10/17/2015IENG 475: Computer-Controlled Manufacturing Systems 1 IENG Lecture 01 Introduction to Computer- Controlled Manufacturing Systems

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 2 IENG 475 Instructor: D. H. Jensen 308 Industrial Engineering & Research Bldg (605) Office Hours: M: 1:00 – 1:50 PM W: 1:00 – 1:50 PM and 4:30 – 5:30 PM Class Meetings: Mon, Wed, but NOT Fri: 2:00 PM – 2:50 PM, 205 IER

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 3 IENG 475 Labs: Manufacturing Inductive Learning Lab (MIL Lab) Rm 310 Industrial Engineering & Research Bldg As Arranged: 4 person Lab Teams Tuesday: 1:00 – 2:20 2:30 – 3:50 4:00 – 5:20 Thursday: 1:00 – 2:20 2:30 – 3:50 4:00 – 5:20** ** last choice!

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 4 Course Overview Students will demonstrate: the ability to describe a solid in terms of engineering specifications, tolerances, and basic manufacturing features. the ability to identify production sequences and specify processing parameters for turning and milling.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 5 Learning Objectives Students will demonstrate: the ability to describe and manipulate a solid in terms of the computer data structures used for CAD. the ability to design and evaluate a system to hold and locate workpieces. the ability to classify a GT-PC&C coding for two parts to retrieve and modify the process plan/routing.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 6 Learning Objectives Students will demonstrate: the ability to determine a feasible sensor and specify an actuator to accomplish a task. the ability to design and construct a control system in fluid, electric, electronic, or programmable logic. the ability to identify, analyze, and utilize robots for computer-controlled material handling.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 7 Course Overview See Schedule Page for Details: Basic manufacturing problem solving tools including PC&C, process planning, and CNC programming are covered on Exam I. Sensors, control logic and PLC programming, robotics/automation principles and ethics are covered on Exam II. Project covers automated material handling and computer-integrated control in addition to demonstrating abilities of the TEAM.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 8 Materials Textbook: NOT REQUIRED Groover, M. P. (2008). Automation, Production Systems, and Computer-Integrated Manufacturing (3rd ed.). Upper Saddle River NJ: Prentice-Hall. 856pp. ISBN Engineering Notebook TWO REQUIRED 9-3/4" x 7-1/2", 5x5 quad-ruled, pp. (approx.). Engineering Problems Paper REQUIRED 8-1/2" x 11", three hole drilled, ruled five squares/division, 50 pp. (approx.).

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 9 Engineering Notebook Anything you can copy, cut, staple, paste, glue, or otherwise persuade to live permanently within the covers of your engineering notebook may be used on the exams … … EXCEPT old exams and other’s notebook pages. One notebook for class/exams One notebook for lab/project

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 10 Recommended Materials Engineering/Scientific calculator Mechanical Pencil 0.5 mm, HB or B lead with comfortable grip Plastic-based Eraser clickable pen-style suggested

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 11 Expectations Grading Scale: A 90% B 80% C 70% D 60% F < 60% Weighting: Homework20% Project30% Midterm Exam I25% Midterm Exam II25%

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 12 Expectations Assignments & Project Components: Each question / project component is graded on a 10 point basis. Each assignment is equally weighted. Exams: Exams are open Engineering notebook; and closed textbook and homework. Necessary tables are identified/provided – store in your engineering notebook.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 13 Expectations Due Dates / Late Work: Assignments and project work are due at the start of class on the due date (see Schedule page). Unapproved late assignments turned in more than one class period after the due date will not be graded and will not receive any credit. Unapproved late assignments turned in before the next class period will be held until the end of the term. If the student’s grade is borderline, then the held assignment will be graded and assessed 50% of the earned credit. Borderline is defined as within 1.5% of the next highest grade without considering the late assignment

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 14 Expectations Make-up Work: Make-Up work is the student’s responsibility, and is arranged at the lecturer’s discretion. Policies: Foreseeable Circumstances - contact the lecturer as far in advance as possible ( ). Unforeseeable Circumstances - contact the lecturer as soon as practical (leave phone message).

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 15 Expectations Academic Honesty: OK to work together on HW and Labs for this class: as long as what appears on your sheet is your work, your words, and your writing OK to copy my materials for this class: download and print slides to your engineering notebook for this class download and use my spreadsheet templates for your assignments and practice in this course Exams are always individual work

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 16 Questions & Issues Students with special needs or requiring special accommodations should contact the instructor, Dr. Jensen, at and/or the campus ADA coordinator, Jolie McCoy, at at the earliest opportunity.

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 17 Data Collection NameIENG 475 Preferred nameSPR address Student ID # Your major Hometown Anything else the instructor should know about you

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 18 COURSE ORGANIZATON ISSUES Schedule Needed for Lab Times: (Back of Card) 1 st Choice Lab Time 2 nd Choice Lab Time 3 rd Choice Lab Time 4 th Choice Lab Time List any lab times with a class conflict* Preferred Lab Partners (2 choices) Non-Preferred Lab Partner (if any) Lab Times: Tuesday 1:00 - 2:20 2:30 - 3:50 4:00 - 5:20 Thursday 1:00 - 2:20 2:30 - 3:50 4:00 - 5:20

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 19 Lab Schedule Lab team/time assigned, ed by 10:00 PM tonight 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) EP 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

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 20 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):

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 21 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!

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 22 Manufacturing Operations Mfg Plant Limitations & Capabilities: Technological Processing Capabilities Physical Production Capabilities 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

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 23 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

10/17/2015 IENG 475: Computer-Controlled Manufacturing Systems 24 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