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?

<p>Automation of manufacturing systems and computerization of manufacturing support systems.</p> Signup and view all the answers

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

<p>They manage production and solve technical and logistics problems.</p> Signup and view all the answers

Give an example of a logical grouping within manufacturing systems.

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

What does Computer-Integrated Manufacturing (CIM) encompass?

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

How do manufacturing support systems connect with factory manufacturing systems?

<p>They are linked through automation and computerization.</p> Signup and view all the answers

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

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

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

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

Identify a common barrier to the implementation of PDM systems.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

<p>3D Modeling.</p> Signup and view all the answers

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

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

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

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

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

<p>Multiphase Jet Solidification (MJS).</p> Signup and view all the answers

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

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

How does ultrasonic cleaning contribute to the Rapid Prototyping process?

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

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

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

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

<p>To bond individual powders and strengthen the part.</p> Signup and view all the answers

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

<p>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.</p> Signup and view all the answers

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

What factors influence the build time in stereolithography?

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

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

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

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

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

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

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

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

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

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

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

What are the main components of a CNC system?

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

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

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

List two examples of input devices used in CNC systems.

<p>Examples include Floppy Disk Drive and USB Flash Drive.</p> Signup and view all the answers

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

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

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

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

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

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

Flashcards

Production Systems

Production systems are the processes and resources used to create goods and services. They involve the planning, scheduling, and execution of various operations.

Automation in Production Systems

Automation in production systems refers to using technology to perform tasks previously done by humans. This can include robots, sensors, and software.

PLM (Product Lifecycle Management)

PLM (Product Lifecycle Management) is a comprehensive strategy for managing the lifecycle of a product, from ideation to retirement. It involves collaborating across teams and departments to ensure efficient product development, production, and support.

PLCM (Product Lifecycle Cost Management)

PLCM (Product Lifecycle Cost Management) is a subset of PLM focused on managing the cost of a product during its entire lifecycle. It helps optimize costs by managing design, development, production, and maintenance phases.

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Strategies for End-of-Life Product Recovery

Strategies for end-of-life product recovery include recycling, reuse, and disposal. They prioritize resource conservation and minimizing environmental impact.

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Product Data Management (PDM) Systems

Product Data Management (PDM) systems are software tools that manage the design, engineering, and related information throughout a product's lifecycle. They facilitate collaboration and version control.

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Barriers to PDM Implementation

Barriers to PDM implementation can include resistance to change, lack of training, cost considerations, and integration challenges with existing systems.

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Benefits of PDM within PLCM

The benefits of using PDM systems within PLCM include improved collaboration, reduced errors, enhanced efficiency, and better decision-making.

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What is a production system?

A group of people, equipment, and processes that work together to make products.

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What are production system facilities?

The physical location and organization of a factory, including its machines, layout, and equipment.

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What are manufacturing support systems?

The procedures and systems that manage production processes, including ordering supplies, moving products, and ensuring quality.

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What is plant layout?

The physical arrangement of equipment and machines in a factory.

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What is a production line?

A group of machines and people working together to produce products in a specific sequence.

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What is a stand-alone workstation?

A single machine or workstation with a person operating it.

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What is automation of manufacturing systems?

The use of technology to automate manufacturing processes within a factory.

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What is computerization of manufacturing support systems?

The use of computers to manage and control the information and processes in manufacturing support systems.

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Stereolithography (STL)

A manufacturing process that builds 3D objects layer by layer using a UV laser to solidify a liquid photopolymer resin.

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Photopolymer Resin

A liquid material that hardens (cures) when exposed to ultraviolet light, used in stereolithography.

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Curing

The process of hardening the photopolymer resin in STL by applying UV light from the laser, forming solid layers.

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Build Platform

The platform used to support the growing 3D object during the layer-by-layer building process in STL.

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Wiper Blade

In STL, a wiper blade spreads the liquid photopolymer resin evenly across the build platform before each layer is cured.

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Layer Thickness

The thickness of each layer in STL, determining the resolution and detail of the final object.

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Scan Speed

The speed at which the UV laser scans the build platform to cure the photopolymer resin in STL.

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Baking

A finishing step in STL, where the partially cured object is heated in an oven to fully solidify the polymer.

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Powder-Based RP Systems

A category of Rapid Prototyping (RP) systems that use powder materials in a granular form to build objects. These systems differ from solid-based RP techniques, which rely on materials in solid form.

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Selective Laser Sintering (SLS)

A popular powder-based RP technology developed by 3D Systems. It uses a laser to selectively sinter powdered materials, fusing them layer by layer to create the desired shape.

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EOSINT Systems

Another powerful powder-based RP technology from EOS. It utilizes a similar principle to SLS, employing a laser to fuse powdered materials, but with a more sophisticated approach.

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Three-Dimensional Printing (3DP)

A powder-based RP technology pioneered by Z Corporation. It utilizes a unique process called 'Three-Dimensional Printing' to create objects by selectively binding powdered materials with a liquid binder material.

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Laser Engineered Net Shaping (LENS)

A powder-based RP process that uses a laser to melt and fuse metal powder materials. Known for its high-precision capabilities, especially with metals.

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Direct Shell Production Casting (DSPC)

A powder-based RP method developed by Soligen. It involves spraying melted metal onto a rotating core in a layer-by-layer process.

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Multiphase Jet Solidification (MJS)

A powder-based RP technology from Fraunhofer. It utilizes a specialized jet to control different material phases during the build process, offering flexibility in material composition.

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Electron Beam Melting (EBM)

A powder-based RP technology developed by Acram, using an electron beam to melt and fuse metal powder material. It's known for high-speed and high-precision capabilities.

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3D Printing: Binder Jetting

A 3D printing method that builds objects layer by layer by selectively binding powder particles together using an ink-jet printing head that deposits a binder material on those regions that are to become the solid part.

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Sintering in 3D Printing

The process of applying heat to powder materials to create a solid object. It is often used in binder jetting 3D printing to solidify the part after binding the powder.

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Laminated-Object Manufacturing (LOM)

A 3D printing method that involves stacking thin layers of material and cutting each layer to the desired shape using a laser or other cutting tool.

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LOMSlice Software

The software used in LOM to slice the 3D model into thin horizontal layers for the printer to process.

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Sheet Stock in LOM

Thin sheets of material used as input for Laminated-Object Manufacturing (LOM). They can be made from paper, plastic, metal, and other materials.

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Adhesive Backing in LOM

The adhesive coating that is applied to each layer in LOM to bond the layers together.

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Fused Deposition Modeling (FDM)

A 3D printing method that builds objects by selectively melting and bonding materials, typically polymers, using a focused heat source.

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Closed-loop system

A system where the output of a process is measured and fed back to the input to adjust the process, creating a continuous loop of optimization.

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Open-loop system

A system where the output is not measured or used to adjust the input.

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Point-to-Point control

A type of CNC control where the machine moves to a specific point and performs an operation. This operation is done at that point, and the machine then moves to the next location.

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Continuous Path Control

A type of CNC control where the machine performs an operation while it is moving. This is often used for creating shapes or contours.

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Input Device in CNC System

A device that inputs data or commands into a CNC system (e.g., a USB drive, a network connection).

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Central Processing Unit (CPU) in CNC

The brain of the CNC system, it interprets commands from the input device, controls the machine's motions and performs calculations.

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Machine Tool in CNC

The physical machine that performs the task - e.g., a drilling machine, a milling machine, a turning machine.

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Feedback Device in CNC

A sensor that monitors the position or speed of the machine's moving parts (e.g., a linear scale, a rotary encoder).

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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.

Other topics

  • Specific details and examples of each aspect (machines, processes, and methods used in each case are discussed in more detail, along with relevant diagrams and explanations within the context of automation of industrial processes. These should be referred to in conjunction with the course notes.)

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