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ENGINEERING COLLEGES
2017 – 18 ODD Semester

IMPORTANT QUESTIONS AND ANSWERS
Department of Mechanical Engineering
SUBJECT CODE: ME 6703
SUBJECT NAME: COMPUTER INTEGRATED MANUFACTURING SYSTEMS

Regulation: 2013 Year and Semester: IV and VII
Prepared by:
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Sl. No. Name of the Faculty Designation Affiliating College
Mr. J. Allwyn Kingsly Gladston

1. Asst.Prof SCADCET
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Mr. M.Senthilkumar
Mr. M. Poovaragan
Verified by DLI, CLI and Approved by the Centralized Monitoring Team dated 20.06.2017
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SYLLABUS
ME 6703 - COMPUTER INTEGRATED MANUFACTURING SYSTEMS
OBJECTIVES:
To understand the application of computers in various aspects of Manufacturing viz.,
Design, Proper planning, Manufacturing cost, Layout & Material Handling system.
UNIT I INTRODUCTION 10
Brief introduction to CAD and CAM – Manufacturing Planning, Manufacturing
control- Introduction to CAD/CAM – Concurrent Engineering-CIM concepts –
Computerised elements of CIM system –Types of production - Manufacturing models
and Metrics – Mathematical models of Production Performance– Simple problems –
Manufacturing Control – Simple Problems – Basic Elements of an Automated system
– Levels of Automation – Lean Production and Just-In-Time Production.
UNIT II PRODUCTION PLANNING AND CONTROL AND
COMPUTERISED PROCESS PLANNING 10
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Process planning – Computer Aided Process Planning (CAPP) – Logical steps in
Computer Aided Process Planning – Aggregate Production Planning and the Master
Production Schedule – Material Requirement planning – Capacity Planning- Control
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Systems-Shop Floor Control-Inventory Control –Brief on Manufacturing Resource

Planning-II (MRP-II) & Enterprise Resource Planning (ERP) - Simple Problems.
UNIT III CELLULAR MANUFACTURING 9
Group Technology(GT), Part Families – Parts Classification and coding – Simple
Problems in Opitz Part Coding system – Production flow Analysis – Cellular
Manufacturing – Composite part concept –Machine cell design and layout –
Quantitative analysis in Cellular Manufacturing – Rank Order Clustering Method -
Arranging Machines in a GT cell – Hollier Method – Simple Problems.
UNIT IV FLEXIBLE MANUFACTURING SYSTEM (FMS) AND
AUTOMATED GUIDED VEHICLE SYSTEM (AGVS) 8
Types of Flexibility - FMS – FMS Components – FMS Application & Benefits
– FMS Planning and Control– Quantitative analysis in FMS – Simple Problems.

Automated Guided Vehicle System (AGVS) – AGVS Application – Vehicle Guidance

technology – Vehicle Management & Safety.
UNIT V INDUSTRIAL ROBOTICS 8
Robot Anatomy and Related Attributes – Classification of Robots- Robot Control
systems – End Effectors – Sensors in Robotics – Robot Accuracy and Repeatability -
Industrial Robot Applications – Robot Part Programming – Robot Accuracy and
Repeatability – Simple Problems.
TOTAL:45 PERIODS
OUTCOMES:
Upon completion of this course, the student can able to understand the use of
computers in process planning and use of FMS and Robotics in CIM
TEXT BOOK:
1. Mikell.P.Groover ―Automation, Production Systems and Computer Integrated
Manufacturing‖, Prentice Hall of India, 2008.
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2. Radhakrishnan P, Subramanyan S.and Raju V., ―CAD/CAM/CIM‖, 2nd Edition,
New Age International (P) Ltd, New Delhi, 2000.
REFERENCES:
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1. Kant Vajpayee S, ―Principles of Computer Integrated Manufacturing‖, Prentice Hall

India, 2003.
2. Gideon Halevi and Roland Weill, ―Principles of Process Planning – A Logical
Approach‖ Chapman & Hall, London, 1995.
3. Rao. P, N Tewari &T.K. Kundra, ―Computer Aided Manufacturing‖, Tata McGraw
Hill Publishing Company, 2000.

TABLE OF CONTENTS
PAGE.
S.NO TABLE OF CONTENTS
NO
a. Aim and Objective of the subject 5

b. Detailed Lesson Plan 5
c. Unit I- Introduction of CIM -Part A 8
d. Unit I- Introduction of CIM -Part B 12
Unit II- Production planning and control and
e. 22
computerised Process planning -Part A
Unit II-Production planning and control and
f. 25
computerised Process planning -Part B
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g. Unit III- Cellular manufacturing -Part A 38
h. Unit III- Cellular manufacturing -Part B 41
Unit IV- Flexible manufacturing system (FMS) and
i. 53
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automated Guided vehicle system (AGVS) -Part A

Unit IV- Flexible manufacturing system (FMS) and
j. 56
automated Guided vehicle system (AGVS) -Part B
k. Unit V-Industrial robotics - Part A 69
l. Unit V- Industrial robotics - Part B 73
m. Anna University Question Papers 82
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1. Aim and objective of the subject

To understand the application of computers in various aspects of Manufacturing
viz., Design, Proper planning, Manufacturing cost, Layout & Material Handling
system.
2. Need and importance for study of the subject
The student can able to understand the use of computers in process
planning and use of FMS and Robotics in CIM.
LESSON PLAN:
Sl. No of Book
WEEK Topics
No. Hours No.
UNIT-I : INTRODUCTION OF CIM
1 Brief introduction to CAD and CAM 1 T1,R1
2 Manufacturing Planning, Manufacturing control 1 T1,R1

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Introduction to CAD/CAM – Concurrent
1 T1,R1
3 Engineering
WEEK I CIM concepts – Computerised elements of CIM
1 T1,R1
system –Types of production
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4
Manufacturing models and Metrics –
Mathematical models of Production 1 T1,R1
5
Performance Simple problems
T1,R1,
Manufacturing Control – Simple Problems 1
6 R3
7 Basic Elements of an Automated system. 1 T1,R1

WEEK II
8 – Levels of Automation 1 T1,R1
9 Lean Production 1 T1,R1
10 Just-In-Time Production 1 T1,R1

UNIT – II
PRODUCTION PLANNING AND CONTROL AND COMPUTERISED
PROCESS PLANNING
Process planning – Computer Aided Process T1,R1,
1
11 Planning (CAPP) R3

Sl. No of Book
WEEK Topics
No. Hours No.
Logical steps in Computer Aided Process T1,R1,
1
12 Planning R3
T1,R1,
13 Aggregate Production Planning 1
WEEK III R3
T1,R1,
14 Master Production Schedule 1
R3
T1,R1,
Material Requirement planning 1
15 R3
T1,R1,
Capacity Planning- Control Systems 1
16 R3
T1,R1,
Shop Floor Control-Inventory Control 1
17 R3
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WEEK Brief on Manufacturing Resource Planning-II T1,R1,
1
18 IV (MRP-II) R3
T1,R1,
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Enterprise Resource Planning (ERP) 1

19 R3
20 Simple Problems. 1 T1,R1

UNIT – III : CELLULAR MANUFACTURING
21 Group Technology(GT), Part Families 1 T1,R1
22 – Parts Classification and coding – 1 T1,R1
23 WEEK V Simple Problems in Opitz Part Coding system 1 T1,R1
24 Production flow Analysis 1 T1,R1
25 Cellular Manufacturing 1 T1,R1

Composite part concept, Machine cell design
1 T1,R1
26 and layout
Quantitative analysis in Cellular Manufacturing
1 T1,R1
27 WEEK – Rank Order Clustering Method
28 VI Arranging Machines in a GT cell 1 T1,R1
29 Hollier Method – Simple Problems 1 T1,R1

Sl. No of Book
WEEK Topics
No. Hours No.
UNIT – IV : FLEXIBLE MANUFACTURING SYSTEM (FMS) AND
AUTOMATED GUIDED VEHICLE SYSTEM (AGVS)
30 Types of Flexibility - FMS – FMS Components 1 T1,R1
31 FMS Application & Benefits 1 T1,R1
32 FMS Planning and Control 1 T1,R1

Quantitative analysis in FMS – Simple
1 T1,R1
33 WEEK Problems.
34 VII Automated Guided Vehicle System (AGVS) 1 T1,R1
35 AGVS Application 1 T1,R1
36 Vehicle Guidance technology 1 T1,R1

WEEK
VIII Vehicle Management & Safety 1 T1,R1
37
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UNIT – V : INDUSTRIAL ROBOTICS
38 Robot Anatomy and Related Attributes 1 T1,R1

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Classification of Robots- Robot Control

1 T1,R1
39 systems
40 End Effectors – Sensors in Robotics 1 T1,R1

T1,R1,
Robot Accuracy and Repeatability 1
41 R2
T1,R1,
Industrial Robot Applications 1
42 R2
T1,R1,
Robot Part Programming 1
43 R2
WEEK T1,R1,
Robot Accuracy and Repeatability 1
44 IX R2
T1,R1,
Simple Problems 1
45 R2

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-
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processing activities in manufacturing planning include process planning, master
scheduling, requirements planning, and capacity planning.
4. Define manufacturing control.
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Manufacturing control is concerned 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 factor y 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.
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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
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"just in time."
11. What are the benefits of automation?
To reduce labour cost
To mitigate the effects of labour shortages
To reduce 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
Zero handling * 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
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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.
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16. Illustrate the components of an automated system with simple
sketch.(Apr/May2017)
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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.
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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)
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PART-B
1. Explain the computerized elements of CIM system.
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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.
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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 concerned 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.

(Nov/Dec 2016)
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In some manufacturing operations, the percentage of scrap produced is high
enough to adversely affect production rate, plant capacity, and product costs.
Production Rate:
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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.
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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
(shift/wk),
H = hr/5hift, and
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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.
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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.
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3. Explain the basic elements an automated system.
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
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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:
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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 alternative 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.
Alternative power sources include fossil fuels, solar energy, water, and wind. However,
their exclusive use is rare in automated systems. In many cases when alternative power
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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 alternative 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
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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
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treatment cycle. In this case, programming simply involves sensing the temperature dial
on the furnace, 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.
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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.
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Controller. and
Actuator.
The input parameter often referred to as the set point, represents the desired
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value of the output.
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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.
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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.
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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:
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This is the highest level consisting of the corporate information system. It is
concerned with all of the functions necessary to manage the company. Marketing and
sales, accounting, design, research, aggregate planning, and master production
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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
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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,
(4) Unnecessary processing steps,
(5) Unnecessary movement of people,
(6) Unnecessary transport of materials, and
(7) 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
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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
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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
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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 concerned 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.
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UNIT II
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.
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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.
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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 two main components.
i) Manufacturing data base (part description, machine tool library etc..)
ii) Decision logic (to represent the process planner)
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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
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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
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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 mea ns 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, it is retrieved and displayed for the user. Hence this
CAPP is called as retrieval CAPP system.
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11. Differentiate process planning and production planning.(Nov/Dec 2016)

Process planning is concerned 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 concerned with logistics issues of making the product. It is
concerned 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)
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Generating an Idea
Evolution of the Idea
Market Research
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Product Introduction
Product Life Cycle
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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)
COMPUT ER AID ED PROCES S PLANNING
Group te c hnology
approac h E xac t a pproa c h
Varia nt CAPP Ge ne ra tive

CAP P
S imilarity o f pa rts Mathe ma tic

and proc e s s plans mode lling
Sys k la s s Pa rt
(C APP software )
(C APP software )
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T e xtual proc e s s
All form of
plan
proc e s s plan
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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.
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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
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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
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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
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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
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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.
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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.
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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
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component, and heuristics and algorithms are used to calculate operation steps,
times and sequences.
v ) A database of available machines and tooling.
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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) It has potential for integrating with an automated manufacturing facility to
provide
iii) 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
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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.
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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
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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) Order release
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
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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.
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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
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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.
(i) 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
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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:
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(i) Earliest due date: These are given high priority

(ii) 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
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provide the information that is useful in managing the factory based on the data
collected from the factory. The order progress report includes:
(i) 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.
(ii) 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
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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)
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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.
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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
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into the MRP processor and its conversion into useful output reports.
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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,
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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.
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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 program run.
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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
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agreement between actual and programmed item lead times and between actual and
programmed quantity usage and costs.
 Exceptions reports that point out serious discrepancies, such as errors, out of range
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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 concerned 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
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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.
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• 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.
•Labor 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
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• 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.
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• Purchase of existing plants from other companies.
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UNIT-III
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
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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
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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 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 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.
To reduce work-in-process inventory.
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To improve quality.
To simplify production scheduling.
To reduce 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,
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Parts classification and coding system, and
Production flow analysis.
9. Explain the two categories of attributes of parts.
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Design attributes, which are concerned 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.
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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.
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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.
Code position Item

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1 Main shape
2
Shape elements
3
4 Position of shape element
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5 Main dimension
6
7 Dimension ratio Auxiliary dimension
8 Auxiliary dimension
9
Tolerance codes
10
11
Material codes
12
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OPTIZ SYSTEM
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The optiz coding is most likely the best-known coding system. It was developed by H.
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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
It is non proprietary.
It is widely used.
It provides a basic framework for understanding the classification and coding
process.
It can be applied to machined parts, non-machined parts, and purchased parts.
It considers 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
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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
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Step 1: The total length of the part is 1.75, overall diameter 1.25, L/D = 1.4
Step 2: External shape - a rotational part that is stepped on both with one thread
Step 3: Internal shape - a through hole
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Step 4: By examining the drawing of the part

Step 5: No auxiliary holes and gear teeth
2. 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.
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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
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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
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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.
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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
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analysis, Once this decision is made, then the procedure in PFA consists of the following
steps:
Data collection:
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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,
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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 Xii = l or 0: a value of Xij = 1 indicates that the corresponding part i
requires processing on machine j, and Xij = 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 pattern of data in the PFA chart. Related groupings are identified and
rearranged into a new pattern 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
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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.
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Operation or
Code
Machine
Cutoff 01
Lathe 02
Turret lathe 03
Mill 04
Drill manual 05
NC drill 06
Grind 07
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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.
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• 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
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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.
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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
Binary values 26 27 26 25 24 23 22 21 20 Decimal equivalent Rank

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parts
Machines A B C D E F G H I
1 1 1 1
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290 1
2 1 1
17 7
3 1 1
81 5
4 1 1
136 4
5 1 1
258 2
6 1 1
65 6
7 1 1 1
140 3
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parts
Machines
A H D B F G I C E
1 1 1 1
5 1 1
7 1 1 1
4 1 1
3 1 1 1
6 1 1
2 1 1
PARTS
machines A B C D E F G H I Binary
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values
1 1 1 26
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5 1 1 25
7 1 1 1 24
4 1 1 23
3 1 1 1 22
6 1 1 21
1 1 20
Decimal
equivalent 96 24 6 64 5 24 16 96 7
rank
1 4 8 3 9 5 6 2 7
49 : www.LearnEngineering.in
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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
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attributes allow them to be made on one basic type of process, such as turning 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
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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.
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Machine cell with manual handling between machines. Shown is a If-shaped

machine layout. (Key: "Proc" 0= processing Operation (e.g., mill. turn, etc.), "Man" =
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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
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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: (a) in line layout, (b) loop layout, and (c) rectangular layout.
(Key"Proc'' = processing operation (e.g., mill, turn, etc.]. "Man" = manual operation; arrows
indicate work now)
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UNIT-IV
FLEXIBLE MANUFACTURING SYSTEM AND AGVS
PART-A
1. 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.
2. What are the advantages or benefits of FMS? (Nov/Dec 2016)
a. Reduced manufacturing cost
b. Lower cost per unit produced,
c. Greater machine efficiency,
d. Improved quality,
e. Increased system reliability,
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3. What are the types of FMS?
a. Sequential FMS
b. Random FMS
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c. Dedicated FMS
d. Engineered FMS
e. Modular FMS
4. Give the types of FMS layouts.
a. In-line layout
b. Loop layout
c. Ladder layout
d. Open field layout
e. Robot-centered layout
5. Mention the applications of FMS.
a. Metal cutting machining
b. Metal forming
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c. Welding
d. Assembly
e. Testing
f. 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
c. Finished product handling
d. Raw materials handling
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e. Pallet handling
8. What are the material handling equipments in FMS?
a. Trucks
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b. Conveyors
c. Cranes and hoists
d. AGVs
e. Robots
9. State the components of FMS.
The basic components of FMS are:
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System.
10. What are the various functions of automated material handling and storage
system?
The various functions of automated material handling and storage system are
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(i) Random and independent movement of work parts between workstations
(ii) 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
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AGVS pallet trucks
AGVS forklift trucks
AGVS light-load transporters
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AGVS assembly-line vehicles
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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.
c. 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
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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
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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
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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
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flexibility depends on factors such as:
Similarity of parts in the mix
Machine flexibility
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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 fixturing 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
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Routing Flexibility:
It can define as capacity to produce parts on alternative workstation in case of
equipment breakdowns, tool failure, and other interruptions at any particular
station. It helps in increasing throughput, in the presence of external 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 Flexibility:
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:
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Level of manual labor performing production
Amount invested in capital equipment
Expansion Flexibility:
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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 is to 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.
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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.
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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
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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.
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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
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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:

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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.
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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 Carnegie 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.
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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
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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-warning signals, emergency stop buttons,
and non-contact obstacle detectors. When the AGV is approaching a turn, the
warning 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.
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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 warning field of any of these sensors, the
AGV will decelerate to a slower speed in anticipation of a full stop. If the obstacle is
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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
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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.
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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:
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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;
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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. turning, 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.
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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.
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Material-Handling Equipments:
The material-handling equipments used in flexible manufacturing systems
include robots, conveyers, automated guided vehicle systems, monorails and other
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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 turning 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.
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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
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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
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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.
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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.
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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.
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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.
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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
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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.
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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
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Polar or spherical coordinate system
Revolute coordinate system.
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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
Arc welding Torch
Spray painting nozzle
Water jet cutting tool
6. What are the basic classifications of sensors?

Tactile Sensors,
Proximity Sensors,
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Range sensors,
Voice sensors etc.,
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
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9. Define servo controlled robots.
Servo controlled robots, which are programmed by lead through an textual
language methods tend to actuate all axes simultaneously.
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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:
(2) pitch, which involves up-and-down rotation, typically using a R joint; and (3) yaw,
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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 R joints).
12. What is accuracy and repeatability in industrial robots? (Nov/Dec 2016).

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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
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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
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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.
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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:
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Robots used in medicine and medical institutions. First and foremost surgery
robots. Also, some automated guided vehicles and maybe lifting aides.
Service robots:
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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,
etc.
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.
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Space robots:
This type would include robots used on the International 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
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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.
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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
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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.
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Polar configuration :
The designation of the arm for this configuration can be TRL or TRR. Robots with
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the designation TRL are also called spherical robots. Those with the designation TRR are
also called articulated robots. An articulated robot more closely resembles the human
arm.
Joint-arm Configuration:
The jointed-arm is a combination of cylindrical and articulated configurations. The
arm of the robot is connected to the base with a twisting joint. The links in the arm are
connected by rotary joints. Many commercially available robots have this configuration.
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3. Briefly explain the working principle of position sensors with neat sketch.
Position sensors are used to monitor the position of joints. Information
about the position is fed back to the control systems that are used to determine
the accuracy of positioning.
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In most cases in robots, a primary interest is to control the position of the
arm. There is a large variety of devices available for sensing position. However,
the most popular angular-position sensors are the following devices:
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Encoders
Synchros
Resolvers
Potentiometers
Types of Position Sensor:
Position sensors use different sensing principles to sense the
displacement of a body. Depending upon the different sensing principles used
for position sensors, they can be classified as follows:
Resistance-based or Potentiometric Position sensors
Capacitive position sensors
Linear Voltage Differential Transformers
Magnetostrictive Linear Position Sensor
Eddy Current based position Sensor
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Hall Effect based Magnetic Position Sensors

Fiber-Optic Position Sensor
Optical Position Sensors
Potentio-metric Position Sensors:
Potentio-metric position sensor use resistive effect as the sensing principle.

The sensing element is simply a resistive (or conductive) track. A wiper is
attached to the body or part of the body whose displacement is to be measured.
The wiper is in contact with the track. As the wiper moves, the resistance
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between one end of the track and the wiper changes. Thus, the resistance
becomes a function of the wiper position. The change in resistance per unit
change in wiper position is linear.
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Resistance, proportional to wiper position, is measured using voltage divider

arrangement. A constant voltage is applied across the ends of the track and the
voltage across the resistance between the wiper and one end of the track is
measured. Thus, voltage output across the wiper and one end of the track is
proportional to the wiper position.
The conductive track can be made linear or angular depending upon the
requirements. The tracks are made from carbon, resistance wire or piezo
resistive material.
4. Briefly explain the Robot Programming Languages in detail.
(Nov/Dec 2016).
Robot languages have been developed for ease of control of motions of
robots having different structures and geometrical capabilities.
Some of the robot languages have been developed by modifying the
existing general-purpose computer languages and some of them are written in a
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completely new style.

Programming languages have been developed by the pioneer efforts of
various researchers at Stanford Artificial Intelligence Laboratory; research
laboratories of IBM Corporation, under U.S. Air Force sponsorship, General
Electric Co., Unimation and many other robot manufacturers.
WAVE and AL:
WAVE, developed at Stanford, demonstrated a robot hand—eye
coordination while it was implemented in a machine vision system.
Later a powerful language AL was developed to control robot arms. WAVE
incorporated many important features.
Trajectory calculations through coordination of joint movements, end-
effectors positions and touch sensing were some of the new features of WAVE.
But the algorithm was too complex and not user friendly.
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They could not be run in real-time and on-line. On the other hand,
trajectory calculations are possible at compile time and they can be modified
during run time.
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AML:
A manufacturing language, AML was developed by IBM. AML is very
useful for assembly operations as different user—robot programming interfaces
are possible.
The programming language AML is also used in other automated
manufacturing systems.
The advantage of using AML is that integers, real numbers and strings can be
specified in the same aggregate which is said to be an ordered set of constants or
variables.
MCL:
US Air force ICAM project led to the development of another manufacturing
control language known as MCL by McDonnel—Douglas.
This is a modification of the popular APT (Automatically Programmed
78

Tooling) language used in CNC machine tools as many similar commands are
used to control machine tools in CAM applications.
RAIL:
RAIL was developed by Automatic for robotic assembly, inspection, arc
welding and machine vision. A variety of data types as used in PASCAL can be
used.
An interpreter is used to convert the language into machine language
commands. It uses Motorola 68000 type microcomputer system; It supports many
commands and control of the vision system.
HELP:
HELP was developed by General Electric Company. It acts more or less
like RAIL.
It has the capability to control two robot arms at the same time. The structure of
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the language is like PASCAL.
JARS:
JARS was developed by NASA JPL. The base of the language is
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PASCAL. JARS can be interfaced with PUMA 6000 robot for running robotic
programs.
RPL:
RPL was developed at SRI International. A compiler is used to convert a
program into the codes that can be interpreted by an interpreter. Unimation
PUMA 500 can be controlled with the help of RPL. The basic ideas of LISP (an
Al language) have been organized into a FORTRAN-like syntax in RPL. It is
modular and flexible.
Besides these, there are some other languages like PAL, ADA etc. PAL
has been written by Richard Paul by modifying WAVE and incorporating features
of PASCAL. But the representations of syntaxes used in the program are difficult
to handle. ADA developed by the Department of Defense (DOD) in USA is a
real-time system that can be run on several microcomputers like Zilog, VAX,
Motorola 68000, etc. ADA is convenient for controlling the robots used in a
manufacturing cell.
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Different textual robot languages have different attributes. Far example,

VAL, HELP and MC though powerful for many simple tasks, do not have the
same structured modular programming capability like AL, AML, JARS and ADA
or VAL II. In a manufacturing cell, multiple robots or robotic equipment work in
unison. Control of two or more operations done by the robots in a coordinated
manner is complex.
Synchronizing the motions of the robots requires necessary software
commands. AL, ADA, AML, MCL have the capability of controlling multiple
arms. The programming language must be capable of expressing various
geometric features like joint angles, coordinate transformations such as rotation,
translation, and vector quantities. Homogeneous matrices are used to specify the
rotation. Rotation can also be specified by Euler angles. AML, RAIL and VAL use
Euler angles while AL manipulates homogeneous matrix for control. AL is very
suitable for assembly tasks wherein many sensors are employed, though other
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languages like AML and HELP are flexible enough to run various subroutines.
Slewing and straight- line motions control are available with most of the
languages.
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5. Explain the various parts of a robot with neat sketch.
Controller:
Every robot is connected to a computer, which keeps the pieces of the arm
working together. This computer is known as the controller. The controller
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functions as the "brain" of the robot. The controller also allows the robot to be
networked to other systems, so that it may work together with other machines,
processes, or robots.
Robots today have controllers that are run by programs - sets of instructions
written in code. Almost all robots of today are entirely pre-programmed by people;
they can do only what they are programmed to do at the time, and nothing else. In
the future, controllers with artificial intelligence, or AI could allow robots to think
on their own, even program themselves.
Arm:
Robot arms come in all shapes and sizes. The arm is the part of the robot
that positions the end-effectors and sensors to do their pre-programmed business.
Many resemble human arms, and have shoulders, elbows, wrists, even
fingers. This gives the robot a lot of ways to position itself in its environment.
Each joint is said to give the robot 1 degree of freedom.
AD
Drive:
The drive is the "engine" that drives the links (the sections between the
joints into their desired position. Without a drive, a robot would just sit there,
SC
which is not often helpful. Most drives are powered by air, water pressure, or
electricity.
End-Effectors:
The end-effectors is the "hand" connected to the robot's arm. It is often
different from a human hand - it could be a tool such as a gripper, a vacuum pump,
tweezers, scalpel, blowtorch - just about anything that helps it do its job. Some
robots can change end-effectors, and be reprogrammed for a different set of tasks.
Sensor:
Most robots of today are nearly deaf and blind. Sensors can provide some
limited feedback to the robot so it can do its job. The sensor sends information, in
the form of electronic signals back to the controller. Sensors give the robot
controller information about its surroundings and it knows the exact position of the
arm, or the state of the world around it.
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Reg.No:
Question Paper code: 80672
B.E/B.TECH .DEGREE EXAMINATION, NOVEMBER/DECEMBER 2016
Seventh semester
Mechanical Engineering
ME 6703 – COMPUTER INTEGRATED MANUFACTURING SYSTEM
(Common to Mechanical and Automation Engineering)
(Regulation 2013)
Time: Three hours Maximum: 100 marks
Answer ALL questions
PART A – (10 X 2 =20 Marks)

AD
1. Define concurrent engineering. (Refer page no: 8, Q.no: 5, unit: 1)
2. What are the three basic elements of an automated system? (Refer page no: 10, Q.no: 15,
unit: 1)
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3. Differentiate process planning and production planning. (Refer page no: 24, Q.no: 11,
unit: 2)
4. Distinguish materials requirement planning and manufacturing resource planning. (Refer

page no: 23, Q.no: 9, unit: 2)
5. What is cellular manufacturing? (Refer page no: 38, Q.no:3, unit: 3)
6. Explain composite part concept. (Refer page no: 40, Q.no: 11, unit: 3)
7. State any four benefits of FMS. (Refer page no: 53, Q.no: 2, unit: 4)
8. List out the types of AGV’s. (Refer page no: 55, Q.no: 12, unit: 4)
9. Define pitch, yaw and roll. (Refer page no: 70, Q.no: 11, unit: 5)
10. What is accuracy and repeatability in industrial robots? (Refer page no: 71, Q.no: 12,
unit: 5)
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PART B – (5 X 16 = 80 Marks)
11. (a) Write in detail about the production performance metrics. (Refer page no: 13, Q.no: 2,
unit: 1) (16)
Or
(b) (i) Explain the concept of Lean manufacturing and Just-in-time production systems.
(Refer page no: 19, Q.no: 5, unit: 1) (10)
(ii) The average part produced in batch manufacturing plant must be processed
sequentially through six machines on average. Twenty new batches of parts are
launched each week. Average operation time = 6 min., average set up time = 5
hours, average batch size = 36 parts, and average non-operation time per batch
=10 hrs/ machine. There are 18 machines in the plant working in parallel. Each of
the machines can be set up for any type of job processed in the plant. The plant
operates an average of 70 production hours per week. Scrap rate is negligible.
Determine manufacturing lead time for an average part, plant capacity and plant
utilization. (6)
12.(a) Explain in detail about the computer aided process planning. (16)
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(Refer page no: 25, Q.no: 1, unit: 2)
Or
(b) (i) What is MRP and explain the inputs of MRP.(Refer page no: 32, Q.no: 4, unit: 2)
(8)
SC
(ii) Enumerate shop floor control system. (Refer page no: 29, Q.no: 3, unit: 2) (8)
13.(a) Explain OPITZ parts classification and coding system. (Refer page no: 41, Q.no:
1, unit: 3) (16)
Or
(b) (i) Apply the rank ordering clustering technique to the part-machine incidence
matrix in the following table to identify logical part families and machine groups.
Parts are identified numerically. (Refer page no: 47, Q.no: 4, unit: 3) (8)
Parts
Machines A B C D E
1 1
2 1 1
3 1 1
4 1 1
5 1
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(ii) Four machines used to produce a family of parts are to be arranged into a GT cell.
The from to data for the parts processed by the machines are shown in the table
below. Determine the most logical sequence of machines for this data by Hollier
method. (8)
To
From 1 2 3 4
1 0 10 0 40
2 0 0 0 0
3 50 0 0 20
4 0 50 0 0
14.(a) Define FMS and explain in detail about the FMS components. (Refer page no: 62,
Q.no: 4, unit: 4) (16)
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Or
(b) Explain the vehicle guidance technology of AGVs. (Refer page no: 58, Q.no: 2,
unit: 4) (16)
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15.(a) (i) Explain the types of mechanical joints commonly used in industrial robot
construction, with neat sketch.(Refer page no: 74, Q.no: 2, unit: 5) (8)
(ii) Explain about any three types of robot control systems. (8)
Or
(b) Explain in detail about the types of robot part programming. (Refer page no: 77,
Q.no: 4, unit: 5) (16)
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2017 – 18 ODD Semester

SUBJECT CODE: ME 6703

SUBJECT NAME: COMPUTER INTEGRATED MANUFACTURING SYSTEMS

Mr. J. Allwyn Kingsly Gladston

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Systems-Shop Floor Control-Inventory Control –Brief on Manufacturing Resource

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Automated Guided Vehicle System (AGVS) – AGVS Application – Vehicle Guidance

1. Kant Vajpayee S, ―Principles of Computer Integrated Manufacturing‖, Prentice Hall

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a. Aim and Objective of the subject 5

automated Guided vehicle system (AGVS) -Part A

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1. Aim and objective of the subject

1 Brief introduction to CAD and CAM 1 T1,R1

2 Manufacturing Planning, Manufacturing control 1 T1,R1

7 Basic Elements of an Automated system. 1 T1,R1

9 Lean Production 1 T1,R1

10 Just-In-Time Production 1 T1,R1

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Enterprise Resource Planning (ERP) 1

20 Simple Problems. 1 T1,R1

21 Group Technology(GT), Part Families 1 T1,R1

22 – Parts Classification and coding – 1 T1,R1

23 WEEK V Simple Problems in Opitz Part Coding system 1 T1,R1

24 Production flow Analysis 1 T1,R1

25 Cellular Manufacturing 1 T1,R1

28 VI Arranging Machines in a GT cell 1 T1,R1

29 Hollier Method – Simple Problems 1 T1,R1

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30 Types of Flexibility - FMS – FMS Components 1 T1,R1

31 FMS Application & Benefits 1 T1,R1

32 FMS Planning and Control 1 T1,R1

34 VII Automated Guided Vehicle System (AGVS) 1 T1,R1

35 AGVS Application 1 T1,R1

36 Vehicle Guidance technology 1 T1,R1

38 Robot Anatomy and Related Attributes 1 T1,R1

Classification of Robots- Robot Control

40 End Effectors – Sensors in Robotics 1 T1,R1

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Manufacturing control is concerned with managing and controlling the physical

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7. What are the functions of automated manufacturing system?

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Push-button panels, with or without visual displays.

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CAD (computer-aided design)

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Manufacturing Planning: The information and documentation that constitute the

2. Explain the mathematical models of production performance.

The production rate for an individual processing or assembly operation is usually

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Expressing this as an equation,

Where, U- Utilization of the facility,

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3. Explain the basic elements an automated system.

An automated system consists of three basic elements:

An automated system is used to operate some process, and power is required to

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value of the output.