8/9/2015IENG 475: Computer-Controlled Manufacturing Systems 1 IENG Lecture 02 Manufacturing Operations

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 2 Agenda Lab Schedule Lab Plan Manufacturing Operations Levels of Automation Questions & Issues

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 3 Tuesday 1:00 PM Lab Mike Dietz Austin Louchart Jesse Wilkins Zach Kohama Ziad Alzuhair*

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 4 Tuesday 2:30 PM Lab

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 5 Tuesday 4:00 PM Lab Dylan McLellan Joel Niesche Taylor Mammenga

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 6 Thursday 1:00 PM Lab Terry Nguyen Kristy Rennick Cassie Kulesa Zach Boyd Brianna Dodge*

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 7 Thursday 2:30 PM Lab Rick Vanderhulst Nate Hibl Andrea Sawyer Tyler Derickson* Caleb Miller*

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 8 Thursday 4:00 PM Lab** Ben Johnson* Anne Christensen* Stevey Lee* Cody Kopriva*

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 9 Tuesday 2:30 PM Lab Ben Johnson Anne Christensen Stevey Lee Cody Kopriva Brianna Dodge

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 10 Lab Schedule Review Lab assignment off of Materials Page Meet in MIL Lab (need to start/stop labs on time) Take notes during lab in LAB Engineering Notebook (everyone) Lab assignments (1 per team) – usually due next lab brief summary and documentation of design/exercise short answer to questions (if any) copy pages from everyone 5S at end of each lab Primary result of lab exercises is to complete project Open Lab times as necessary Open class and lab periods reserved at end of term Use Finals Week for project documentation & demo

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 11 Project Concept 1 Desk Clock / Business Card Holder / Name Plate Clock Face & Base: Two pieces – must contain clock mechanics & business cards One color – Material: Red Oak Design of clock face must incorporate S M D moniker Design of base must incorporate four button feet Design of base must hold cards and be individually customized w/ name Design of base must incorporate CO 2 laser engraving Stock: 5.45” x 5.45” x ¾” – Base Final dimensions depend on your fixture design(s) Card & Clock Face Posts: One color – Material: Red Oak Each member designs their own sculpted posts Stock: ½” dia x 4” long Final: 0.25” dia x 1.00” long (max, each post)

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 12 Project Concept 2 Desk Caddy / Business Card Holder / Tablet Holder Tablet Brace & Caddy Base: Two pieces – must contain clock mechanics & business cards One color – Material: Red Oak Design of one piece must incorporate S M D moniker Design of base must incorporate four button feet Design of base must hold cards and be individually customized w/ name Design of base must incorporate CO 2 laser engraving Stock: ¾” – Red Oak Final dimensions depend on your fixture design(s) Card & Brace Posts: One color – Material: Red Oak Each member designs their own sculpted posts Stock: ½” dia x 4” long Final: 0.25” dia x 1.00” long (max, each post)

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 13 Project Concept 3 Expanding Cribbage Board Bottom, Slide Base & Slide: One color – Material: Red Oak Design of slide must incorporate SMD moniker Design of slide base must incorporate individually customized text Design of slide base must incorporate CO 2 laser engraving Design of bottom must contain card deck and pegs Bottom must have four button feet Stock: 5.45” x 5.45” x ¾” – Slide Base & Bottom Stock: 5.45” x 5.45” x ¼” – Slide Final dimensions depend on your fixture design(s) Pegs: One color – Material: Red Oak Each member designs their own sculpted posts Stock: ½” dia x 3” long Final: 0.25” dia x 1.00” long (max, each post)

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 14 Project Concept 4 Modular Parchisi Board – four modules make a game set Slide Base & Slide: One color – Material: Red Oak Design of slide top must incorporate S M D moniker & custom text Design of slide bottom must be ¼ of game board Design of slide must incorporate CO 2 laser engraving Design of slide base must contain pawns & dice (dice are purchased) Slide Base bottom must have four button feet & connect to slide as the Start Stock: 5.45” x 5.45” x ¾” – Slide Base Stock: 5.45” x 5.45” x ¼” or ¾”– Slide (team choice!) Final dimensions depend on your fixture design(s) Pawns: One color – Material: Red Oak Each member designs their own sculpted pawns Stock: ½” dia x 4” long Final: 0.25” dia x ¾ ” long (max, each pawn)

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 15 Project Concept 5 Mini Chess Set Custom Case Top & Chess Board Base: Two parts – must contain all chess pieces One color – Material: Red Oak & Plastic/Metal Design of case top must incorporate SMD moniker Design of base bottom will be chess board Engraved Insert (plastic/metal) Design of chess board must incoporate CO 2 laser engraving Stock: 5.45” x 5.45” x ¾” – Case Top & Base Final dimensions depend on your fixture design(s) Chess Pieces: Two colors – Material(s): Red Oak/Ash, Stains/Paint Each member designs at least one piece, add group pawn design Stock: ½” dia x 3” long Final: 0.25” dia x 1.00” long (max, piece), 1/2” long (max, pawn)

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 16 Project Concept 6 Boxed CATAN Board – box & five hex types make a game set Box Case & Hexagonal Squares One / two color – Material: Red Oak or Laminated Acrylic Design of sliding top must incorporate S M D moniker & custom text – milling! Slide top must fit with box case and must function well Design of slide box case must contain parts & dice (dice are engraved) Design of hexes and must incorporate CO 2 laser engraving, could interlock Stock: ½” or ¾” – Red Oak for sides of Slide Box Case (team choice!) Stock: ¼” Red Oak – Slide Top / Back Final dimensions depend on your fixture design(s) Pieces: Four colors – Material: Red Oak, PLA or ABS plastic Each member designs their own sculpted pieces Dice would be laser engraved Buildings / Cities are either turned on lathe or 3-D printed Production disks are laser engraved

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 17 Manufacturing Operations What competitive trends exist? Where are products being made? What kind of products are being made at these locations? How are products being made at these locations? What is the basis for manufacturing competitiveness? Competitive Advantage(s):

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 18 Levels of Automation 1. Manual Production – using single station manned cells operating independently 2. Automated Production – using single station automated cells operating independently 3. Automated, Integrated Production – using multi- station automated systems with automated material handling The appropriate level of automation is situational – there is no universal best answer!

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 19 Manufacturing Operations Mfg Plant Capabilities & Capacity Limitations: Technological Processing Capabilities Physical Production Capabilities/Capacities Production Capacity Limits Conditions for Appropriate Automation: Predictable, stable / expanding market Need to satisfy business objectives of firm Technology must be available at the right: Performance Cost Maturity

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 20 Reasons for Automating Increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or eliminate routine manual tasks To improve worker safety To accomplish processes that cannot be done manually To improve product quality To reduce manufacturing lead time To avoid the high cost of not automating

8/9/2015 IENG 475: Computer-Controlled Manufacturing Systems 21 Reasons NOT to Automate Task is too technologically difficult to automate Product life cycle is too short Product is too customized Product demand is too variable To reduce the risk ($) of product failure To deal with these aspects, use the USA Principle: Understand Simplify Automate