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ME6703 SCAD MSM by WWW - Learnengineering.in
ME6703 SCAD MSM by WWW - Learnengineering.in
in
ENGINEERING COLLEGES
Prepared by:
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Sl. No. Name of the Faculty Designation Affiliating College
Mr. M.Senthilkumar
2. Asst.Prof SCADCET
Mr. M. Poovaragan
3. Asst.Prof SCADCET
Verified by DLI, CLI and Approved by the Centralized Monitoring Team dated 20.06.2017
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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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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TABLE OF CONTENTS
PAGE.
S.NO TABLE OF CONTENTS
NO
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
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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Sl. No of Book
WEEK Topics
No. Hours No.
UNIT – IV : FLEXIBLE MANUFACTURING SYSTEM (FMS) AND
AUTOMATED GUIDED VEHICLE SYSTEM (AGVS)
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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"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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17. What are the factors that lead to the evolution of CIM? (Apr/May2017)
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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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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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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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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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scheduling.
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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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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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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)
Group te c hnology
approac h E xac t a pproa c h
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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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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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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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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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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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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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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.
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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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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.
5 Main dimension
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7 Dimension ratio Auxiliary dimension
8 Auxiliary dimension
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Tolerance codes
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Material codes
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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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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
Work-in-process is reduced.
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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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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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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
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
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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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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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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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11. List the four tests for flexibility in FMS research. (Apr/May 2017)
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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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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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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:
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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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protective field.
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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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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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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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UNIT-V
INDUSTRIAL ROBOTICS
PART- A
1. What are the benefits of industrial robots?
Increased Productivity
Significant Savings
Improved Quality
Better Safety
Competitive Edge
Proximity Sensors,
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Range sensors,
Voice sensors etc.,
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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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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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.
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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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
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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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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.
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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,
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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:
Seventh semester
Mechanical Engineering
(Regulation 2013)
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)
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.
(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)
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(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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