions of units 15. What are the three basic elements of an automated system? (Nov/Dec 2016) Basic elements of an automated system ¢ Power to accomplish the process and operate the system © A program of instructions to direct the process. © A control system to actuate the instructions 16. Illustrate the components of an automated system with simple sketch.(Apr/May2017) + Push-button panels, with or without visual displays. + Touch-panel displays, with fixed or programmable screen layouts. + Computer keyboards and monitors + Hand-held remote controls + Telephone interfaces to allow long-distance remote control. « Television controllers with on-screen menus. t races (17. What are the factors that lead to the evolution of CIM? (Apr/May2017) © CAD (computer-aided design) © CAE (computer-aided engineering) © CAM (computer-aided manufacturing) © CAPP (computer-aided process planning) © CAQ (computer-aided quality assurance) PPC (production planning and control) ERP (enterprise resource planning)PART-B 1. Explain the computerized elements of CIM system. _————__—_, Geometric modeling Engineering apalyss [Design review and evaluation Automated daticg CAM ‘Cont estimation CAPP. [NC pert programing Computerized work stds MRP, capacity pianning Orderentey Accousting Paveol Customer biting CAM Process contret Process monitoring ‘Shop floor control Computer-aided inspection ‘Computerized elements of a CIM system. Business Functions: The business functions are the principal means of communicating with the customer. They are therefore, the beginning and the end of the information- processing cycle. Included in this category are sales and marketing, sales forecasting, order entry, cost accounting, and customer billing Product Design: If the product is to be manufactured to customer design, the design will have been provided by the customer. The manufacturer's product design department will not be involved. If the product is to be produced to customer specifications, the manufacturer's product design department maybe contracted to do the design work for the product as well as to manufacture it. If the product is proprietary the manufacturing firm is responsible for its development and design. The cycle of events that initiates a new product design often originates in the sales and marketing department. The departments of the firm that are organized to accomplish product design might include research and development, design engineering, drafting, and perhaps a prototype shopManufacturing Planning: The information and documentation that constitute the product design flows into the manufacturing planning function. The information processing activities in manufacturing planning include process planning. master scheduling, requirements planning, and capacity planning. Process planning consists of determining the sequence of individual processing and assembly operations needed to produce the part. The manufacturing engineering and industrial engineering departments are responsible for planning the processes and related technical derails, Manufacturing planning includes logistics issues. Manufacturing control: Manufacturing control is concemed with managing and controlling the physical operations in the factory to implement the manufacturing plans. Manufacturing control functions are shop floor control, inventory control, and quality control 2. Explain the mathematical models of production performance. Wov/Dec 2016) In some manufacturing operations, the percentage of scrap produced is high enough to adversely affect production rate, plant capacity, and product costs Production Rate: The production rate for an individual processing or assembly operation is usually expressed as an hourly rate, that is, parts or products per hour. Let us consider how this rate is determined for the three types of production: job shop production, batch production, and mass production For any production operation. the operation cycle time T, is defined as the time that one work unit spends being processed or assembled, It is the time between when one work unit begins processing (or assembly) and when the next unit begins. T, is the time an individual part spends at the machine, but not all of this time is productive. In a typical processing operation. Such as machining time, T consists of: © Actual machining operation time © Work part handling time Tool handling time per work pieceProduction Capacity: Production capacity is defined as the maximum rate of output that a production facility is able to produce under a given set of assumed operating conditions. The production facility usually refers to a plant or factory, and so the term plant capacity is often used for this measure. As mentioned before, the assumed operating conditions refer to the number of shifts per day, Plant capacity is typically defined as one or two shifts, In the manufacture of discrete parts and production growing trend is to define plant capacity {or the full 7-day week, 24 hr/day, PC =nSHRp Where PC = production capacity of the facility (output units/wk), n = number of work centers producing in the facilities = number of shifts per period (shiftiwk), H=hr/Shift, and Rp =hourly production rate of each work center (output units/hr) Utilization and Availability: It refers to the amount of output of a production facility relative to its capacity. Expressing this as an equation, Where, U- Utilization of the facility, Q Actual quantity produced by the facility during a Given time period, and Pc - production capacity for the same period Utilization can be assessed for an entire plant, a single machine in the plant, or any other productive resources. For convenience, it is often defined as the proportion of time that the facility is operating relative to the time available under the definition of capacity, utilization is usually expressed as a percentage3. Explain the basic elements an automated system. a = Power a Program of Process Elements of an automated system: (1) power, (2) pro- ‘gram of instructions, and (3) control systems. An automated system consists of three basic elements © Power to accomplish the process and operate the system A program of instructions to direct the process, and A.control system to actuate the instructions The relationship amongst these elements is illustrated in figure. All systems that qualify as being automated include these three basic elements in one form or another. Power to Accomplish the Automated Process: An automated system is used to operate some process, and power is required to drive the processes as well as the controls. The principal source of power in automated systems is electricity. Electric power has many advantages in automated as well as non- automated processes “Electrical power is widely available at moderate cost. It is an important part of our industrial infrastructure + Electrical power can be readily converted 10 altemative energy forms: mechanical, thermal, light, acoustic, hydraulic, and pneumatic. + Electrical power at low levels can be used to accomplish functions such as signal transmission, information processing, and data storage and communication. + Electrical energy can be stored in long-life batteries for use in locations where an external source of electrical power is not conveniently available. Altemative power sources include fossil fuels, solar energy, water, and wind, However, their exclusive use is rare in automated systems. In many cases when altemative powersources used to drive the process itself, electrical power is used for the controls that automate the operation. For example, in casting or heat treatment, the furnace may be heated by fossil fuels. But the control system to regulate temperature and time cycle is electrical. In other cases, the energy from these altemative sources is converted to electric power to operate both the process and its automation. Program of Instructions: The actions performed in an automated process are defined by a program of instructions whether the manufacturing operation involves low, medium, or high production, each part or product style made in the operation requires one or more processing steps that are unique to that style, these processing steps are performed during a work cycle. A new part is completed during each work cycle. The particular processing steps for the work cycle are specified in a work cycle program Work cycle programs are called part programs in numerical control. Other process control applications use different names for this type of program Work Cycle Programs. In the simplest automated processes, the work cycle consists of essentially one step, which is to maintain a single process parameter at a defined level, for example, maintain the temperature of a furnace at a designated value for the duration of a heat treatment cycle. In this case, programming simply involves sensing the temperature dial on the fumace, to change the program, the operator simply changes the temperature setting. An extension of this simple case is when the single-step process is defined by more than one process parameter, for example, a furnace in which both temperature and atmosphere are controlled. In more complicated systems, the process involves a work cycle consisting of multiple steps that are repeated with no deviation from one cycle to the next. Most discrete part manufacturing operations are in this category a typical sequence of steps is 1) Load the part into the production machine, 2) Perform the process, and 3) Unload the part. During each step, there are one or more activities that involve changes in one or more process parameters. Process parameters are inputs to the process.Control System: The control element of the automated system executes the program of instructions The control system causes the process to accomplish its defined function, which for our purpose is to carry out some manufacturing operation. Let us provide a brief introduction to control systems here The controls in an automated system can be either closed loop or open loop. A closed loop control system, also known as a feedback control system is one in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input A closed loop control system consists of six basic elements Input parameter, © Process, © Output variable © Feedback sensor. © Controller. and © Actuator The input parameter often referred to as the set point, represents the desired value of the output4, Explain the various level of automation. (Apr/May 2017) LEVELS OF AUTOMATION: The concept of automated systems can be applied to various levels of factory operations One normally associates automation with the individual production machines. However, the production machine itself is made up of subsystems that may themselves be automated. vet vei | Beg a —— 1 ae esi secre ‘ scan hardware elements Five levels of automation and control in manufacturing. Device level: This is the lowest level in our automation hierarchy. It includes the actuators, sensors, and other hardware components that comprise the machine level. The devices are combined into the individual control loops of the machine. Machine level: Hardware at the device level is assembled into individual machines. Examples include CNC machine tools and similar production equipment, industrial robots, powered conveyors, and automated guided vehicles. Control functions at this level include performing the sequence of steps in the program of instructions in the correct order and making sure that each step is properly executed.Cell or system level This is the manufacturing cell or system level, which operate under instructions from the plant level. A manufacturing cell or system is a group of machines or workstations connected and supported by a material handling system, computer. and other equipment appropriate to the manufacturing process. Production lines are included in this level. Functions include part dispatching and machine loading Coordination among machines, material handling system, and collecting and evaluating inspection data Plant level: This is the factory or production systems level. It receives instructions from the corporate information system and translates them into operational plans for production Likely functions include: order processing, process planning, inventory control, purchasing, material requirements planning, shop floor control, and quality control. Enterprise level: This is the highest level consisting of the corporate information system. It is concemed with all of the functions necessary to manage the company. Marketing and sales, accounting, design, research, aggregate planning, and master production scheduling 5. Explain the lean production.(Nov/Dec 2016) Lean production can he defined as an adaptation of mass production in which workers and work cells are made more flexible and efficient by adopting methods that reduce waste in all forms. According to another author of The Machine that Changed the World, lean production is based on four principles 1. Minimize waste 2, Perfect first-time quality 3. Flexible production lines 4, Continuous improvementMinimize Waste: All four principles of lean production are derived from the first principle: minimize waste (1)Production of defective parts, (2 Production of more than till number of items needed, (3) Unnecessary inventories, (@ Unnecessary processing steps, (5) Unnecessary movement of people, (© Unnecessary transp ort of materials, and (D Workers waiting Perfect First-Time Quality: In the area of quality, the comparison between mass production and lean production provides a sharp contrast. In mass production, quality control is defined in terms of an acceptable quality level. This means that a certain level of fraction defects is sufficient, even satisfactory. In lean production, by contrast, perfect quality is required. The just-in-time delivery discipline used in lean production necessitates a zero defects level in parts quality, because if the part delivered to the downstream workstation is defective, production stops. There is minimum inventory in a lean system to act as a buffer. In mass production, inventory buffers are used just in case these quality problems occur. The defective work units are simply taken off the line and replaced with acceptable units; However, the problem is that such a policy tends to perpetuate the cause of the poor quality. Therefore, defective parts continue to be produced, In lean production a single defect draws attention to the quality problem, forcing corrective action and a permanent solution. Workers inspect their own production, minimizing the delivery of defects to the downstream production station Flexible Production Systems: In mass production, the goal is to maximize efficiency. This is achieved using long production runs of identical parts. Long production runs tolerate long setup changeovers, In lean production procedures are designed to speed the changeover. Reduced setup times allow for smaller batch sizes. Thus providing the production system with greater flexibility. Flexible production systems were needed in Toyota's comebackperiod because of the much smaller car market in Japan and the need to be as efficient as possible Continuous Improvement: In mass production, there is a tendency to set up the operation, and if it is working, leave it alone. Mass production lives by the motto “if it ain't broke, don’t fix it" By contrast lean production supports the policy of continuous improvement Continuous improvement means constantly searching for and implementing ways to reduce cost, improve quality, and increase productivity The scope of continuous improvement goes beyond factory operations and involves design improvements as well. Continuous improvement is carried out one project at a time The projects may be concemed with any of the following problem areas: cost reduction Quality improvement, productivity improvement, setup time reduction, cycle time reduction, manufacturing lead time and work-in-process inventory reduction, and improvement of product design to increase performance and customer appealUNIT I PRODUCTION PLANNING AND CONTROL AND COMPUTERISED PROCESS PLANNING PART-A 1. What is process planning in a manufacturing system? Process plans which typically provide more detailed, step-by-step work instructions including dimensions related to individual operations, machining parameters, set-up instructions, and quality assurance checkpoints, Fabrication and assembly drawings to support manufacture 2. List any advantages of CAPP. * Investment in hardware and software is not much * The system offers a shorter development time and lower manpower * Consumption to develop process plan. 3. Define MRP II. ‘The MRP II process is carried out by a synergistic combination of computer and human resources. It differs fundamentally from point contact planning, in which individual characteristics and functions have their own dedicated systems 4. Define master production schedule. ‘A Master Production Schedule or MPS is the plan that a company has developed for production, inventory, staffing, etc. It sets the quantity of each end item to be completed in each week of a short-range planning horizon. A Master Production Schedule is the master of all schedules 5. What is production planning? It is a preproduction activity. It may be defined as the determination, acquisition and arrangement of all facilities necessary for future production of products 6. Give the main component of generative CAPP systems CAPP system contains of twro main components. i) Manufacturing data base (part description, machine tool library etc.) iu) Decision logic (to represent the process planner)7. What are the important reasons for shop floor scheduling? Job shops have to produce products against customer order for delivery dates have to be promised production lots tend to be quite small and may require numerous machine change over possibility of assigning and reassigning workers and machines to many different orders due to flexibility. 8. What are the phases for shop floor control? ‘A. typical shop floor control system consist of three phases # Order release © Order scheduling © Order progress 9. Distinguish clearly between MRP and MRP II. (Nov/Dec 2016) ‘Material requirement Planning (MRP) : It is a computational technique that converts the master schedule for end products into a detailed schedule for the raw materials and components used in the end products. The detailed schedule identifies the quantities of each raw material and component items. It indicates when each item must be ordered and delivered to meet the master schedule for final products ‘Manufacturing Resource Planning (MRP II): It can be defined as a computer based system for planning, scheduling, and controlling the materials, resources and supporting activities needed to meet the master production schedule. It is a closed loop system that integrates and coordinates all of the major functions of the business to produce the right products at the right times. Closed loop system means that MRP II incorporates feedback of data on various aspects of operating performance so that corrective action can be taken in a timely manner 10. Why retrieval CAPP is called as variant CAPP system? For a new component for which the process plan is to be determined, the first step is to derive the GT code number for the part. With this code number, a search is made of the part family file to determine if a standard route sheet exists for the given part code. If the file contains a process plan for the part, itis retrieved and displayed for the user. Hence this CAPP is called as retrieval CAP system11. Differentiate process planning and production planning. (Nov/Dec 2016) Process planning is concemed with the engineering and technological issues of how to make the product and it parts. It deals with what types of equipment and tools required to fabricate the parts and assemble the product. Production planning is concemed with logistics issues of making the product. It is concemed with ordering the materials and obtaining the resources required to make the product 12. Comment on the output of aggregate production planning. (Apr/May 2017) Inputs to aggregate planning include demand forecast, available resources, and policies regarding employment levels, and so on. The output of the aggregate planning is a production plan or an operations plan with overall decisions on level of output, capacity, employment, and inventory 13. List the basic steps in developing a process plan. (Apr/May 2017) © Generating an Idea Evolution of the Idea Market Research Product Introduction © Product Life CyclePART-B 1. Define variant CAPP systems. Explain the general procedure for using one of the variant CAPP systems. (Apr/May 2017), (Nov/Dec 2016) © OMPUTER AIDED PROCESS PLANNING| Sysiaass ‘Textual process pan Variant Process Planning Variant process planning implements a coding and classification scheme by which a process plan for a previously planned part is retrieved. The retrieved plan is based on the similarity to the new part. The process plan is then manually modified as required for the new part design. There is high probability that similar parts have similar process plans. This is a basic assumption of utilizing the variant process planning method Variant methods assume that the user is able to determine the appropriate classification codes needed to retrieve appropriate plans, and that plans exist and include features which are closely analogous to those of the new part Because variant systems are based on the process plans on historic data, it is also assumed that the factory configuration is stable, with only minimal workstation or process capability changes‘The variant approach to CAPP was the first approach used in computer process planning Variant CAPP is based on the concept that similar parts have similar process plans. The computer is used as a tool to assist in identifying similar process plans, as well as in retrieving and editing the plans to suit the requirements for specific parts Variant CAPP is related to part classification and Group Technology coding In these approaches, parts are classified and coded based upon several characteristics or attributes. A Group Technology code can be used for the retrieval of process plans for similar parts. A retrieval CAPP system, also called a variant CAPP system, has been widely used in machining applications. The basic idea behind the retrieval CAPP is that similar parts will have similar process plans. In this system, a process plan for a new part is created by recalling, identifying and retrieving an existing plan for a similar part, and making the necessary modifications for the new part. In fact, the variant CAPP is a computer — assisted extension of the manual approach. The computer assists by providing an efficient system for data management, retrieval, editing and high speed printing of the process plans. The retrieval CAPP system has the capacity to alter an existing process plan. That's why it is also known as variant CAPP system. Procedure for using Retrieval CAPP system A retrieval CAPP system is based on the principles of group technology (GT) and parts classification and coding. In this system, for each part family a standard process plan is prepared and stored in computer files Through classification and coding, a code number is generated. These codes are often used to identify the part family and the associated standard plan, The standard plan is retrieval and edited for the new part Variant CAPP system procedure: Step 1: Define the coding scheme Adopt existing coding or classification schemes to label parts for the purpose of classification, In some extreme cases, a new coding scheme maybe developed Step 2: Group the parts into part familiesGroup the part families using the coding scheme defined in Step 1. based on some common part features. A standard plan is attached to each part family (see step 3) Often, a number of part types are associated with a family, thereby reducing the total number of standard process plan Step 3: Develop a standard process plan for each part family based on the common features of the part types. This process plan can be used for every part type within the family with suitable modifications Step 4: Retrieve and modify the standard plan. When a new part enters the system, it is assigned to a part family based on the coding and classification scheme. Then the corresponding standard process plan is retrieved and modified to accommodate the unique features of the new part. Advantages of Retrieval CAPP system © Once a standard plan has been written, a variety of parts can be planned © Comparatively simple programming and installation ( compare with generative CAPP systems) is required to implement a planning system. «Efficient processing and evaluation of complicated activities and decisions, thus reducing the time and labour requirements © Lower development and hardware costs. 2. Explain in detail the Generative and Variant approaches in process planning and differentiate both approaches? (Apr/May 2017) Generative approaches in Computer aided manufacturing process planning: In the generative approach, an automatic computerized system is used to synthesize or generate each individual process plan automatically and without reference to any prior plan. The automatic computerized system normally consists of decision logic, formulas, technology algorithms and geometry based data to uniquely determine the many processing decisions required for generating process plans Unlike the retrieval CAPP no standard manufacturing plans are predefined or stored Instead, the computer automatically generates a unique operation/ route sheet whenever the part is orderedThus the generative CAPP system automatically generates the process plan based on decision logics and pre-coded algorithms. The computer stores the rules of manufacturing and the equipment capabilities ‘When using a system, a specific process plan for a specific part can be generated without any involvement of a process planner. The human role in running the system includes Inputting the GT code of the given part design, and (ii) monitoring the function Components of Generative CAPP system The various components of a generative system are, i) A part description, which identifies a series of component characteristics, including geometric features, dimensions, tolerances and surface condition ii) A subsystem to define the machining parameters for example using look — up tables and analytical results for cutting parameters. iii) A subsystem to select and sequence individual operations. iv) Decision logic is used to associate appropriate operations with features of a component, and heuristics and algorithms are used to calculate operation steps, times and sequences v) A database of available machines and tooling vi) A report generator which prepares the process plan report. Advantages of Generative CAPP: i) New components can be planned as easily as existing components ii) thas potential for integrating with an automated manufacturing facility to provide iti) Detailed control information. Variant or Retrieval approaches in Computer aided manufacturing process planning A retrieval CAPP system, also called a variant CAPP system, has been widely used in machining applications. The basic idea behind the retrieval CAPP is that similar parts will have similar process plans. In this system a process plan for a new part is created by recalling. Identifying and retrieving an existing plan for a similar part, and making the necessary modifications for the new part. In fact, the variant CAPP is acomputer — assisted extension of the manual approach. The computer assists by providing an efficient system for data management, retrieval, editing and high speed printing of the process plans. The retrieval CAPP system has the capacity to alter an existing process plan. That’s why it is also known as variant CAPP system, Procedure for using Retrieval CAPP system: A retrieval CAPP system is based on the principles of group technology (GT) and parts classification and coding In this system, for each part family a standard process plan is prepared and stored in computer files. Through classification and coding, A code number is generated These codes are often used to identify the part family and associated standard plan. The standard plan is retrieval and edited for the new part Variant CAPP system procedure: Step 1: Define the coding scheme Adopt existing coding or classification schemes to label parts for the purpose of classification In some extreme cases, a new coding scheme maybe developed. Step 2: Group the parts into part families Group the part families using the coding scheme defined in Step 1. Based on some common part features, a standard plan is attached to each part family. Often, a Numbers of part types are associated with a family, thereby reducing the total number of Standard process plan Step 3: Develop a standard process plan for each part family based on the common features of the part types. This process plan can be used for every part type within the family with Suitable modifications 3. Explain the three phases of shop floor control. (Apr/May 2017), (Nov/Dec 2016). The three phases of shop floor control i) Orderrelease ii) Order scheduling iii) Order progress Order Release: The order release in shop floor control provides the documentation needed to process a production order. The documents in the shop floor order may consists of the following documentsi) Route Sheet ii) Material requisition to draw necessary materials from the stores iii) Job cards or other means to report direct labour time given to the order iv) Instructions to material handling personnel to transport parts between the work centers in the factory v) Parts list for assembly, in the case of assembly operations. In a typical factory which works on manual processing of data these documents move with the production order and are used to track the progress through the shop. In a CIM factory, more automated methods are used to track the progress of the production orders. The order release is connected with two inputs. Authorization proceeds through the various planning functions (MRP, capacity planning). These provide timing and scheduling information. The engineering and manufacturing database provides the product structure and process planning information needed to prepare the various documents that accompany the order through the shop D 4 4 poe e Hours and Quantities Tracking Routing hstructions = . ‘Work Order and Rate Schedules Creaton Reporting = Shop Fleor Gonvro Features Blending, Filing and Packaging al . Manufacturing Accourting Material Tracting Produstion Scheduling ane Tracking Order Scheduling: This module assigns the production orders to various work centres, machine tools, welding stations, moulding machines etc., in the plant. It follows directly from the order release module. Order scheduling executes the dispatch function in productionplanning and control. The order scheduling module prepares a dispatch list that indicates which production order should be accomplished at the various work centers. It provides the information on the relative priorities of the various jobs by showing the due dates for each job. By following the dispatch list in making work assignments and allocating resources to different jobs the master schedule can be best achieved. The order schedule module addresses to two important activities in shop floor production control. @ Machine loading (ii) Job sequencing Allocating the orders to the work centers is termed as machine loading or shop loading, which refers to the loading of all machines in the plant. In most cases each work centre will have a queue of orders waiting to be processed. This queue problem can be solved by job sequencing, This involves determining the order in which the jobs will be processed through a given work centre. To determine this sequence, priorities are given to jobs in the queue and the jobs are processed according to the priorities. Several queuing models are available in operations management to solve this problem This control of priorities is an important input to the order scheduling module. Rules to establish the priorities are @ Earliest due date: These are given high priority Gi) Shortest processing time: Shorter processing time orders are given high priority, (iii) Least slack time: Orders with least slack time are given high priority. Fluctuations in market demand, equipment breakdown, cancellation of the order by customer and defective raw material or delay in the receipt of materials affect the priority. The priority control plan reviews the relative priorities of the orders and adjusts the dispatch list accordingly. Order Progress: The order progress module in the shop floor control system monitors the status of the various orders in the plant work-in-process and other characteristics that indicate the progress and performance of production. The function of the order progress module is toprovide the information that is useful in managing the factory based on the data collected from the factory. The order progress report includes @ Work order status reports: These reports indicate the status of the production orders. Typical information in the report includes the current work centre where each order is located, processing hours remaining before completion of each order, whether the job is on-time or behind schedule, and priority level. Gi) Progress report: A progress report records the performance of the shop during the period of master schedule and reports the number of operations completed and not completed during the time period. Exception reports: These reports bring out the deviations from the production schedule (ex. overdue jobs). The above reports are useful to production management in making the decisions about allocation of resources, authorization of the overtime hours, and other capacity issues, and in identifying areas of problems in the plant that adversely affect the implementation of the master production schedule 4. What is MRP? Explain the inputs to MRP and various MRP outputs. Also list the various benefits of MRP. (Nov/Dec 2016) Material requirements planning (MRP): It is a production planning and inventory control system used to manage Manufacturing processes. Most MRP systems are software-based, while it is possible to conduct MRP by hand as well.Master Production Schedule (MPs) Inventroy - Bil of aerial Requirements Planning xo (WR) Loge J} natorats 20m Fle ¥ 1. Planned Order Release 2. Order Rescheduling 3, Planned Orders Receipls Inputs to the MRP System: Function of the MRP program must operate on data contained in several files These file server as inputs to the MRP processor They are: MPS, bill of materials file and other engineering and manufacturing data. An inventory record files the flow of data into the MRP processor and its conversion into useful output reports. Variant Process Planning Preparatory Sta Pt ee ee = fe ie 1 & Je Lie Standare process reparation 1 formation prepa pi ee SS S| itive process plans finished process | 1 ian eating | | t- - - - eo eee Procuction StageIn a properly implemented MRP system capacity planning also provides input to ensure that the MRP schedule does not exceed the production capacity of the firm. The MPS lists what end product, and how many of each are to be produced and when they are to be ready for shipment Manufacturing firms generally work toward monthly delivery schedules, but the master schedule in our figure uses weeks as the time periods MRP makes its computations of materials and parts requirements in terms of time buckets The bill of materials (BOM) file is used to compute the raw material and component requirements for end products listed in the master schedule. It provides information on the product structure by listing the component parts and subassemblies that make up each product. INPUTS TO A STANDARD MRP PROGRAM Demand for Products: Product demand for end items stems from two main reasons. The first is known customers who have placed specific orders, such as those generated by sales personnel, or from interdepartmental transactions. The second source is forecast demand. Demand from known customers and demand forecast are combined and become the input to the master production schedule Bill of Materials File: The bill of Materials file contains the complete product description, listing materials, parts, and components but also the sequence in which the product is created. The BOM file is often called the product structure file or product tree because it shows how a product is put together. It contains the information to identify each item and the quantity used per unit of the item of which it is a part Inventory Records File: Inventory records file under a computerized system can be quite lengthy. Each item in inventory is carried as a separate file and the range of details carried about an item is almost limitless. The MRP program accesses the status segment of the file according to specific time periods. These files are accessed as needed during the programrunOUTPUT REPORTS Primary Reports: Primary reports are the main or normal reports used for the inventory and Production control. These report consist of i) Planned orders to be released at a future time. ii) Order release notices to execute the planned orders iii) Changes in due dates of open orders due to rescheduling iv) Cancellations or suspensions of open orders due to cancellation or suspension of orders on the master production schedule v) Inventory status data Secondary Reports > Planning reports to be used, for example, in forecasting inventory and specifying requirements over some future time horizon. > Performance reports for purposes of pointing out inactive items and determining the agreement between actual and programmed item lead times and betwreen actual and programmed quantity usage and costs. > Exceptions reports that point out serious discrepancies, such as errors, out of range situations, late or overdue orders, excessive scrap, or nonexistent parts. 5. Briefly explain Capacity Planning. A realistic master schedule must be consistent with the production capabilities and limitations of the plant that will produce the product Accordingly the firm must know its production capacity and must plan for changes in capacity to meet changing production requirements specified in the master schedule, we defined production capacity and formulated ways for determining the capacity of a plant Capacity planning is concemed with determining what labor and equipment resources are required to meet the current MPS as well as long-term future production needs of the firm Capacity planning also serves to identify the limitations of the available production resources so that an unrealistic master schedule is not planned. When the MRS is established: and second, when the MRP computations are done A rough-cut capacity planningcalculation is made to assess the feasibility of the master schedule Such a calculation indicates whether there is a significant violation of production capacity in the MPS. On the other hand, if the calculation shows no capacity violation, neither does it guarantee that the production schedule can be met a second capacity calculation is made at the MRP schedule is prepared This detailed calculation determine, there is sufficient production capacity in the individual departments and work cells to complete the specific parts and assemblies that have been scheduled by MRP. If the schedule is not compatible with capacity, then adjustments must be made either in plant capacity or in the master schedule Capacity adjustments can be divided into short term adjustments and long-term adjustments aa Resource Utilization CAPACITY PLANNING. Production Cost] Firefighting WIP & Lead Times + Employment levels. Employment in the plant can be increased or decreased in response to changes in capacity requirements, + Temporary workers. Increases in employment level can also be made by using work a temporary agency. When the busy period is passed, these workers move to Positions at other companies where their services are needed + Number of work shifts. The number of shifts worked per production period can be increased or decreased sLabor hour. The number of labor hours per shift can be increased or decreased, through the use of overtime or reduced hours. * Inventory stockpiling. This tactic might be used to maintain steady employment levels during slow demand periods+ Order backlash deliveries of the product to the customer could be delayed during busy periods when production resources are insufficient to keep up with demand + Sub contracting this involves the letting of jobs to other shops during busy periods Capacity planning adjustments for the long term include possible changes in production capacity that generally requires long lead times. These adjustments include the following types of decisions’ + New equipment Investments. This involves investing in more machines or more productive machines to meet increased future production requirements, or investing in new types of machines to match future changes in product design + New plant construction. Building a new factory represents a major investment for the company. However it also represents a significant increase in production capacity for the firm. + Purchase of existing plants from other companiesUNIT-I CELLULAR MANUFACTURING PART-A 1. Define Group Technology (GT). Group Technology (GT) is a manufacturing methodology in which identical or similar components grouped processed together during design, process planning and manufacturing so that a wide variety of components can be manufactured, at the least expense of time, inventory, man hours and material handling 2. Define Part family. Part-family is defined as" collection of parts which are similar in terms of geometric shape, size, and similar processing steps required in manufacturing, so flow of materials through the plant improves" 3. Define: Cellular Manufacturing. (Nov/Dec 2016) Cellular manufacturing is an application of group technology in which dissimilar machines have been aggregated into cells, each of which is dedicated to the production of a part family. The machines in a multi station system with variable routing may be manually Operated, semi-automatic, or fully automated. When manually operated or semi automatic the machine groups are often called machine cells, and the use of these cells in a factory is called cellular manufacturing 4. Explain opitz coding system. The optiz code consists of a form code and supplementary code. The form code can represent parts of the following variety: long, short, cubic, flat, rotational ete. A dimension ratio is further used in classifying the geometry: the length/diameter ratio is used to classify the rotational components and the length/height ratios are used to classify Non rotational components. The optiz form code uses five digits that focus on 1) component class 2) basic shape 3) rotational-surface machining 4) plane surface machining 5) auxiliary holes, gear teeth, and forming 5. What are the main objectives of cellular manufacturing? © To shorten manufacturing lead times. * Toreduce work-in-process inventory.¢ Toimprove quality, To simplify production scheduling © Toreduce setup times 6. What do you mean by PFA? Production flow analysis is a technique for identifying part families and associated grouping of machine tools. It does not use a classification and system and part drawing to identify families. Production flow analysis makes the use of information contained on route sheets instead of part drawing 7. What is the most appropriate condition in GT? GT is most appropriately applied under the following conditions: 1. The plant currently uses traditional batch production and the process type layout. 2. The parts can be grouped into part families 8. General methods used for part families. (Apr/May 2017) © Visual inspection, © Parts classification and coding system, and * Production flow analysis 9. Explain the two categories of attributes of parts, «Design attributes, which are concemed with part characteristics such as geometry, size, and material. © Manufacturing attributes, which consider the sequence of processing steps required to make a part. 10. List out the premises for the developed of DCLASS code. © A part may be best characterized bytes basic shape, usually is most apartment attribute Each basic shape may have several features, such as holes, slots, threads and grooves * A part can be completely characterized by basic shape, size, precision and material type, from and condition. © Several short code segments can be linked to from classification code that is human recognizable and adequate for human monitoring11. Explain composite part concept. (Nov/Dec 2016). The composite part concept is based on part families. It conceives of a hypothetical part for a given family that includes all of the design and manufacturing attributes of the family. In general, an individual part in the family will have some of the features that characterize the family, but not all of them. The composite part possesses all of the features 12, What are the problems in implementing group technology? (Apr/May 2017) © Implementing GT is expensive Because large costs may be incurred in rearranging the plant into machine cells or groups. Installing a coding and classification system is very time-consumingPART-B 1. Briefly explain the MICLASS and OPITZ coding system with suitable examples. (Apr/May 2017), (Nov/Dec 2016). MICLASS Originally TNO of Holland developed MICLASS system, and is maintained in the United States by the organization for industrial research. It is a chain- structured code of 12 digits. It includes both design and manufacturing information Information such as the main shape, shape elements, position of shape elements, main dimensions, ratio of dimensions, auxiliary dimension, tolerance, and the machinability of the material is included An additional 18 digits of code is also available for user-specified information These supplementary digits provide flexibility expansion Codeposition | Item T Main shape 2 5 Shape elements 4 Position of shape element 5 Main dimension 6 7 Dimension ratio Auxiliary dimension 8 ‘Auxiliary dimension 9 Tolerance codes 10 ir Material codesOPTIZ SYSTEM. Suppiment Form code ee Digit Digi Digt3 Digs Digits Dist Pareles 6789 Mainstape Rotational ——-‘Panesurlce Adon oles chin micining ‘ethan or o Lipsos madieles aT Ly ual me Extemal Tnteral Machining F ‘Other 1] foseues| tape [| tape oi plane holes and element clement series eth 7 2|#| ues 3 vith ei 5 3/a|tpes Main Rotational Macning TY iter os, i ‘shape ‘machining [~) Lee] a Ff z y) [Win aeie ssraces [O] terming Bly LD>2 il? 3| | Spec Main He stipe AC ; Aces = z iar Minboreand |} —]Masining TY Otherto, 2 7 AB>3 Ly has rotational ‘of plane teeth and ° ‘id machining surfaces forming a gp ans aces a | 9 Special shape | The optiz coding is most likely the best-known coding system. It was developed by H. optiz of the Aachen Tech University in West Germany. The code uses a hybrid structure. However, except the first digit, it resembles a chain structure more closely. It has following advantages over the existing system Itisnon proprietary. © Itis widely used © It provides a basic framework for understanding the classification and coding process ® Itcan be applied to machined parts, non-machined parts, and purchased parts # Itconsiders both design and manufacturing information © The optiz code consists of a form code and supplementary code the form code can represent parts of the following variety: long, short, cubic, flat, rotational etc. A dimension ratio is further used in classifying the geometry: the length/diameter ratio is used to classify the rotational components and the length/height ratios are used toclassify Non rotational components. The attributes of rotational parts are described as shown in table 7.2. The optiz form code uses five digits that focused on 1) Component class 2) basic shape 3) rotational-surface machining 4) Plane surface machining 5) auxiliary holes, gear teeth, and forming ‘A supplementary code is a poly code consisting four digits is usually appended to the optiz systems Example: Given the part design shown define the "form code" using the Opitz system aol = 0250 0.750 en a [0500-1 |-— 0.875 —+| b- 1.500 Step 1: The total length of the part is 1.75, overall diameter 1.25, L/D = 1.4 Step 2: Extemal shape - a rotational part that is stepped on both with one thread Step 3: Internal shape - a through hole Step 4: By examining the drawing of the part, Step 5: No auxiliary holes and gear teeth . List the benefits and applications of group technology. © GT promotes standardization of tooling, fixtures and setups © Material handling is reduced because parts are moved within a machine cell rather than within the entire factory. Process planning and production scheduling are simplified © Setup times are reduced, resulting in lower manufacturing lead times. © Work-in-process is reduced © Worker satisfaction usually improves when workers collaborate in a OT cell. + Higher quality work is accomplished using group technology.Applications of Group Technology Manufacturing applications: The most common applications of GT are in manufacturing and the most common application III manufacturing involves the formation of cells of one kind or another, not all companies rearrange machines to form cells. There are three ways in which group technology principles can be applied in manufacturing 1. Informal scheduling and routing of similar parts through selected machines: This approach achieves setup advantages. But no formal part families are defined, and no physical rearrangement of equipment is undertaken. 2. Virtual machine cells : This approach involves the creation of part families and dedication of equipment to the manufacture of these part families, but without the physical re-arrangement of machines into formal cells. The machines in the virtual cell remain in their original locations in the factory. Use of virtual cells seems to facilitate the sharing of machines with other virtual cells producing other part families 3. Formal machine cells: This is the conventional GT approach in which a group of dissimilar machines are physically relocated into a cell that is dedicated to the production of one or a limited set of part families The machines in a formal machine cell are located in close proximity to minimize part handling, throughput time, setup time, and work-in-process. Other GT applications in manufacturing include process planning family tooling, and numerical control (NC) part programs. Process planning of new parts can be facilitated through the identification of part families. The new part is associated with an existing part family and generation of the process plan for the new part follows the routing of the other members of the part family. This is done in a formalized way through the use of parts classification and coding The approach is discussed in the context of automated process planning In the ideal, all members of the same part family require similar setups, tooling, and fixtures, This generally results in a reduction in the amount of tooling and fixtures needed instead of determining a special tool kit for each part, a tool kit is developed for each part family. The concept of a modular fixture can often be exploited, in which a common base fixture is designed and adaptations are made to switch between different parts in the family.3. Discuss the production flow analysis in detail. This is an approach to part family identification and machine cell formation. Production flow analysis (PFA) is a method for identifying part families and associated machine groupings that use the information contained 011 production route sheets rather than on part drawings. Work parts with identical or similar routings are classified into part families These families can then be used to form logical machine cells in a group technology layout. Since PFA uses manufacturing data rather than design data to identify part families, it can overcome two possible anomalies that can occur in parts classification and coding, First, parts whose basic geometries are quite different may never the less require similar or even, identical process routings. Second, parts whose Geometries are quite similar may nevertheless require process routings that are quite different. 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. Should all of the parts in the shop be Included in the study, or should a representative sample be selected for analysis, Once this decision is made, then the procedure in PFA consists of the following steps Data collection: The minimum data needed in the analysis are the part number and operation sequence, which is contained in shop documents called route sheets or operation sheets or some similar name. Each operation is usually associated with a particular machine, so determining the operation sequence also determines the machine sequence .Additional data such as 101size, time standards, and annual demand might be useful for designing machine cells of the required production capacity. Sortation of process routings: In this step, the parts are arranged into groups according to the similarity of their process routings. To facilitate this step, all operations or machines included in the shop are reduced to code numbers, for each part, the operation codes are listed in the order in which they are performed. A sortation procedure is then used to arrange parts into packs,” which are groups of parts with identical routings. Some packs may contain only one part number,indicating the uniqueness of the processing of that part. Other packs will contain many parts, and these will constitute a part family PFA chart: The chart is a tabulation of the process or machine code numbers for all of the part packs. PFA chart has been referred to as part-machine incidence matrix. In this matrix, the entries have a value Xu =1 or 0: a value of Xj = 1 indicates that the corresponding part i requires processing on machine j, and Xj = 0 indicates that no processing of component i is accomplished on machine j. For clarity of presenting the matrix, the D's are often indicated as blank (empty) entries, as in our table. Cluster analysis: From the pattem of data in the PFA chart. Related groupings are identified and rearranged into a new pattem that brings together packs with similar machine sequences The blocks might be considered as possible machine cells. It is often the case. These parts might be analyzed to see if a revised process sequence can be developed that fits into one of the groups. If not, these parts must continue to be fabricated through a conventional process layout, We examine a systematic technique called rank order Cluster that can be used to perform the cluster analysis. Operation or secre coe Cutoff 01 Lathe 02 Turret lathe 03 Mill 04 Drill manual 0s NC drill 06 Grind 074, Explain Cellular Manufacturing in detail. (Apr/May 2017), (Nov/Dec 2016). Cellular manufacturing is an application of group technology in which dissimilar machines or processes have been aggregated into cells, each of which is dedicated to the production of a part or product family or a limited group of families The typical objectives in cellular manufacturing are similar to those of group technology: + To shorten manufacturing lead times, by reducing setup, work part handling, waiting times, and batch sizes + To reduce work-in-process smaller batch sizes and shorter lead times reduce work-in- process + To prove quality. This is accomplished by allowing each cell to specialize in producing a smaller number of different parts. This reduces process variations + To simplify production scheduling, The similarity among parts in the family reduces the complexity of production scheduling, Instead of scheduling parts through a sequence of machines in a process-type shop layout, the parts are simply scheduled though the cell. + To reduce setup times. This is accomplished by using group tooling (cutting tools, jigs, and fixtures) that have been designed to process the part family, rather than part tooling, which is designed for an individual part. This reduces the number Grouping Parts and Machines by Rank Order Clustering Algorithm: It is an efficient and easy-to-use algorithm for grouping machines into cells. In a starting part-machine incidence matrix that might be compiled to document the part routings in a machine shop (or other job shop), the occupied locations in the matrix are organized in a seemingly random fashion. Rank order clustering works by reducing the part-machine incidence matrix to a set of diagonal blocks that represent part families and associated machine groups. Starting with the initial part-machine incidence matrix. The algorithm consists, of the following steps 1. In each row of the matrix. Read the series of is and G's (blank entries = D's) from left to fight as a binary number. Rank the rows in order of decreasing value. In case of a tie, rank the rows in the same order as they appear in the current matrix 2. Numbering from top to bottom, is the current order of rows the same as the rank order determined in the previous step? If yes, go to step 7, If no, go to the following step3. Reorder the rows in the part-machine incidence matrix by listing them in decreasing rank order, starting from the top 4 In each column of the matrix. Read the series of I’s and O's (blank entries = (j's) from top to bottom as a binary number. Rank the columns in order of decreasing value, In case of a tie. Rank the columns in the same order as they appear in the current matrix 5. Numbering from left to right, is the current order of columns the same as the rank order determined in the previous step? If Yes go to step 7. If No go to the following step 6. Reorder the columns in the part-machine incidence matrix by listing them in decreasing rank order, starting with the left column, Go to step I 7. Stop Binaryvaes J ]2 ||P ]2]2 [= [2 | | decimal equivalent Rank parts Machines A [B [c [D JE F G ]H ft T T T T 290 1 2 I T 7 7 a T I at 5 a T I 136 4 5 T T Be 2 6 T T 6 6 7 T 1 [a 140 3parts Machines A H E a 1 a 5 1 a 7 4 3 1 6 2 1 PARTS machines | A Binary values 1 1 a z 5 1 a z 7 a 1 a 2 4 a 1 2 3 2 6 2 1 2 Decimal equivalent | 96 | 28 am | 16 | 96 Tank 1 4 5 6 25. Explain Machine Cell Design and Layouts Machine Cells and Layouts: GT manufacturing cells can be classified According to the number of machines and the degree to which the material flow is mechanized between machines. In our classification scheme for manufacturing systems all GT cells are classified as type X in terms of part or product variety. Here we identify four common GT cell configurations 1. Single machine cell (type I M) 2. Group machine cell with manual handling (type n M generally, type III M less common) 3. Group machine cell with semi-integrated handling (type II M generally, type III M less common) 4. Flexible manufacturing cell or flexible manufacturing system ‘As its name indicates, the single machine cell consists of one machine plus supporting fixtures and tooling. This type of cell can be applied to work parts whose attributes allow them to be made on one basic type of process, such as tuning or milling The group machine cell with manual handling is an arrangement of more than one machine used collectively to produce one or more part families There is no provision for mechanized parts movement between the machines in the cell. Instead, the human operators who run the cell perform the material handling function. The cell is often organized into a U-shaped layout, this layout is considered appropriate when there is variation in the work flow among the parts made in the cell. It also allows the multi functional workers in the cell to move easily between machines. The group machine cell with manual handling is sometimes achieved in a conventional process type layout without rearranging the equipment. This is done simply by assigning certain machines to be included in the machine group and restricting their work to specified part families. This allows many of the benefits of cellular manufacturing to be achieved without the expense of rearranging equipment in the shop. Obviously, the material handling benefits of OT are minimized with this organization.Work in eee Manual handling 6 Proc between machines Man FH OY Workout Proc Proc @oe Man Man Machine cell with manual handling between machines Shown is a If-shaped machine layout (Key: *Proct 0= processing Operation (e.g, mull. tum, etc), "Man" = manual operation, arrows indicate work flow.) The group machine cell with semi-integrated handling uses a mechanized handling system, such as a conveyor, to move parts between machines in the cell. The flexible manufacturing system (FMS) combines a fully integrated material handling system with automated processing stations. The FMS is the most highly automated of the group technology. Other GT layouts include in-line, loop, and rectangular Machine cells with semi-integrated handling: (@) in line layout, (b) loop layout, and (c) rectangular layout. (Key'Pro: indicate work now) processing operation (¢.g., mill, tum, etc ]. "Man* = manual operation; arrowsMechanized work handling Man Man | 3 Mas | 3 Man @ Mon |3 @| Rion Proc Man @ Mon | 2 Man |2 e = poe] Mechanized Procla g [Prec] work handling Proc Man > Man | 3 Man |3 © Work out eoceUNIT-IV FLEXIBLE MANUFACTURING SYSTEM AND AGVS PART-A . Define FMS A flexible manufacturing system (FMS) is a method for producing goods that is readily adaptable to changes in the product being manufactured, in which machines are able to manufacture parts and in the ability to handle varying levels of production . What are the advantages or benefits of FMS? (Nov/Dec 2016) a, Reduced manufacturing cost b. Lower cost per unit produced, ¢. Greater machine efficiency, 4, Improved quality, e. Increased system reliability, . What are the types of FMS? a, Sequential FMS b. Random FMS ¢. Dedicated FMS 4, Engineered FMS e Modular FMS Give the types of FMS layouts a, In-line layout b. Loop layout ¢. Ladder layout 4. Open field layout e. Robot-centered layout . Mention the applications of FMS. a, Metal cutting machining b. Metal formingc. Welding 4 Assembly e. Testing £ Inspection 6. What do you mean by AGV? An automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires in the floor, or uses vision, magnets, or lasers for navigation. They are most often used in industrial applications to move materials around a manufacturing facility or warehouse. 7. What are the applications of AGVs? (Apr/May 2017) AGVs are used in, a, Assembly lines b. Delivery of supplies ¢. Finished product handling 4. Raw materials handling e. Pallet handling 8. What are the material handling equipments in FMS? a, Trucks b. Conveyors ¢. Cranes and hoists 4. AGVs e Robots 9. State the components of FMS. The basic components of FMS are 1, Workstations Automated Material Handling and Storage system, 3. Computer Control System 10.What are the various functions of automated material handling and storage systern? The various functions of automated material handling and storage system are@ Random and independent movement of work parts betvreen workstations (i) Handling of a variety of work part configurations (iii) Temporary storage (iv) Convenient access for loading and unloading of work parts (v) Compatible with computer control. 11. List the four tests for flexibility in FMS research. (Apr/May 2017) © Part variety test Schedule change test «Error recovery test © New part test 12. List out the types of AGV’s. (Nov/Dec 2016). © AGVS towing vehicle © AGVS unit load carriers © AGVS pallet trucks © AGVS forklift trucks ¢ AGVS light-load transporters ¢ AGVS assembly-line vehiclesPART-B 1. Explain flexibility and its types. Flexibility is an attribute that allows a mixed model manufacturing system to cope up with a certain level of variations in part or product style, without having any interruption in production due to changeovers between models. Flexibility measures the ability to adapt “to a wide range of possible environment”. To be flexible, a manufacturing system must possess the following capabilities a. Identification of the different production units to perform the correct operation b. Quick changeover of operating instructions to the computer controlled production machines © Quick changeover of physical setups of fixtures, tools and other working units. These capabilities are often difficult to engineer through manually operated manufacturing systems. So, an automated system assisted with sensor system is required to accomplish the needs and requirements of contemporary business milieu. Flexible manufacturing system has come up as a viable mean to achieve these prerequisites. The term flexible manufacturing system, or FMS, refers to a highly automated GT machine cell, consisting of a group of computer numerical control (CNC) machine tools and supporting workstations, interconnected by an automated material handling and storage system, and all controlled by a distributed computer system. The reason, the FMS is called flexible, is that it is capable of processing a variety of different part styles simultaneously with the quick tooling and instruction changeovers. Also, quantities of productions can be adjusted easily to changing demand patterns The different types of flexibility that are exhibited by manufacturing systems are given below Machine Flexibility It is the capability to adapt a given machine in the system to a wide range of production operations and part styles. The greater the range of operations and part styles the greater will be the machine flexibility. The various factors on which machine flexibility depends are ¢ Setup or changeover time ¢ Ease with which part-programs can be downloaded to machines,© Tool storage capacity of machines © Skill and versatility of workers in the systems Production Flexibility: It is the range of part styles that can be produced on the systems. The range of part styles that can be produced by a manufacturing system at moderate cost and time is determined by the process envelope. It depends on following factors Machine flexibility of individual stations © Range of machine flexibilities of all stations in the system Mix Flexibility It is defined as the ability to change the product mix while maintaining the same total production quantity that is, producing the same parts only in different proportions. It is also known as process flexibility. Mix flexibility provides protection against market variability by accommodating changes in product mix due to the use of shared resources. However, high mix variations may result in requirements for a greater number of tools, fixtures, and other resources. Mixed flexibility depends on factors such as @ Similarity of parts in the mix © Machine flexibility @ Relative work content times of parts produced Product Flexibility: It refers to ability to change over to a new set of products economically and quickly in response to the changing market requirements. The change over time includes the time for designing, planning, tooling, and fuxturing of new products introduced in the manufacturing line-up. It depends upon following factors ¢ Relatedness of new part design with the existing part family © Off-line part program preparation © Machine flexibilityRouting Flexibility: It can define as capacity to produce parts on altemative workstation in case of equipment breakdowns, tool failure, and other interruptions at any particular station. It helps in increasing throughput, in the presence of extemal changes such as product mix, engineering changes, or new product introductions Following are the factors which decides routing flexibility © Similarity of parts in the mix ¢ Similarity of workstations ¢ Common tooling Volume Flexi It is the ability of the system to vary the production volumes of different products to accommodate changes in demand while remaining profitable. It can also be termed as capacity flexibility. Factors affecting the volume flexibility are ¢ Level of manual labor performing production Amount invested in capital equipment Expansion Flexibility: It is defined as the ease with which the system can be expanded to foster total production volume. Expansion flexibility depends on following factors © Cost incurred in adding new workstations and trained workers ¢ Easiness in expansion of layout © Type of part handling system used 2. How AGVs are guided? (Apr/May 2017), (Nov/Dec 2016). Wired: A slot is cut in to the floor and a wire is placed approximately 1 inch below the surface. This slot is cut along the path the AGV isto follow. This wire is used to transmit a radio signal. A sensor is installed on the bottom of the AGV close to the ground. The sensor detects the relative position of the radio signal being transmitted from the wire, This information is used to regulate the steering circuit, making the AGV follow the wireGuide tape: AGVs (some known as automated guided carts or AGCs) use tape for the guide path, The tapes can be one of two styles: magnetic or colored. The AGC is fitted with the appropriate guide sensor to follow the path of the tape One major advantage of tape over wired guidance is that it can be easily removed and relocated if the course needs to change Colour tape is initially less expensive, but lacks the advantage of being embedded in high traffic areas where the tape may become damaged or dirty. A flexible magnetic bar can also be embedded in the floor like wire but works under the same provision as magnetic tape and so remains unpowered or passive Another advantage of magnetic guide tape is the dual polarity. small pieces of magnetic tape may be placed to change states of the AGC based on polarity and sequence of the tags Laser target navigation: The navigation is done by mounting reflective tape on walls, poles or fixed machines. The AGV carries a laser transmitter and receiver on a rotating turret The laser is transmitted and received by the same sensor. The angle and (sometimes) distance to any reflectors that in line of sight and in range are automatically calculated. This information is compared to the map of the reflector layout stored in the AGV's memory. This allows the navigation system to triangulate the current position of the AGV. The current position is compared to the path programmed in to the reflector layout map. The steering is adjusted accordingly to keep the AGV on track. It can then navigate to a desired target using the constantly updating position. + Modulated Lasers: The use of modulated laser light gives greater range and accuracy over pulsed laser systems. By emitting a continuous fan of modulated laser light a system can obtain an uninterrupted reflection as soon as the scanner achieves line of sight with a reflector ‘The reflection ceases at the trailing edge of the reflector which ensures an accurate and consistent measurement from every reflector on every scan. By using a modulated laser a system can achieve an angular resolution of ~ 0.1 mrad (0.006°) at 8 scanner revolutions per second.+ Pulsed Lasers A typical pulsed laser scanner emits pulsed laser light at a rate of 14,400 Hz which gives a maximum possible resolution of ~ 3.5 m rad (0.2%) at 8 scanner revolutions per second. To achieve a workable navigation, the readings must be interpolated based on the intensity of the reflected laser light, to identify the centre of the reflector Inertial (Gyroscopic) navigation: Another form of an AGV guidance is inertial navigation With inertial guidance, a computer control system directs and assigns tasks to the vehicles Transponders are embedded in the floor of the work place. The AGV uses these transponders to verify that the vehicle is on course. A gyroscope is able to detect the slightest change in the direction of the vehicle and corrects it in order to keep the AGV on its path. The margin of error for the inertial method is +1 inch. Inertial can operate in nearly any environment including tight aisles or extreme temperatures. Inertial navigation can include use of magnets embedded in the floor of the facility that the vehicle can read and follow. Natural features (Natural Targeting) navigation: Navigation without retrofitting of the workspace is called Natural Features or Natural Targeting Navigation, One method uses one or more range-finding sensors, such as a laser range-finder, as well as gyroscopes or inertial measurement units with Monte- Carlo/Markov localization techniques to understand where it is as it dynamically plans the shortest permitted path to its goal. The advantage of such systems is that they are highly flexible for on-demand delivery to any location. They can handle failure without bringing down the entire manufacturing operation, since AGVs can plan paths around the failed device. They also are quick to install, with less down-time for the factoryVision guidance: Vision-Guided AGVs can be installed with no modifications to the environment or infrastructure. They operate by using cameras to record features along the route, allowing the AGV to replay the route by using the recorded features to navigate. Vision- Guided AGVs use Evidence Grid technology, an application of probabilistic volumetric sensing, and was invented and initially developed by Dr. Moravec at Camegie Mellon University. The Evidence Grid technology uses probabilities of occupancy for each point in space to compensate for the uncertainty in the performance of sensors and in the environment The primary navigation sensors are specially designed stereo cameras. The vision-guided AGV uses 360- degree images and build a 3D map, which allows the vision-guided AGVs to follow a trained route without human assistance or the addition of special features, landmarks or positioning systems Geo- guidance: A. geo-guided AGV recognizes its environment to establish its location Without any infrastructure, the forklift equipped with geo-guidance technology detects and identifies columns, racks and walls within the warehouse Using these fixed references, it can position itself, in real time and determine its route. There are no limitations on distances to cover or number of pick-up or drop-off locations. Routes are infinitely modifiable 3. What are the safety systems in AGVs? Warning and Alarm Lights: AGVs have warning lights, audible-waming signals, emergency stop buttons, and non-contact obstacle detectors. When the AGV is approaching a tum, the warming lights function as directional signals to alert personnel in the area of the AGV's intention to branch right or left on the Guide path, When the AGV goes into an alarm mode, the Alarm Lights blink to indicate an alarm,Audible Warning/Alarm Signals: Two distinct tones are used during the vehicle's operation, an acknowledge tone and an alarm tone The AGV emits a slow repeating acknowledge (run) tone during normal operation. The alarm tone sounds when an alarm is active Emergency Stop Buttons: Emergency stop buttons are provided on each AGV. When activated, the AGV enters an emergency stop state and all motion capable equipment will become inactive. Collision Avoidance System: The non-contact collision avoidance system on the AGV can utilize a number of different laser sensors mounted on the front, rear, side, and upper locations of the AGV. When the AGV is traveling on the Guide path, this system will detect an obstacle in any of the coverage locations. When the obstacle is within the waming field of any of these sensors, the AGV will decelerate to a slower speed in anticipation of a full stop. If the obstacle is still detected within protective field of the sensor, the AGV will apply its brakes so that it comes to a complete stop before contact is made. AGV will resume automatic operation approximately three seconds after the obstacle is removed from the protective field. 4, Explain the components of FMS. (Nov/Dec 2016) A flexible manufacturing system consists of two subsystems © Physical subsystem © Control subsystem Physical subsystem includes the following elements: Workstations: It consists of NC machines, machine-tools, inspection equipments, loading and unloading operation, and machining area Storage-retrieval systems: It acts as a buffer during WIP (work-in-processes) and holds devices such as carousels used to store parts temporarily between work stations or operations.Material handling systems: It consists of power vehicles, conveyers, automated guided vehicles (AGVS), and other systems to carry parts between workstations. Control subsystem comprises of following elements: Control hardware: It consists of mini and micro computers, programmable logic controllers, communication networks, switching devices and others peripheral devices such as printers and mass storage memory equipments to enhance the working capability of the FMS systems Control software: It is a set of files and programs that are used to control the physical subsystems. The efficiency of FMS totally depends upon the compatibility of control hardware and control software Basic features of the physical components of an FMS are discussed below Numerical control machine tools: Machine tools are considered to be the major building blocks of an FMS as they determine the degree of flexibility and capabilities of the FMS. Some of the features of machine tools are described below, The majority of FMSs use horizontal and vertical spindle machines. However, machining centers with vertical spindle machines have lesser flexibility than horizontal machining centers © Machining centers have numerical control on movements made in all directions e.g. spindle movement in x, y, and z directions, rotation of tables, tilting of table etc to ensure the high flexibility. © The machining centers are able to perform a wide variety of operations e.g. tuming, drilling, contouring etc. They consist of the pallet exchangers interfacing with material handling devices that carry the pallets within and between machining centers as well as automated storage and retrieval systemsWork holding and tooling considerations: It includes pallets/fixtures, tool changers, tool identification systems, coolant, and chip removal systems. It has the following features Before machining is started on the parts, they are mounted on fixtures. So, fixtures must be designed in a way, to minimize part- handling time. Modular fixturing has come up as an attractive method to fixture a variety of parts quickly. The use of automated storage and retrieval system (AS/RS) and material handling systems such as AGVs, lead to high usage of fixtures. © All the machining centers are well equipped with tool storage systems called tool magazines. Duplication of the most often used tools in the tool magazines is allowed to ensure the least non- operational time. Moreover, employment of quick tool changers, tool re-grinders and provision of spares also help for the same Material Handling Equipments The material-handling equipments used in flexible manufacturing systems include robots, conveyers, automated guided vehicle systems, monorails and other rail guided vehicles, and other specially designed vehicles. There important features are: They are integrated with the machine centers and the storage and retrieval systems For prismatic part material handling systems are accompanied with modular pallet fixtures. For rotational parts industrial robots are used to load/unload the tuning machine and to move parts between stations The handling system must be capable of being controlled directly by the computer system to direct it the various work station, load/unload stations and storage areaInspection equipment: It includes coordinate measuring machines (CMMs) used for offline inspection and programmed to measure dimensions, _concentricity, perpendicularity, and flatness of surfaces. The distinguishing feature of this equipment is that it is well integrated with the machining centers Other components It includes a central coolant and efficient chip separation system. Their features are © The system must be capable of recovering the coolant. ¢ The combination of parts, fixtures, and pallets must be cleaned properly to remove dirt and chips before operation and inspection 5, Explain FMS layout. Line layout: An Automated guided vehicle is most efficient when the movement is in straight-lines along the AGV path in a single-row machine layout, Machines are arranged only on one side of AGV path, and in double row machine layout, machines are arranged on both sides. A possible arrangement of this layout is shown in figure Loop layout The loop layout uses conveyor systems that allow unidirectional flow of parts around the loop. A secondary material handling system is provided at a workstation which permits the flow of parts without any obstruction. A possible arrangement of this layout is shown in figure.starting of work part Ladder type layout: Ladder type layout consists of rungs on which workstations are located This reduces the average travel distance thereby reducing the transfer time between workstations. A possible arrangement of this layout is shown in figure. {Loan luo Cone > vam Carousel layout: In the Carousel layout configuration, parts flow in one direction around the loop. The load, unload stations are placed at one end of loop, A possible arrangement of this layout is shown in figureJOB Robot centered cell: If a handling robot is used in a Flexible manufacturing system cell , the machines are laid out in a circle, such a layout is called circular layout. A possible arrangement of this layout is shown in figure. q [o Te sia prs] The open field layout The open field layout is also an adoption of the loop configuration. The open field layout consists of loops and ladders organized to achieve the desiredprocessing requirements, This is used for the processing of a large family of parts The number of different machines may be limited, and the parts are routed to different workstations depending on availability of machines A. possible arrangement of this layout is shown figure. Starting WORK STATIONS workpart son I LOAD a UNLOA a ‘Completed ‘workpartUNIT-V INDUSTRIAL ROBOTICS PART-A 1. What are the benefits of industrial robots? © Increased Productivity © Significant Savings © Improved Quality © Better Safety © Competitive Edge 2. What is work volume? The volume of the space swept by the robot arm is called work volume 3. What are the four basic robot configurations available commercially? © Cartesian coordinate system © Cylindrical coordinate system © Polar or spherical coordinate system Revolute coordinate system 4. What are the types of Mechanical Grippers? Linkage actuation gripper © Gear and rack actuation gripper © Cam actuated gripper © Screw actuated gripper 5. Give some examples of tool as robot End effector. © Spot Welding Tools © Are welding Torch © Spray painting nozzle © Water jet cutting tool 6. What are the basic classifications of sensors? © Tactile Sensors, © Proximity Sensors,Range sensors, © Voice sensors ete, 7. Classify the position sensors. © Incremental encoders © Absolute encoders © Resistive position sensors Linear variable differential transformer. Encoders © Potentiometer 8. What are the methods of robot programming? Lead through methods Textual robot languages © Mechanical Programming 9. Define servo controlled robots. Servo controlled robots, which are programmed by lead through an textual language methods tend to actuate all axes simultaneously 10. What is manual lead through programming? In manual lead through programming the programmer moves the manipulated wrist to teach spray-painting or arc welding The movements consist of combination of smooth motion segments. 11. Define pitch, yaw and roll. (Nov/Dec 2016). The robot's wrist is used to establish the orientation of the end effector. Robot wrists usually consist of two or three degrees-of-freedom, The Figure illustrates one possible configuration for a three-degree-of-freedom wrist assembly. The three joints are defined as: (1) roll, using a T joint to accomplish rotation about the robot's arm axis © pitch, which involves up-and-down rotation, typically using a R joint, and (3) yaw,which involves right-and-left rotation, also accomplished by means of an R joint. A two d.o.f wrist typically includes only roll and pitch joints (T and B joints). Attached to robot 12. What is accuracy and repeatability in industrial robots? (Nov/Dec 2016). Industrial robots are used in applications that require high levels of accuracy and repeatability. Repeatability is a measure of the ability of the robot to consistently reach a specified point. Accuracy is a measure of the distance error associated with the desired point and achieved point 13. Classify the robot control systems. (Apr/May 2017) The robotic systems are classified mainly into three main types on the basis of application. They are + Manipulation Robotic system + Mobile robotic system + Data acquisition and control robotic system 14, Differentiate between world and tool coordinate system in robotics with simple sketch. (Apr/May 2017). Based on a mechanical interface coordinates system, you may define tool coordinates system, which is Cartesian coordinates, by offsetting the origin of the mechanical interface coordinates system to a different point, along with the size and direction of atool, and then rotating the origin around the Z-axis of the mechanical interface coordinates system. World coordinate system is a coordinate system whose origin is specified by a user This system enables multiple robots to use a common coordinate system for position designation. By setting the origin of the facilities to that of the world coordinate system, you can set positions of different robots on the same coordinate system Coordinate Systems i—_—PART-B 1. Briefly explain the different types of robots. Industrial robots: Industrial robots are robots used in an industrial manufacturing environment. Usually these are articulated arms specifically developed for such applications as welding, material handling, painting and others. If we judge purely by application this type could also include some automated guided vehicles and other robots. Domestic or household robots: Robots used at home. This type of robots includes many quite different devices such as robotic vacuum cleaners, robotic pool cleaners, sweepers, gutter cleaners and other robots that can do different chores. Also, some surveillance and tele-presence robots could be regarded as household robots if used in that environment Medical robots: Robots used in medicine and medical institutions. First and foremost surgery robots. Also, some automated guided vehicles and maybe lifting aides Service robots: Robots that don’t fall into other types by usage. These could be different data gathering robots, robots made to show off technologies, robots used for research, ete Military robots: Robots used in military. This type of robots includes bomb disposal robots, different transportation robots, reconnaissance drones. Often robots initially created for military purposes can be used in law enforcement, search and rescue and other related fields Entertainment robots: These are robots used for entertainment. This is a very broad category. It starts with toy robots or the running alarm clock and ends with real heavyweights such as articulated robot arms used as motion simulatorsSpace robots: This type would include robots used on the Intemational Space Station, Can arm that was used in Shuttles, as well as Mars rovers and other robots used in space Hobby and competition robots: Most of the hobbyist robots are mobile and made to operate by rolling around on wheels propelled by electric motors controlled by an on board microprocessor. Explorer robots: The majority of these robots are completely self-reliant due to their sensory systems, however they may also be controlled by humans giving orders through computer commands. The other types of explorer robots are underground mine exploring robots, seeing and walking undersea robots, and even bomb defusing robots used by police. Laboratory robots: Laboratory robotics is the act of using robots in biology or chemistry labs. For example, pharmaceutical companies employ robots to move biological or chemical samples around to synthesize novel chemical entities or to test pharmaceutical value of existing chemical matter. Playback robots: The playback robots are capable of performing a task by teaching the position. These positions are stored in the memory, and done frequently by the robot. Generally, these playback robots are employed with a complicated control system, It can be divided into two important types, namely Point to Point control robots Continuous Path control robots 2. Sketch and explain the four basic robot configurations classified according to the coordinate system. (Apr/May 2017), (Nov/Dec 2016). Classification Based on Physical Cartesian configuration Cylindrical configuration © Polar configurationJoint-arm configuration Cartesian Configuration: Robots with Cartesian configurations consist of links connected by linear joints (L) Gantry robots are Cartesian robots (LLL) Cylindrical Configuration: Robots with cylindrical configuration have one rotary (R) joint at the base and linear (L) joints succeeded to connect the links KU sexible manufacturing cell has just been created, After considering © A Serie designe, the eystem engineer choso a layout that consists of numer fining workstations plus a losd/unload station. Ip dete the Weyout consists of : The load/unload station is station t,t 2 Hxtforms milling operations and consists of ane seme" (one ENC milling Perper) Station 3 has one server that performs driling (one CNC drill, Statin uations are connected by part ending system, Set prose) Tipork cartier, The mean transport time in the 90 ‘4 min. thee oC produces three parts, A, B, and C. The Pal 05 fractions and ‘rocess routings fr the three parts tre ‘presented in the table below. The pperation frequency, ‘for all operations. Determine () maximum (roduction rate of the FMC, (3) ‘Corresponding production rates of each Producti) utilization ofeach machine in the system, and (i) number of Busy servers at each station. (16) Part} | Part Mix| Operation ‘Daveription | Station i | Process time tx Bi A 04 1 Load i 2 ‘Mill 2 [ 2. | 3 Drill, 3 {ee | —__} 4 Unload 1 mn