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Printed in Great Britain. # 2001 TEMPUS Publications.
558
A Systems Approach to Manufacturing 559
PLANNED IMPROVEMENTS
Facilities
. Develop a manufacturing processes facility to
ORIGINAL CURRICULUM allow for hands-on student learning
In Fall 1996, the primary design and manufac- Curriculum
turing courses required within the ME curriculum . Incorporate and develop better tools to aid in
were: the teaching of manufacturing processes
1. MECH407: Manufacturing Processes, an intro- . Better integrate manufacturing and design
duction to fabrication techniques, within the curriculum, including design for
2. MECH392: Mechanical Design, a focus on manufacturability and concurrent engineering
functional design and analysis, and . Distribute appropriate manufacturing concepts
3. MECH401±402: Senior Capstone Design series, within other related courses
a full year design project that culminated in the
fabrication and assembly of the final design Research & industry involvement
(Fig. 1). . Develop a manufacturing research program and
incorporate research into the classroom
The Capstone design series was the only vehicle . Develop partnerships with local industry in an
that allowed integration of lecture materials from effort to provide mutual benefits
MECH407 and MECH392. The laboratory
portions of this three course series did not repre- The remaining sections of this paper describe some
sent any logical progression or integration of of these activities and the associated results.
knowledge due to a lack of any hands-on manu-
facturing experience in MECH407. The dedicated
laboratory facility for all three courses was the FACILITY IMPROVEMENTS
college Computer-Aided-Engineering and Design
(CAED) lab, composed of twenty-five Unix-based The first priority was the goal of developing a
workstations. Although the specific purposes of manufacturing processes facility for instructional
MECH407 lectures were to teach basic manufac- use. This effort received financial support from the
turing processes, the laboratory exercises focused National Science Foundation's (NSF) Instrumen-
on the computer aided design and analysis of tation and Laboratory Improvement (ILI)
parts, as in MECH302. As a result, students were program in Spring 1997 [DUE#9750788]. The
missing a crucial component of the learning experi- result of this is the `Integrated Manufacturing
ence and often completed the course without a Processes Laboratory (IMPL)', a facility that
significant physical understanding and apprecia- enables students to get vital hands-on experience
tion of fabrication techniques used in realizing an in conjunction with the study of manufacturing
engineering design. Seniors entered the Capstone processes. There is also an emphasis on the
design series (MECH401/402) still unprepared to integration of product fabrication and other key
use the industrial size equipment available in the tasks in the development cycle. The equipment
college Product Development Laboratory (PDL), available in the facility includes computer-based
requiring them to rely on college technicians and machines capable of numerically controlled cutting
560 C. Ziemian
CNC Milling Machines (3) Light Machines Corp.: PLM1000 $18,000 Material Removal
CNC Lathes (2) Light Machines Corp.: PLT3000 $17,000 Material Removal
Injection Molding Machine Morgan Industries, Inc: G±100T $15,000 Casting-polymer processing
Fused Deposition Modeler Stratasys, Inc.: FDM2000 $120,000 Layered Manufacturing
Manual CMM Brown & Sharpe: Gage 2000 $20,000 Quality Inspection
operations, injection molding, layered manufactur- projects for incorporation within MECH407. The
ing, and dimensional inspection (Table 1). Several intention of the projects was to provide students
machines are educational, as opposed to indus- with a hands-on experience in the computer aided
trial-grade, sacrificing power and size capabilities design and manufacture (CAD/CAM) of a simple
for improved safety. This smaller scale manufac- assembly. Initial MECH407 projects targeted the
turing equipment allows for students personal process of computer-numerically controlled
involvement, gives them responsibility for part (CNC) machining, with an emphasis on compo-
fabrication without lengthy machine training, nent assembly requirements and tolerances of fit.
and prepares them for the later use of industrial Projects require the use of Pro/ENGINEER
grade equipment in the PDL. software for the first four laboratory sessions,
The Integrated Manufacturing Processes comprising the CAD/CAM portion of the exercise.
Laboratory became fully operational in Fall The generation of solid models for each compo-
1999, although portions of it began being incorpo- nent in a simple part, the creation of fully dimen-
rated into classes in Spring 1998. The equipment sioned and toleranced part specifications, and the
has served to fill the previously existing curricular verification of the feasibility of resulting compo-
void, providing the vital link between theory and nent assembly were included in the CAD tasks.
application, and creating a more comprehensive The CAM tasks include the placement/assembly of
and interesting learning environment. The facility component models within solid models of planned
does not function as a stand-alone facility for raw stock, the generation of machine tool paths,
manufacturing courses, but as one integrated and and the simulation/verification of tool paths within
associated with other departmental and college Pro/MFG. Resulting cutter location files are post-
laboratories and classes. In this role, striving to processed into the machine language required by
emphasize the importance of communication and the ProLIGHT mills and lathes.
interaction between all functions of the product The next five laboratory sessions involve the
development cycle, the laboratory provides the physical fabrication and inspection of designed
necessary equipment to fabricate components in parts. Students are first given the opportunity to
conjunction with activities in product design, become familiar with the benchtop mills and
prototyping, and quality inspection. lathes. They receive instruction on various techni-
ques such as computerized code verification, local
machine zero setup, and running machine code at a
COURSE CURRICULUM z-value above the actual stock. Students are then
responsible for the workholding and machining of
The ME department's manufacturing curricu- each of their components. There is inspection of
lum has changed in several ways over the past critical features and assessment of dimensional
three years. The most obvious improvements have quality. The completion of successful projects
been: includes part assembly and finishing. Timing of
these laboratory exercises is in conjunction with
. the use of the new manufacturing facility within lecture material intended to assist students with the
existing courses; various tasks, such as defining feasible design
. the development of a new elective course entitled tolerances, computing appropriate machine para-
MECH462: Computer Aided Manufacturing. meters such as spindle speed and feed rate, select-
In addition to these changes, there was consider- ing tool geometry (Table 2).
able effort placed on more subtle curricular adjust- Figure 2 presents a sample student project
ments to improve the teaching of manufacturing entitled `Tee Time'. Student responsibilities
processes and to integrate manufacturing and included:
design better.
. solid modeling of the golf ball, the tee, and the
Use of integrated manufacturing laboratory in octagonal base;
existing courses . computer-aided assembly verification and calcu-
With the availability of necessary fabrication lation of tolerances of fit between ball and tee,
equipment, initial curricular enhancements and between tee and base;
included the development of manufacturing . generation of associated design specifications;
A Systems Approach to Manufacturing 561
. computer-aided tool path generation for 3. improved process efficiency and productivity,
material removal on all three components; and
. CNC milling and drilling of octagonal base and 4. better control of operation resulting in lower
golf ball; cost.
. CNC turning of golf tee;
. dimensional inspection of features involved in The effectiveness, however, depends largely on
tee-base placement; integrated communication systems involving
. physical assembly and finishing. computers, machines, and their controls [5].
MECH462: Computer Aided Manufacturing
Although MECH407 still includes several indus- (CAM), offered for the first time in Spring 1999,
trial field trips and in-house processing demonstra- focuses on the computerized integration specific to
tions, this hands-on fabrication project dominates design and manufacture. The course begins with
the laboratory experience and successfully replaces an in-depth look at solid modeling and CAD as the
the once passive learning environment. This transi- major key to integrated information in manufac-
tion establishes a pedagogical goal for students: to turing systems, offering a more advanced look at
develop a genuine understanding of the problems, CAD and CAM than that offered in MECH407. It
limitations, and benefits associated with various builds upon the students general knowledge of
manufacturing processes. This has included an CAD applications obtained in prerequisite
understanding of: courses, and provides them with a deeper under-
. the specifics of the process and the associated standing of geometric modeling, basic computer
material effects; graphics, feature modeling, and associated data-
. its viability as an option for the fabrication of a base issues. They are then able to use this informa-
given design, including a formal awareness of tion to explore a variety of manufacturing
design for manufacturability (DFM) issues; concepts and techniques in both lecture and
. its role and position in the product realization laboratory, focusing on their related computer-
process. aided and integrated applications. Primary topics
are:
Through the course of the project students are also
required to identify tools for solving any problems 1. Communication and exchange of data between
that may arise. varying design and manufacturing systems.
Once completed, students are able to fabricate 2. Computer-aided processing, rapid prototyping,
many of their own components in the Capstone and inspection.
design course. Experience has shown that these 3. Computer-aided process planning (CAPP),
activities help develop student awareness of some focusing on the selection of production
common stumbling blocks in fabricating a design. methods, tooling, fixturing and machinery,
This comprehension helps improve the quality of operation sequencing, and assembly.
many Capstone design projects, rendering students
The CAPP unit includes the direct integration of
more careful with their own designs, and more
ongoing research projects in computer aided plan-
capable to assess the processing ramifications of
ning of dimensional inspection and layered manu-
design decisions and the feasibility of manufacture.
facturing processes.
The laboratory portion of the class uses the
Computer-aided manufacturing elective
processing machines in the IMPL and Pro/ENGI-
Computer-integrated manufacturing is a broad
NEER software modules as provided through the
term used to describe the computerized integration
CAED laboratory. Students first complete a series
of all aspects of design, planning, manufacturing,
of four laboratory exercises intended to familiarize
distribution, and management [4]. If successful, the
them with certain concepts, equipment, and soft-
benefits of this computerized integration include:
ware beyond the scope of MECH407 (Table 3).
1. responsiveness to shorter product life cycles, After this, the students use the remaining eight
changing markets, and global competition, weeks of laboratory sessions for the development
2. emphasis on product quality and uniformity and completion of a CAD/CAM project of their
through better process control, choice. The expectation is that course projects will
562 C. Ziemian
Fig. 2. MECH407 project: `Tee-Time': (a) Solid models of main parts; (b) Machined parts and clock; (c) Final product.
A Systems Approach to Manufacturing 563
include the usage of a minimum of three different offering a more advanced experience in informa-
processing types as available in the IMPL, includ- tion flow between design and manufacture.
ing: Figure 3 presents a sample student project that
. resulted in the fabrication of a plastic medallion
material removal (milling and turning);
. bearing an image of Bucknell's Bertrand Library
internal flow (injection molding);
. [6]. Student responsibilities included:
layered manufacturing (FDM);
. quality inspection on the CMM. . digitization of library image;
The primary objective is to integrate CAD and . image processes from wireframe, to surface, to
CAM in the design and fabrication of a product, solid model of planned medallion;
Fig. 3. MECH462 project: (a) Digital photo of Bertrand Library; (b) Solid model of injection molded medallion.
564 C. Ziemian
Fig. 3. Continued
. solid modeling of inverted image and die set for to the presentation of the product realization
injection molding machine; process within undergraduate curriculums. The
. generation of associated design specifications; affiliate award enabled MECH407 students to
. computer-aided tool path generation for participate in the beta-testing of multimedia modu-
material removal on die set; lar courseware developed to address key issues in
. CNC milling of dies, included mold cavities, integrated manufacturing. The test included a
sprues, runners, and threaded holes required laboratory session based on the use of OPTLINE,
for die installation; a computerized manufacturing system model that
. mold inspection & finishing; simulates the production of a simple part using
. injection molding of thermoplastic medallion; casting, drilling, and turning [8]. OPTLINE assists
. sprue and runner removal and part finishing. students to understand the connection between the
physical and economic design of manufacturing
Improved practices within existing courses processes, and to demonstrate the direct effect of
As well as these changes, there has been consid- fabrication decisions on other upstream processes.
erable effort placed on smaller curricular adjust- Many students showed amazement at their obser-
ments to improve the teaching of manufacturing vations of the impact of their various process
processes and to integrate manufacturing and variable decisions. According to their evaluation
design education better. In Fall 1996, sufficient forms and related feedback, this exercise served
funding became available to provide the ME successfully to solidify many concepts addressed
department with affiliate status within the Product throughout the semester, and use of the OPTLINE
Realization Consortium [7]. The consortium is a software continues in the laboratory portion of
group of five schools, funded in conjunction with a MECH407.
National Science Foundation Cooperative Agree- In the Fall of 1997, collaboration with Cornell
ment (DMI±9412089), focused on initiating a University's Product REALIZATION team
systematic reform of engineering education specific enabled further examination of these topics. This
A Systems Approach to Manufacturing 565
project included the development of second phase ideas into products, the PDC provides assistance
modular courseware and computerized models in various types of projects including product
used in teaching the concepts of a systems design and/or redesign, prototype development,
approach to design and manufacture to under- product testing, feasibility and manufacturability
graduates. The author was involved in developing analyses, process improvements, and preliminary
models and lecture material for test by consortium patent searching.
affiliates through web-based dissemination [9]. The PDC requires engineering consultants,
Enhancement and incorporation of these materials expertise and advanced manufacturing facilities
within MECH 407 continues. to serve best in this role. Bucknell faculty serve
In additional efforts to distribute manufacturing as technical consultants, and engineering students
topics within college-wide programs, the ME often become involved through the Capstone
department continues to participate in Bucknell's design course. This relationship provides students
`Institute for Leadership in Technology and with real-world product development projects, and
Management (ILTM)' program. Providing a six offers them the opportunity to collaborate with
week summer experience to selected juniors in actual clients. This aspect of the relationship
management and engineering departments, the between industry and academia has proven
department is responsible for several technical successful for several years.
presentations and demonstrations related to In the past few years, however, an additional
manufacturing systems, design, and robotics. benefit has evolved through this partnership. The
Presentations have included sessions on: SBDC director and the author have worked
together to obtain relatively expensive processing
1. `An Introduction to Manufacturing Processes',
equipment intended to benefit both the academic
including demonstrations on machining CNC
mission of the manufacturing program and the
machining, injection molding, fused deposition
service mission of the SBDC. One instance was
modeling, and robotics.
the purchase of the layered manufacturing
2. `World Class Manufacturing: Improving the
machine, FDM2000. Although partially funded
Process of Product Realization', representing
through NSF grants, SBDC and the Ben Franklin
a higher level look at issues affecting global
Partnership Program also provided additional
competitiveness.
funding.. Another example is the recently ordered
Another effort focused on the integration of manu- computer-controlled coordinate measuring
facturing and design within the curriculum has machine (CMM). This piece of equipment should
been the development and inclusion of multimedia enhance the college's measuring and quality
course material on geometric and dimensional inspection facilities, as well as provide enhanced
tolerancing (GD&T) concepts and practices. reverse engineering capabilities.
There is now a GD&T unit included within The bi-directional information flow between the
MECH407, in conjunction with discussion on college and local industry partners offers the
process capability. The students are introduced to students a unique opportunity to apply engineer-
the related ANSI standard and are required to ing problem solving skills to real world scenarios
complete various activities focused on proper before graduation. Recent product development
interpretation of defined geometric tolerances. projects have been in the areas of: material hand-
There is further enhancement of this topic using ling and manufacturability improvements [10],
videos, and various experiments that make use of design feasibility and strength testing, product
the manual CMM within the IMPL. performance testing, and product design and/or
redesign.
Fig. 4. Two parts fabricated for senior design project entitled `Single-step FDM fabrication of Assemblies'.
The effort towards developing a basic research [12, 13] documented the accomplishments to date.
program received initial financial support from If successful, the research will serve to provide
NSF [#9813042] for a project intended to develop time-saving tools which facilitate the rapid identi-
a methodology for the computer aided decision fication of design possibilities and the early inte-
support and design feedback associated with the gration of manufacturing considerations. The
Fused Deposition Modeling process (FDM). The developed methodology will highlight the impor-
overall project goal is to provide the knowledge tant elements in manufacturability assessment, and
and the means by which the design engineer is able demonstrate the possibility of linking back to the
to make manufacturing and prototyping decisions. product model in investigating redesign options.
This system will serve to improve the interface Improved decision support and assessment
between the design and the manufacture of FDM capabilities will also serve to promote the further
parts, and to provide important evaluation use and industry approval of layered manufactur-
capabilities for design feedback. The project is ing methods as more than a rapid prototyping
working towards providing these enhancements technique.
with a special focus on the needs of small business Less tangible benefits have included the educa-
manufacturers, who by nature suffer from the tional impact on graduate and undergraduate
limitations of a smaller work force. students in the ME department. Elective course
Project objectives include: MECH462 now includes related process planning
techniques specific to the FDM process. A new
1. FDM experimentation and process modeling,
laboratory experiment recently designed presents
2. the development of computational tools to
the benefits of the developing decision support
optimize the FDM process based on the
system over the unskilled machine operation of
design specifications and feature requirements;
the FDM machine. Capstone design projects that
3. the implementation of associated algorithms
include a process planning exercise specific to the
and models to provide predictive capabilities
single-step fabrication of engineering assemblies
and decision support for designers and FDM
(Fig. 4) have focused on related use of the
users.
FDM2000.
The focus of the objectives is to provide a more
seamless design and/or fabrication interface and to
improve the quality of the freeform fabrication CONCLUSIONS AND
process specific to functional design requirements RECOMMENDATIONS
of key part features. Demonstration and validation
of the decision support system will make use of Implementation of the current design and manu-
industry data provided through SBDC collabora- facturing curriculum, (as presented in Fig. 5),
tion with local manufacturers. occurred during Spring 1999. Achievement of the
Further enhancement of this research occurs primary objective of improved manufacturing
through additional funding from the Ben Franklin education occurred in various ways, such as by
Partnership Program [11], and Ziemian and Crawn using funding and resources from assorted sources.
A Systems Approach to Manufacturing 567
Capstone design projects and related projects within AcknowledgmentsÐThe National Science Foundation funds
the Management department may be another these activities under grant awards #9750788 and #9813042,
the Ben Franklin Technology Center of Pennsylvania, the
potential avenue towards multidisciplinary team SBDC, and Bucknell University. There is grateful acknowl-
formation. Interdepartmental collaboration is edgment for this funding and support. Special thanks to Dan
perhaps the most important area requiring effort Johnson, engineering college technician, for all of his hard work
towards the continued improvement of Bucknell's and contributions towards these efforts (including his `Tee-
Time' concept).
manufacturing education program.
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1. ASME, Integrating the Product Realization Process (PRP) into the Undergraduate Curriculum,
The American Society of Mechanical Engineers, New York, (1995).
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Education, 12(1), pp. 26±35 (1996).
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Sons, Inc., New York, (1996).
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Department of Mechanical Engineering, Bucknell University, May, (1999).
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Integrating the product realization process in the engineering curriculum ± challenges and
opportunities, Manufacturing Education for the 21st Century: Volume III, Preparing World Class
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(1996).
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9. C ?????
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