Production Systems and PLM Strategies

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Questions and Answers

What are the two main categories that define a production system?

Facilities and manufacturing support systems.

Define 'Facilities' in the context of a production system.

Facilities include the factory, production machines, tooling, and equipment arrangement.

What does 'plant layout' refer to in a production system?

Plant layout refers to the physical arrangement of equipment in the factory.

What are the two categories of automation in production systems?

Automation of manufacturing systems and computerization of manufacturing support systems. Signup and view all the answers

What is the role of manufacturing support systems in a production system?

They manage production and solve technical and logistics problems. Signup and view all the answers

Give an example of a logical grouping within manufacturing systems.

A production line is an example of a logical grouping. Signup and view all the answers

What does Computer-Integrated Manufacturing (CIM) encompass?

CIM encompasses the integration of computer systems into manufacturing support systems. Signup and view all the answers

How do manufacturing support systems connect with factory manufacturing systems?

They are linked through automation and computerization. Signup and view all the answers

What is the primary focus of Product Lifecycle Management (PLM) strategies?

The primary focus of PLM strategies is to manage a product's lifecycle from inception to disposal, ensuring efficiency and sustainability. Signup and view all the answers

What is one benefit of utilizing Product Data Management (PDM) systems in the context of PLM?

One benefit of PDM systems is improved collaboration and data accuracy among teams throughout the product lifecycle. Signup and view all the answers

Identify a common barrier to the implementation of PDM systems.

A common barrier to PDM implementation is resistance to change from employees accustomed to existing workflows. Signup and view all the answers

Explain the significance of recycling strategies at the end of a product's life.

Recycling strategies are significant as they reduce waste, conserve resources, and minimize environmental impact. Signup and view all the answers

What role does a class quiz serve in understanding PLCM tools and strategies?

A class quiz serves to assess students' comprehension of PLCM tools and strategies, reinforcing key concepts through engagement. Signup and view all the answers

How can 'Think Pair Share' activities contribute to the learning process in a PLM course?

'Think Pair Share' activities encourage collaborative learning, allowing students to articulate their ideas and gain diverse perspectives. Signup and view all the answers

What is one fundamental takeaway regarding the automation of production systems?

One fundamental takeaway is that automation increases efficiency and reduces human error in production processes. Signup and view all the answers

What are PLCM tools aimed at achieving in product lifecycle management?

PLCM tools are aimed at achieving effective tracking, analysis, and improvement of a product throughout its lifecycle. Signup and view all the answers

What is the primary characteristic that distinguishes the RP systems listed from solid-based RP systems?

They are categorized as producing powder in grain-like form. Signup and view all the answers

Name three RP systems that fall under the powder-based definition.

Selective Laser Sintering (SLS), Electron Beam Melting (EBM), and Direct Metal Deposition (DMDTM). Signup and view all the answers

What is the first step in the generalized Rapid Prototyping process chain?

3D Modeling. Signup and view all the answers

Describe the role of data conversion in the Rapid Prototyping process chain.

Data conversion transforms the 3D model into a format suitable for manufacturing and allows for its transmission. Signup and view all the answers

List two technologies included in the category of powder-based RP systems.

Laser Engineered Net Shaping (LENS) and Direct Shell Production Casting (DSPC). Signup and view all the answers

Identify a technology that uses chemical materials in its RP process.

Multiphase Jet Solidification (MJS). Signup and view all the answers

What is the significance of the 3D UV Curing Oven in the Rapid Prototyping process chain?

It is used for curing or solidifying materials in the RP process. Signup and view all the answers

How does ultrasonic cleaning contribute to the Rapid Prototyping process?

It removes any residual powder or contaminants from the prototype. Signup and view all the answers

What is the primary action of the laser in the stereolithography process?

The laser cures the photosensitive polymer where the beam strikes, forming a solid layer of plastic. Signup and view all the answers

What is the primary purpose of the sintering step in automated manufacturing systems?

To bond individual powders and strengthen the part. Signup and view all the answers

How does the platform's movement contribute to the creation of parts in stereolithography?

The platform is lowered by a distance equal to the layer thickness after each layer is formed, allowing the next layer to be cured on top. Signup and view all the answers

Describe the role of the ink-jet printing head in the 3D printing process.

It ejects droplets of binder onto specific regions to create the solid part. Signup and view all the answers

What is the purpose of the wiper blade in the stereolithography process?

The wiper blade levels the viscous liquid resin across the surface before each new layer is cured. Signup and view all the answers

What materials are typically used as starting materials in 3D printing?

Ceramic, metal, or cermet powders and polymeric or colloidal silica binders. Signup and view all the answers

What is the typical range for layer thickness in stereolithography, and how does it affect resolution?

Layer thickness typically ranges from 0.076 to 0.50 mm, with thinner layers providing better resolution but longer processing time. Signup and view all the answers

What additional steps are taken to finalize the polymer after the layers are formed?

The polymer is baked in a fluorescent oven to complete curing, and excess polymer is removed with alcohol. Signup and view all the answers

In laminated-object manufacturing (LOM), what is the main function of the adhesive backing on sheet materials?

To bond layers together as they are stacked during the manufacturing process. Signup and view all the answers

Explain how the layer thickness in 3D printing typically affects the printing process.

Layer thickness ranges from 0.10 to 0.18 mm, influencing the resolution and quality of the final part. Signup and view all the answers

What types of materials are typically used as photopolymers in stereolithography?

Photopolymers are typically acrylic, but epoxy materials can also be used. Signup and view all the answers

What is the significance of the spindle speed during the ink-jet printing process?

The speed, around 1.5 m/s, affects the efficiency and timing of the binder application. Signup and view all the answers

What factors influence the build time in stereolithography?

Factors include scan speed, layer thickness, and the complexity of the part geometry. Signup and view all the answers

What range of scan speeds is typical for STL lasers, and how does it impact the process?

Scan speeds typically range from 500 to 2500 mm/s, affecting the precision and efficiency of the layering process. Signup and view all the answers

How does the cycle time per layer in 3D printing relate to the printing process?

The cycle time is approximately 2 seconds per layer, allowing for efficient and rapid layer production. Signup and view all the answers

What function does the LOMSliceTM software serve in the laminated-object manufacturing process?

It slices the geometric CAD model into layers for the LOM process. Signup and view all the answers

What is a key characteristic of a Point-to-Point CNC drilling machine?

It moves to a specific location and performs an operation, such as drilling, at that location. Signup and view all the answers

How does Continuous Path Control differ from Point-to-Point Control in CNC systems?

Continuous Path Control performs operations during movement, while Point-to-Point Control operates at specific locations only. Signup and view all the answers

What are the main components of a CNC system?

The main components include the Input Device, Central Processing Unit, Machine Tool, Driving System, Feedback Devices, and Display Unit. Signup and view all the answers

What is the role of the Central Processing Unit in a CNC system?

The CPU decodes input data into position control and velocity signals and oversees the movement of the control axis. Signup and view all the answers

List two examples of input devices used in CNC systems.

Examples include Floppy Disk Drive and USB Flash Drive. Signup and view all the answers

What corrective action does the CPU take when movement does not match programmed values?

The CPU takes corrective actions by adjusting the position control signals to align with programmed values. Signup and view all the answers

What is the significance of feedback devices in a CNC system?

Feedback devices monitor the machine's performance and ensure it aligns with the programmed operations. Signup and view all the answers

Why is Ethernet communication considered an input method in CNC systems?

Ethernet communication allows for fast and efficient data transfer between the CNC system and external devices. Signup and view all the answers

Study Notes

Automated Manufacturing Systems

This course is offered by the Department of Mechatronics Engineering.
It targets students interested in automating manufacturing systems.
The automotive industry is an example of a sector that uses automated systems.
Good automation practices improve production efficiency, a key for industrial growth.
The course covers technology for both discrete and continuous manufacturing.

Course Objectives

Identify automation basics and different levels of automation along with relevant strategies.
Summarize different manufacturing aspects related to additive manufacturing.
Examine rapid prototyping systems.
Understand cellular manufacturing and flexible manufacturing systems (FMS).
Understand Product Lifecycle Management (PLM) aspects.

Assessment Plan

Sessional Exam (Closed Book): 30 marks
Internal Assessment (Summative): Class quizzes, assignments, activity feedbacks (accumulated and averaged), 30 marks
End Term Exam (Closed Book): 40 marks
Attendance (Formative): 100% attendance is required for end-term exam, 25% for leaves. Makeup assignments for missed classes within 1 week with no extension
Make-up Assignments(Formative): maximum 5 assignments for entire semester.

Syllabus

Overview of Manufacturing and Automation: production systems, automation principles and strategies, manufacturing operations, production facilities, and additive manufacturing (process chain).
Additive Manufacturing: additive manufacturing processes, rapid prototyping, data formats, liquid-based, rapid freeze prototyping, solid-based, powder-based process, rapid tooling application.
Subtractive Manufacturing: computer numerically controlled machining, numerical control in non-traditional machining, and adaptive control machining system.
Flexible Manufacturing Systems (FMS): group technology, cellular manufacturing, quantitative analysis of cellular manufacturing (rank-order clustering), Quantitative analysis of FMS (bottleneck model), Computer Aided Process Planning (CAPP), product life cycle and data management (PLDM), components of PLM, phases of PLM, PLM strategies, recovery strategies at end of life, recycling, product data management (PDM) systems and importance, barriers to PDM implementation.

References

C.K. Chua, K.F. Leong, C.S. Lim, Rapid Prototyping: Principles and Applications
Gibson, I, Rosen, D W., and Stucker, B., Additive Manufacturing Methodologies: Rapid Prototyping to Direct Digital Manufacturing
Groover, Mikell P, Automation, Production Systems, and Computer Integrated manufacturing
Kalpakajain, Manufacturing Engineering and Technology
Saaksvuori, Antti, Immonen, Anselmi, Product Lifecycle Management

Lecture Plan

Topics and corresponding learning objectives, assessment modes, delivery methods, and corresponding course outcomes.

Lecture 1 - Introduction

Covers production systems and automation in production systems.

Production System Defined

Definition of a collection of people, equipment and procedures.
Two categories: facilities (factory and equipment) and manufacturing support systems (company procedures for production).

Production System Facilities

Components like plant layout, manufacturing systems, production lines, and standalone workstations.

Automation in Production Systems

Two categories of automation: factory and manufacturing support systems.
Computer-integrated manufacturing (CIM).

Automation Principles and Strategies

The USA principle (understand, simplify, and automate the existing process)
Ten Strategies for Automation and Process Improvement (specialization, combined operations, simultaneous operations, integration, increased flexibility, improved material handling and storage, on-line inspection, process control and optimization, plant operations control, and computer-integrated manufacturing).
Automation Migration Strategy (for new products) with three phases:
- Phase 1: Manual production
- Phase 2: Automated production
- Phase 3: Automated integrated production

Additive Manufacturing

Definition of additive manufacturing (AM)
The principle of AM is building up a model layer by layer.
Discusses rapid prototyping, data formats and 3D printing.

Subtractive Manufacturing

Description of subtractive manufacturing (SM) and components
Discusses Computer numerically controlled machining.

Computer Numerically Controlled (CNC) machining

Definition and explanation
Advantages and disadvantages of CNC machining.

Open Loop & Closed Loop Systems

Difference between open and closed loop systems.
Diagrams of both systems.

CNC Terminology

Basic length unit (BLU)
Controller (machine control unit, MCU)
Components of the controller:
- Data Processing Unit (DPU)
- Control Loops Unit (CLU)

Types of CNC Machines

Based on motion type (point-to-point and continuous path).
Based on control loops (open loop and closed loop)
Based on power supply (electric, hydraulic, and pneumatic)
Based on positioning system (incremental and absolute)

CNC Programming

Preparatory codes (G codes and N codes)
Axis codes, feed & speed codes and tool codes and miscellaneous codes.

Table of important G & M Codes

G-codes that describe machine tool movement.
M-codes that are instructions for miscellaneous functions.

Part Programming

Examples: simple turning and CNC milling
Diagrams and examples given

Adaptive Control

Definition and diagrams.

Flexible Manufacturing Systems (FMS)

Definition and characteristics
Distinguishing features of an integrated FMS from a traditional manufacturing line
Advantages, disadvantages and features of FMS

Group Technology

Definition, objectives, identifying part families, and rearranging production machines. advantages of GT, and the issues encountered in applying the method.

Part Classification and Coding

Definitions and explanations of part families, design attributes, and manufacturing attributes
Overview of different coding systems such as Opitz, MICLASS and KK-3.

Product Data Management (PDM)

Definition, architecture, advantages, and vendor examples of PDM systems.

Product Lifecycle Management (PLM)

Discusses PLC concept, its implementation, various benefits for the company, various stages and issues in implementation.

Computer-aided Manufacturing Resource Planning (CAM-MRP)

Brief introduction

Quantitative Analysis of FMS

Discusses deterministic models and bottleneck model in detail.

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Description

This quiz explores key concepts in production systems, including facilities, plant layout, and automation categories. It also delves into the role of manufacturing support systems and the significance of Product Lifecycle Management (PLM) strategies. Engage with questions that connect theoretical knowledge to practical applications in manufacturing.