1. IENG 475: Computer-Controlled Manufacturing Systems
Manufacturing Operations

2. Agenda Lab Schedule Lab Planning CAD – CAM Software
Manufacturing Background
Questions & Issues

3. Lab Schedule 1st Lab Tues, Jan 15 – Safety Theory – Mfg Eng Lab
Review Lab assignment from Schedule Page
Meet in MFG ENG Lab (need to start 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 ( for appointment)
Open class and lab periods reserved at end of term (2 weeks)
Use Finals Week for project documentation & demo

4. Lab Capabilities / Project Req’s
Five processes (plus assembly) needed to produce project
Laser Engraver
CNC Mill
CNC Lathe
CNC Router(s)
3-D Printer(s)
Drill Press (Single-cycle Automatic / Manual)
Miter Saw & Sabre Saw (Must use both)
5 in 1 Machine (Table Saw / Sanding)
Stock
Wood (Red Oak, Ash, MDF)
Plastic (ABS, Acetal, Acrylic, PLA)
Leather
Tile
Purchased Material
Clock Mechanism, Hinges, Magnets, Stock, Stain, Paint …

5. Laboratory Software SolidWorks MasterCAM for Solidworks
This software will model the solids you need for project
We need to follow certain lab conventions for production
MasterCAM for Solidworks
This software will help create process plans for project
Speeds up the generation of CNC code, greatly!
May load SolidWorks & MasterCAM for SolidWorks on yours
See links on Materials page
Takes about 1-1/2 hours – best done from Lab jump drive during a lab
Might only work from MFG ENG Lab
Could try to VPN into SDSM&T
Does work from Collaboration Space, Design Studio
May load MakerWare on any capable computer
This software will let you orient and control the 3-D printers

6. Project Concept 1 Desk Clock / Business Card Holder / Name Plate
Clock Face :
One color – Material: Anodized Aluminum
Design of clock face must incorporate SMD moniker
Clock Back & Base:
Two pieces – must contain clock mechanics & business cards
One color – Material: Red Oak
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 CO2 laser engraving
Stock: 5.45” x 5.45” x ¾” – Base
Final dimensions depend on your fixture design(s)
Card & Clock Face Posts:
Each member designs their own sculpted posts
Stock: ½” dia x 4” long
Final: 0.25” dia x 1.00” long (max, each post)

7. Project Concept 2 Personal (2 player) Desktop Foosball Table
Table Bottom / Sides:
Five pieces (total) – must contain 3 kicker rod mechanics & 2 goals
One color – Material: Red Oak
Design of 2 side pieces must incorporate SMD moniker
Design of base must incorporate 4 legs, 2 goals and connect 4 sides
Design of base must incorporate CO2 laser engraved SMD moniker
Stock: ½ ” thick – Red Oak
Final dimensions depend on your fixture design(s)
Kicker & Kicker Rods, Table Legs:
Kickers – Two Colors – Material: PLA plastic
3 Brass rod sets connect the 3-D printed kickers (7 total kickers / side)
Legs – One color – Material: Red Oak
Each member designs their own sculpted legs
Stock: ½” dia x 4” long
Final: 0.25” dia x 1.50” long (max, each leg)

8. Project Concept 2 Desk Caddy / Business Card Holder / Tablet Holder
Tablet Brace & Caddy Base:
Two+ pieces – must contain device mechanics & business cards
One color – Material: Red Oak
Design of one piece must incorporate SMD 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 CO2 laser engraving
Stock: ¾” – Red Oak
Final dimensions depend on your fixture design(s)
Card & Brace Posts:
Each member designs their own sculpted posts
Stock: ½” dia x 4” long
Final: 0.25” dia x 1.00” long (max, each post)

9. 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 CO2 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:
Two colors – Material: Red Oak/Ash; ABS, ACETAL or PLA plastic
Each member designs their own sculpted posts
Stock: ½” dia x 3” long
Final: 0.25” dia x 1.00” long (max, each post)

10. Project Concept 4
Modular Pachisi (Parcheesi / Sorry) Board – four modules make a game set
Slide Base & Slide(s):
One color – Material: Red Oak
Design of slide top must incorporate SMD moniker & custom text
Design of slide bottom must be ¼ of game board
Design of slides must incorporate CO2 laser engraving
Design of slide base must contain pawns & dice (dice are 3-D printed PLA)
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:
Each member designs their own sculpted pawns
Stock: ½” dia x 4” long
Final: 0.25” dia x ¾ ” long (max, each pawn)

11. 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 CO2 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 & Stain/Paint; ACETAL or PLA plastic
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)

12. 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 SMD 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 CO2 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; ABS, ACETAL or PLA 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

13. 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):

14. Levels of Automation
Manual Production – using single station manned cells operating independently
Automated Production – using single station automated cells operating independently
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!

15. 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

16. Reasons for Automating
IENG 475: Computer-Controlled Manufacturing Systems
Reasons for Automating
To 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
… when you could have!
(c) 2006, D.H. Jensen

17. 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

18. Ten Strategies for Automation and Improvement
Specialization of Operations
Combined Operations
Simultaneous Operations
Integration of Operations (drill 6 holes vs 1)
Increased flexibility (CNC Operations)
Improved material handling (ASRS, kitting)
On-line inspection (visual scan circuit boards)
Process Control (mag 7, SPC, exp. Design)
Plant operations control
Computer Integrated Manufacuting