Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 60 SECONDS

Slide 2 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 50 SECONDS

Slide 3 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 40 SECONDS

Slide 4 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 30 SECONDS

Slide 5 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 20 SECONDS

Slide 6 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN CLASS IN 10 SECONDS

Slide 7 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz BEGIN !!! CLICK

Slide 8 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 7 Discussion Agenda for Tonight: Overview of Exam Discussion Questions from Discussion Leaders Other Questions from Students Let’s Begin …

Slide 9 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Coverage -- System/Operating Philosophies Introduction to CIM, Future (1, 14) Life Cycle Design Process CAD Model as Starting Point for Analysis Information Based Integration Concurrent Engineering (4) Computer Aided Process Planning (5) Group Technology and Cellular Mfg. Sys. (12) Flexible Manufacturing Systems (13) Exam Review (1)

Slide 10 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Exam Review (2) Coverage -- Task/Application Topics CAD, Geometric Modeling (2, 3) Representations/Transformations Data Exchange to Other Functions Computer Control of Manufacturing Systems (6, 8) Numerical Control Programmable Logic Controllers Robotic Systems

Slide 11 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Key Concepts for Exam (1) Computer Integrated Manufacturing Definition -- Key Words/Meanings Concepts -- Life Cycle Orientation/Viewpoint(s) Concurrent Engineering Definition and Goals Comparison to “Traditional” Computer Aided Process Planning Variant/Generative/Group Technology Surface Recognition/Process Association Concurrent Engineering Process Design Quality Deployment Function (QFD) Quantitative Analysis -- Singh Model

Slide 12 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Key Concepts for Exam (2) Group Technology Definition and Philosophy Coding Structures Attributes Used Use of Database Techniques vs. Coding Family and Cell Formation Production Flow Analysis Similarity Indices Procedures -- Linear Programming, Vakaria and Wemmerlov

Slide 13 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Key Concepts for Exam (3) Cellular Manufacturing Definition and Philosophy Cell/Family Formation Flexible Manufacturing Systems Definition and Philosophy Design Steps Numerical Control Definitions/Terms/Types/Programming Relation/Types of CIM -- Cellular, FMS, Group Technology, etc.

Slide 14 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Key Concepts for Exam (4) Robotics Definitions/Terms/Types Use and Justification of Use Programmable Controllers Definition/Use !! NO Programming on this test !!

Slide 15 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz What to Anticipate (Philosophy of Testing) Seek to Test Understanding (not Rote Memorization) Philosophy of Techniques Ability to Convey Understanding of Concepts Compare and Contrast Mutually-Exclusive/Overlapping Concepts When to Apply/When not to Apply Limits to Accuracy/Applicability

Slide 16 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz What to Anticipate (Types of Questions) Essay (70-85%) Compare/Contrast (All Combinations) Pairwise Similarities and Differences Differentiate Pairwise Differences (Only) Situation Described - Solicit Reaction Situation Described - Solicit Approach/Analysis Merge Concepts over Chapters Quantitative (15-30%) Calculation Ability to Discuss Details of Algorithms

Slide 17 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Exam Logistics On-Campus Take on October 11, p.m. Off-Campus Take on October 11, p.m. Call in with Questions Via Tape Arrange a 3 hour period with Kristi Horner (Arrange by 10/10 to take 10/11-13, if possible) 405/ She will Fax test to you, You Fax Back 3 hrs. Later

Slide 18 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Rahul Deshpande)

Slide 19 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Deshpande) 1.In homework problem 13.9, tool magazine capacity has not been mentioned. Do we need to assume the magazine capacity. Assuming different capacities mean variations in batch sizes. How do we go about assuming the magazine capacity? Yes, you should assume one. Any value will do – most students used 5.

Slide 20 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Deshpande) 2. Is there any specific criteria for selecting one Flexible Manufacturing System over the other. Is there a mathematical model/algorithm to arrive at these decisions. Does these criteria lead to the best manufacturing setup after it's implemented. Cost – No Algorithms/Based on Estimates Design, Conversion, Installation, Use, Service, Disposal Remember – Use costs include “managerial complexity/support”, flexibility (savings), …

Slide 21 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Deshpande) 3. Reference to the previous question, how we select either of conveyor, an AGV or a robot in a particular manufacturing setup. Same way ($) – assess technical, operational, and economic feasibility. Include tangible and intangible costs. Use intangibles to “make up” any payback or ROI shortfalls.

Slide 22 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Sheng Ma)

Slide 23 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Sheng Ma) How does FMS relate to continuous processes? For example, continuous processes in chemical industries? Which types of manufacturing systems should we assign to continuous process? Consider a refinery – a continuous stream of product is produced but the mix/ratio of product(s) varies (e.g. heat oil, gasoline). The refinery can be thought of as a FMS handling different products (simultaneously). The mixed model analyses may be used or if the the equipment is a mix of common and dedicated (to product), a batching model can be used (Hwang plus extensions) with concepts of “key” machine (Vakaria and Wemmerlov)

Slide 24 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Sheng Ma) 2. For operational problems in FMS, is there any comprehensive software or methods we could use? Various software to (re)assess the design and operation, notably, family and cell formation algorithms. Standard engineering practice/method: Define Problem, Gather Data, Generate Alternatives, Assess Alternatives, Select/Specify Solution, Implement, Reassess should suffice.

Slide 25 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Abhijit Hora)

Slide 26 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Abhijit Hora) In the figure 13.1, the author has classified volume and variety of production in high, medium and low groups. Can we put these in numbers? Can theses numbers be put in a specific range in order to take into account the factors that affect definition of production and variety like process and product type? Unfortunately no – while numbers of parts indicate economics, variation in product demand, configuration/design, market conditions impact as well and are independent of part volume (numbers).

Slide 27 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Abhijit Hora) What is modular fixturing, the term used by the author (Singh) on page 540? Two uses of term are common: -- Base plate with attachments so that one can quickly develop fixtures for a variety of parts (job shop FMS) -- One fixture that hold the set of parts that make up one unit/module of product – processing the “module” produces one part with no inventory, delay (Mixed Product FMS)

Slide 28 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Abhijit Hora) What organizational changes are needed in an enterprise for adopting Flexible manufacturing systems? Function of Starting point – Ending point/Goal Organization – Production Process Centric on Floor Disciplined – Product Family Centric in Production Control, Marketing, Design

Slide 29 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth)

Slide 30 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth) Could you clarify the differences in the Hwang and Extended (Stecke and Kim) Hwang Model? Hwang (pg. 546) Max x =  z i Any part can enter solution, subject to tool capacity. Stecke and Kim Max x =  (  b ic d c )z i Parts enter solution based on the tool(s) they use and the number of other parts that use the tool(s). Constrained by tool capacity.

Slide 31 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Dennis McInerney) Seagate --

Slide 32 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Dennis McInerney) I know there is no definite answer, but I have to ask -- Are there any numbers or range of numbers (volume and part quantities) associated with the volume-variety categories (H-L, L-H, M-M)? Similar to question we saw from Hora, no universal answer, but there are industry common concepts. Generally, > 50 parts per batch is considered high in machine shops, 1-10 low.

Slide 33 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Class) Other Questions as raised

Slide 34 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Session 7 End of Class Have a Good Week and I’ll see you next time!