Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

Q.No.1.a. W hat is Automation? What are its advantages & disadvantages? Ans: 05

Automation can be defined as a technology concerned with performing a process by means of programmed commands combined with automatic feedback control to ensure proper execution of the instructions. The resulting system is capable of operating without human intervention. Types of Automation Following are the types of automation on the basis of their flexibility to manufacture variations in the component design: 1. 2. 3. -Fixed automation -Programmable automation -Flexible automation

1. Fixed or hard automation: Refers to a system in which the sequence of manufacturing or processing is fixed by the equipment configuration. This type is economical and has high demand for the product at high volumes. The only limitation of a fixed automation is its inflexibility in accommodating different products. 2. Programmable automation: Refers to a system in which sequence of operations can be changed to accommodate different product configurations. 3. Flexible automation: Refers to a system in which varied products can be produced continuously with little or no time loss between changes over from one product to the other. This result in minimum time losses and at the same time gives high flexibility to the product that can be manufactured from the system. Advantages: 1. 2. 3. 4. 5. 6. Continuous production without downtime is possible. Programmable automation gives more flexibility Reduce human errors by reducing human involvement. Reduce work piece damage caused in material handling. Raise safety level. Improves product quality and uniformity.

Disadvantages: 1. High initial cost & high maintenance cost

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2. b. Ans: Highly skilled workers are used. 05 Discuss role played by Computers in various aspect of manufacturing.

Now a days manufacturing operation became easy because the role of computers in production. In industries Computers are used from planning to production & from production to dispatch. But the main part is manufacturing. For this purpose highly precision work is required and this work can be done only with the use of computers. Computers are used to control & perform the manufacturing operation. Computers are assembled in some machines. Machines like CNC, DNC uses computers for all types of controlling & operations. CNC allows direct communication with other computer systems. such as CAD (Computer Aided Design). DNC (Direct Numerical Control), host computers, and CIM (Computer Integrated Manufacture) system. Traditional operational planning is done manually or by computer sheets by feeding manually. Special software tools are available that automate the operations planning of parts & assemblies. Planning is often described as an art form. This traditional approach results in differences between various planners even for near identical parts that have been processed over a period of time. Individuals have their own opinion as to an optimal routing. The manual methods often have similar operations. Methods are available that automate these processes. Various programs have attempted to capture the logic experience & opinion that is so necessary for a manual preparation system. A computer aided process planning system (CAPP) offers a potential and reducing the clerical work, and can offer consistent routing that might be optimal. Many of these computer systems use expert systems or artificial intelligence in their scheme of operation. Retrieval systems use part classification systems or group classification. In this way parts are classified in into families of a similar part and they are identified according to their manufacturing characteristics. Generative process plans use algorithms to create process plans from scratch. It is desirable that these plans do so without human assistance. Input to the system could include a complete set of specification, perhaps even drawings. The analysis of the geometry, material, reduction in physical shape of the part leads to the selection of the sequence, machine and time estimates. The generative plan is considered more difficult to develop, but it is considered more advanced.

c. Ans:

Describe any 5 operations that are carried on lathe, with neat sketches.

10

1. Turning of cylindrical surfaces: Refers to the process to reduce the diameter of a part to a desired dimension to make a machined surface cylindrical. It is also important to know that turning is not a single process but class of many and different operations performed on a lathe. Fig. shows the turning process of cylindrical surfaces:

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Turning of cylindrical surfaces 3. Turning of flat surfaces: Refers to the process to use a latch to create a smooth and flat surface, which is perpendicular to the axis of a cylindrical part .Tool (shown in Figure) is fed radially or axially to create a flat machined surface. Figure shows the process to create a flat surface:

3. Threading or thread turning: Refers to different possibilities available to produce a thread in a lathe. Threads are cut by advancing the cutting tool at a feed exactly equal to the thread pitch in a lathe. The single-point cutting tool cuts in a helical band, which is actually a thread. The procedure calls for correct settings of the machine, and also that the helix be restarted at the same location each time if multiple passes are required to cut the entire depth of thread .The tool point must be grounded so that it has the same profile as the thread to be cut. Another possibility is to cut threads by means of a thread die (external threads). or a tap (internal threads). These operations are generally performed manually for small thread diameters.fig.shows the turning process used to produce threads in a lathe:

4. Form turning: Uses complex and expensive cutting tool and requires linear feed. It does not require special machine tools or devices. It is important to know that a cutting tool has a shape that

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is imparted to the work piece by plunging the tool into it. In form turning cutting tool is complex and expensive but feed is linear and does not require special machine tools or devices.

5. Contour turning (profiling): Refers to the solution to produce tapers on a latch. As you know that a cutting tool has a simple shape. But the feed motion is complex. A cutting tool is fed along a contour thus creating a contoured shape on the work piece. You require special latches and devices for contour turning or profiling, as shown in Figure

6. Miscellaneous operations: Refers to some other operations which do not use the single point cutting tool. These miscellaneous operations can be performed on a lathe and make turning one of the most versatile machining processes as shown in Figure

7. Knurling: Refers to a metal forming operation used to produce a regular crosshatched pattern in the work surface. Knurling is not a machining operation because it does not involve material removal. Instead. Knurling is a metal forming operation used to produce a regular crosshatched pattern in the work surface. Figure is showing the knurling process.

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Q.No.2. a. Explain any one hot working process in detail. Differentiate between hot working & cold working. 06 Ans: i) ii) iii) Following are the various hot working processes iv) Hot extrusion v) Hot drawing vi) Hot piercing.

Hot rolling Hot forging Hot spinning

Hot rolling Hot working refers to the process where metals are deformed above their recrystallization temperature and strain hardening does not occur. Hot working is usually performed at elevated temperatures. The temp. should not be high to reach the solidus temp. Metal is subjected for the following purposes -To reduce the original block or ingot into desired shapes. -To refine grain size. -To control the direction of flow lines. Roller

Workpice Roller

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Sr.No. 1. 2. 3. 4. 5. Hot Working Metals are deformed above their recrystallization temperature Leads to increase in ductility Cold Working Metals are deformed below their recrystallization temperature Leads to decrease in ductility

Low force & power is required for More force & power is required for deformation deformation Due to heating the grain structure of Cold working distorts grain structure of metal is refined metal which leads to work hardening. Mechanical properties such as Tensile strength, yield strength & toughness, ductility, %elongation, hardness is increased due to cold reduction in area, resistant to shock & working. vibration are improved due to refinement of grains. Surface finish of hot worked product is Surface finish of cold worked product is very poor. comparatively better than hot worked.

6.

b. Ans:

Describe any two welding processes in detail.

06

This is a fusion type gas welding performed by a high temperature flame from combustion of acetylene and oxygen. The flame is directed by a welding torch. A filler metal mostly the composition same as that of the parent metal, is sometimes added and pressure is occasionally applied between the contacting part surfaces. The filler metal provides extra metal by melting the end of filler rod. Acetylene is the most popular fuel among the oxyfuel group. A neutral flame is produced by chemical reaction of acetylene & oxygen. TIG arc welding:

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It is an arc welding process that uses a non-consumable tungsten electrode & an inert gas for arc shielding. The process can be implemented with or without filler material. Tungsten has high melting point of 3410C.the heat is produced from an arc between the non-consumable tungsten electrode & the workpiece. In this process either direct or alternating current is used. The purpose of shielding gas is to prevent foreign material on the surface of metal. Application of TIG welding to which it is suited include high quality weld, no weld spatter hence a clean sound weld because no filler metal is transferred across the arc, and little or no post weld cleaning because no flux is used.

c. How are polymers classified? Describe the properties & applications of any four commercially important polymers. 08 A polymer is a compound consisting of long-chain molecules. each molecule is made up of repeating units connected together. Polymers can be divided into three major groups: 1. Thermoplastic polymers (thermoplastics) 2. Thermosetting polymers (thermosets) 3. Elastomers (rubbers) Thermoplastic polymers (thermoplastics): Solid materials at room temperature, become viscous liquids when heated. -Acrylics (Plexiglas): lenses, window glazing -Polyamides (Nylons. Kevlar): fibers

Silicones: waterproof and heat resistance materials Elastomers (rubbers) Exhibit extreme elastic extensibility under low mechanical stresses. The most important rubbers are:

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Natural rubber (Latex): tires. shoes, seals Silicones: seals, thermal insulation, electronics Earliest polymers were made of natural organic materials. such as cellulose. Following are the synthetic polymers: 1. Thermoplastics category: Acrylics, nylons, polycarbonates. polyethylene. polyvinyl chloride (PYC) 2. Thermosetting plastics category: Epoxies, phenolics, polyamides. etc. 3. Elastomers: Natural and synthetic rubber, silicones, polyurethanes. etc. Compared to metals. Polymers have low density, low strength and stiffness, low electrical and thermal conductivity, good resistance to chemicals and high coefficient of thermal expansion. But useful temperature of most polymers is about 3SoC and they are not dimensionally stable in service over a period of time. Because of the diverse properties. Polymers are substituting metal components in automobiles, aircrafts. office equipments to provide the advantages of high strength and low weight, colors and transparencies, ease of manufacturing, and low cost. From production point of view advantages of plastics are their relatively low melting point and their ability to flow into mould. The plastics are conveniently divided into two groups viz. thermoplastics and thermosetting plastics.

Q.No.3. a. Explain in detail the concept of TQM. Discuss various quality activities involved in TQM. 08 Ans: Definitions of TQM "TQM is a management system, not a series of programmes. It is a system that puts customer satisfaction before profit. It is a system that comprises a set of integrated philosophies, tools. and processes used to accomplish business objectives by creating delighted customers consistently meeting or exceeding their expectations and creating happy employees". Following are the principles of TQM: 1. Continuous improvement of quality at all stages of manufacturing and product development. - - 2. Bring about the total cultural change. 3. Meeting the customer's requirements i.e., customer focus customer delight/satisfaction.

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Benefits for the company Following are the benefits for the company hat implements TQM: i. Productivity improvement. ii. Better product quality. iii. Reduced quality costs. iv. Staff is more motivated and quality-conscious. v. Increased market.

Benefits to the staff i. Enhancement of job interest and security. ii. More recognition. iii. Empowerment. iv. Reduced employee grievances. v. More training and improvement in skills.

Quality activities: Plan-Do-Check-Act cycle : It requires continuous participation of all in quality improvement process. The father of TQM W.E. Deming proposed a Plan-Do-Check-Act cycle for the implementation of TQM in any organization. Figure shows the Plan-Do-Check-Act cycle:

PDCA means,

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Plan - Design. innovate Do - Manufacture Check - Inspection and test Act - Counter measure. Modification -KAIZEN is a Japanese word KAI and ZEN, In which KAI means change and ZEN means better i.e.. change for better. It is a Japanese way of life. Quality improvement is central to the Japanese system along with life time employment. seniority bas promotion: group participation etc. so in Japan TQM is succeeded via Kaizen inputs. Kaizen is a continuous on-line improvement in working life, personal life, home life and social life. In every process there was a constant and gradual improvement that was involving everyone from top management. supervisors to workers. It requires little investment. but great effort to maintain it. The results obtained are long lasting and on long term basis. Also it is a process related approach where efforts for process improvement are properly rewarded. Kaizen is a people related approach, which promotes discipline, involvement and participation, morale, communication and motivation, and skill development. -5S - KAIZEN also involves the application of S5 for improvement. which are as follows: Seitoin - put things in order Seiketsu - personal cleanliness Seri - straighten up Shitsuke - discipline Seiso- cleanup

b.

For the given component drawing, prepare a suitable process plan. Mention clearly, the operation number, description of operation, the machine used, tooling used, measuring instrument required. 12

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MANUFACTURING PROCESS PLANNING & SYSTEM

Ans: Part no.

Process Sheet Ordering quantity . Lot requirement All dimensions are in mm Description Std. Tool Measuring Instrument mtl

Part name . Operation planner.. Workstation Operation. No.

Lathe/CNC lathe

10

Position for length Facing to control length 110

HSS tool

Vernier caliper

Lathe/CNC lathe

20

Control 45 OD dia. Turn rough to 45.10 OD Turn finish to 45.00 OD

HSS tool

Vernier caliper

Lathe/CNC lathe

30

Control 25 OD dia. for Length of 40 at right end Turn rough to 25.10 OD Turn finish to 25.00 OD

HSS tool

Vernier caliper

Lathe/CNC lathe

40

Taper turning from R. to L. For 30 length.(from 25OD to 45OD)

HSS tool

Vernier caliper

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Lathe/CNC lathe Drilling machine Deburring 50 60 70 Chamfering Drill 18 hole Deburr sharp edge HSS tool --------

Drill of 18 size Vernier caliper file -------

Q.No.4. a. What are the objectives & advantages of SQC? Explain any two SQC tools, in detail. Ans: Objectives of SQC: 1. To improve the performance. 2. To solve an existing problem and prevent the problem from occurring. 3. Reduce the wastage & achieve better quality. Advantages of SQC: 1. Ensures Standard Price 2. It saves on rejection 3. Reduces expenses of inspection 4. Establishes standards, Determines performance, reliability and cost standards. 5. Corrective action is to be taken to achieve quality. 6. Reduce the wastage SQC Tools: 1) PARETO Chart:

08

Analyzing the before and after impact of changes made in a process Pareto charts are extremely useful because they can be used to identify those factors that have the greatest cumulative effect on the system and thus screen out the less significant factors in an analysis. Ideally this allows the user to focus attention on a few important factors in a process. Pareto analysis is very helpful in studying a quality problem as it helps to breakdown the problem. It is performed by plotting the cumulative frequencies of the relative frequency data.

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2) X Bar charts. It shows the upper and lower limits and control line. Upper and lower limits depict the level of tolerance within which deviations are permissible. For example: X, R. P, C, n charts.

b. Construct the X bar and R charts for the following data & conclude whether the process is able to meet the specifications. 12 Batch No. 1 2 3 4 5 23.765 23.77 23.7716 23.7767 23.7717 R 0.07 0.11 0.06 0.08 0.04

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6 23.7583 0.05

A2=0.48, D3=0, D4=2 Ans:

= =

(23.765+23.77+23.7716+23.7767+23.7717+23.7583)/6 = 23.7688

R = (0.07+0.11+0.06+0.08+0.04+0.05)/6 =0.068

UCLx=23.7688+0.48*0.068=23.8014 LCLx= 23.7688-0.48*0.068=23.7361 UCLR=2*0.068=0.136 LCLR=O*0.068=0 From graph all points lies within upper & lower control limit, hence the process is in statistical control & process can meet the the specifications.

Q.No.5. a. Explain clearly 1. NC

08

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Ans: NC can be defined as the control of operations of machine tools by a series of coded instructions called program. The program consists of mainly alphanumerical characters (numbers and letters). The sequence of events is preplanned and predictable. The functions normally performed by an operator in conventional machines are here performed by the NC system. The coded instructions are supplied to the machine in 'blocks' of information. Each block is interpreted by the NC machine as an instruction to perform a single operation. For example. a typical instruction block could command an NC machine to move a spindle relative to the workpiece through a stated distance and direction and at stated spindle speed and feed rate. The activities. such as starting and stopping of spindle or coolant are done by an operator on conventional machines or are done by the instructions given in the programs in the forms of blocks. Thus the movement of work and tool and all other operations are controlled by numbers; and hence. is the name Numerical Control. Operational Sequence in Traditional NC Part Programming Numerical control program is a set of instruction blocks which commands an NC machine to carry out complete machining of a component or a part; and hence. is known as part program. Traditional NC machines contain no local intelligence and part programs have to be fed into them manually. Usually in the form of punched paper tape. Working from a paper drawing of designed component and from planning sheets. the part program writes out the program blocks for the required machining operations by hand. This is usually done at a location remote from an NC machine. Figure 2 shows the operational sequence in traditional NC part programming:

2. CNC: Ans: Computer Numerical Control (CNC) contains essential principles of traditional NC. but employs a dedicated computer to perform basic NC functions. The computer is housed within machine control unit and allows part programs to be created via its software. These programs are then stored in the computer's memory. NC machines are tape controlled machines: whereas, CNCare computer controlled machines. In NC, tape has to be run repeatedly depending on the number of components to be produced. Also, if there is even a minor change in the design of the component, the tape has to be discarded_and a new tape with program has to be produced. NC is a hard wired system without

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flexibility. The necessary logic and signals are obtained by hard electronic components: whereas. CNCis a flexible or a soft wired system. Since, flexibility and storage capacities are available in computers. The major and minor changes in a program, in dimensions of the produced parts, or in tool management can be done very rapidly with CNC machines. The basic method of creating a CNC part program is called Manual Data Input (MOl) and involves entering instructions via a keyboard, which is attached to a CNCmachine. A CNC part program is similar in format to that of NC. CNC computer converts the alphanumeric instructions into binary pulse signals, which conform to standard ASCII. ISO.or EIA NCcodes. 3. DNC: Ans: Direct Numerical Control. The main functions of the DNC system are: -To control the NC/CNC machines. - To use central computer for storing and editing programs for all machine tools connected to it. -To transfer the stored programs to the connected machines, on demand, in real time. -To maintain the information system. The data like number of parts machined, tool usage, actual cutting time is stored and used subsequently. for scheduling of jobs on different machines. - To integrate CAD with CAM by using common data base.

DNC

4. DNC II: Nowadays, computer-aided part programming is being replaced by computer-aided manufacturing programs (software like master cam, smart cam or surf cam) that can generate the program directly from a CAD file. The following are the advantages of computer-aided programming: o Use of symbolic language o Reduced programming time

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o Reduced possibility of human error o Ability to view machining sequence on screen o Capability of simple changeover of machining sequence

b.

For the given component drawing, write a suitable part program, to machine the outer profile & to drill the holes. Make suitable assumptions regarding the tools, speed & feed rates. Show on your sketch, the set point & the axes. 12

Ans: Part program for given component is as follows N001 G90 G01 N002 G92 X-10 Y-10 Z5 T01 S500 M06 N003 G00 X120 Y-5 Z-10 F0 M03 N004 G03 X165 Y40 R40 F480 M08 N005 -- X120 Y85 R40 F480 N006 G92 X-10 Y-10 Z5 M09 M05 N007 G92 X-10 Y-10 Z10 T02 S950 M06 N008 G00 X40 Y40 Z10 F0 M03 N009 -- X40 Y40 Z-25 F100 M08 N009 -- X120 Y40 Z-25 F100 N010 G00 Z10 M09 N011 G92 X-10 Y-10 Z10 M05

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N012 M02 Q.No.6.a. Explain the concept & working of a Flexible Manufacturing System with a neat sketch of a schematic layout. 10 Ans: FMS is a collection of production equipment logically organized under a host computer & physically connected by a central transport system. FMS facilitates simultaneous manufacturing a mix of variety of parts. At the same time, it is flexible enough to manufacture sequentially, different mixes of parts without cost, consuming time & changeover requirements between mixes. A particular batch of mixed parts can be manufactured simultaneously, on one day & on another day. FMS is a system that combines benefits of two systems: highly productive but inflexible transfer lines & job shop production that can produce large product variety on standalone machines but it is inefficient. Time required for changeover to a different part is very short, in FMS. Hence, market demand variation can be handled easily by responding quickly to product. Advantages to FMS 1. 2. 3. 4. 5. Parts can be produced in small batches or even one part can be produced at lower unit cost. Labor cost & inventory cost are reduced. Utilization of machine is high. Improves productivity Short lead time.

Application of FMS 1. 2. 3. 4. 5. Metal cutting machining Metal forming Assembly Welding Surface treatment, Inspection & testing.

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b. Explain what is MRP. Elaborate on its working, its inputs & outputs & its benefits.

10

Ans:

Material requirement planning (MRP) is a computational technique that converts a master schedule for end products into a detailed schedule for the raw materials and components used in the end product. In other words. MRP is a technique to determine the quantity and timing for the acquisition of dependent demand items needed to meet the requirements of master production schedule. The detailed schedule for components and raw materials identifies the quantities of each raw material and component item. It also indicates when each item must be ordered and delivered to meet the master schedule for final products. Even though it is an effective tool for minimizing unnecessary inventory investment. MRP is often thought of as a method of inventory control. It is also useful in production scheduling and purchasing of materials. Two types of demands are used in MRP: o Independent Demand: Implies that the demand for a product is unrelated to the demand for other items. Final products and spare parts are examples of items whose demand is independent. Independent demand patterns must be usually forecasted. o Dependent Demand: Implies that the demand for an item is directly related to the demand for some other item or items usually a final product. The dependency usually derives from the fact that the item is a component of the other product. Raw materials and subassemblies are examples of items subject to dependent demand. MRP as a technique determines the following questions to ensure timely availability of the components: o What components are needed?

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MANUFACTURING PROCESS PLANNING & SYSTEM

o How many components are needed? o When are the components needed? o When should the components be ordered? The MRP logic serves as the key component in an information system for planning and controlling production operations and purchasing. The information provided by MRP is highly useful in scheduling because it indicates the relative priorities of shop orders and purchase orders. Working purpose: 1. Reducing Production and Delivery lead times: MRP identifies materials and components quantities timings availabilities and procurement and production actions required to meet delivery deadlines. To avoid delays in production. MRP helps coordinate inventories, procurement. and production decisions. It prioritizes production activities by assigning due dates on customer job orders. 2. Reducing Inventory: MRP determines when and how many components are needed to meet the master schedule. MRP also enables a manager to procure that component as it is needed; thereby avoiding costs of excessive inventory. 3. Increasing Efficiency: MRP provides close coordination among various work centers as products progress through them. Consequently, production can proceed with fewer indirect personnel. such as material expeditors with fewer unplanned interruptions, because MRP focuses on having all components available at appropriately scheduled times. The information provided by MRP encourages production efficiencies. 4. Ensuring Realistic Commitments: Realistic delivery promises can enhance customer satisfaction. By using MRP production can provide timely information to the Marketing department about the likely delivery times to prospective customers. Potential new customer orders can be added to the system to show the manager how the revised total load can be handled with existing capacity. The result can be a more realistic delivery date. Inputs to MRP The following inputs must be provided to an MRP system: o Master Production Schedule (MPS): Specifies a list of products to be manufactured, detailing when they should be completed and delivered, and in what quantities. The MPS is initially developed from a firm's customer orders or from forecasts of demand before the MRP system begins to operate. MPS identifies the quantity of each end product (end item) and when it needs to be produced during each future period in the production planning horizon. Orders for' replacement (service) components for customer are also entered as end items in the MPS, Thus, the MPS provides the focal information for the MRP system. The MPS ultimately governs the MRP system's recommended actions on the timing of procuring materials and producing sub-components. Which are geared to meeting the output schedule of the MPS, The MPS must be based on an accurate estimate of the demand arid a realistic assessment of the company's production capacity.

Q.P.Code: GT-6795

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Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

MRP Outputs The most visible outputs of the MRP system are the actual and planned order releases that are used for purchasing of raw material and in house production shops. A variety of reports can be generated from the information made available by an MRP program. The following types of outputs are generated from MRP: 1. Output Sent to MPS Planners: a. Simulation of proposed MPS b. Researching information for open orders due to shortage, delays and cancellation 2. Output Sent to Purchasing and Production: a. Changes to keep priorities valid b. Order releases (purchase and shop order) c. Planned order releases 3. Output Sent to the Management: a. Exception reports (on due dates 80M file etc.) 4. Output Sent to Capacity Requirements Planning: a. Order release information for load profiles, delays shortages Q.No.7. Write short notes on any four out of the following 1. Ans: Group Technology Group Technology Approach for Plant Layout: Group Technology (GT) deals with the analysis and comparisons of items to group them into families with similar characteristics. This approach is used for deciding plant layout that brings the flexibility in manufacturing. It is a hybrid between pure process layout and pure flow line layout. Before implementing this type of layout. You should take the following tests: Determine component families or groups. Arrange the plant equipments used to process a particular family of components. This represents small plants within the plants. The group technology reduces production planning time and progress of work-in-progress. and improves delivery performance. Figure shows group layout: 20

Q.P.Code: GT-6795

[Page 21 of 27]

Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

2. Up Milling & Down Milling. Ans: Up Milling: It is the one of the milling operation in which the direction of work piece travel is opposite to the rotation of milling cutter.

Down Milling: It is the one of the milling operation in which the direction of work piece travel is in the rotation of milling cutter.

Q.P.Code: GT-6795

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Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

3. Lean manufacturing Ans: It is defined as more & more with less & less human effort, less equipment, less time & less time and less space while coming closer & closer to providing customers with exactly what they want. Lean production can be defined as an adaption of mass production in which workers & work cells are made more flexible & efficient by adopting methods that reduce waste in all forms. Lean production is based on four principles. I. II. III. IV. Minimize waste Perfect first time quality Flexible production system Continuous improvement

4. Product layout & Process layout Ans: Product Layout: Represents the line layout. In this layout, various operations on raw material are performed in a sequence and machines are placed along the product flow line i.e., machines are arranged in a sequence in which they would be used in the process of manufacturing the product or group of related products. This type of layout materials work into finished stock through a series of integrated operations that are arranged in a line (may be U-shaped or in-line shaped). This layout is preferred for continuous production and for steady demand of product with limited product variations. Figure shows product layout:

Q.P.Code: GT-6795

[Page 23 of 27]

Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

The following are the advantages of product layout: a. Requires less space for the same volume of production. b. Allows material handling by automation. c. Reduces in process inventory. d. Provides smooth and continuous workflow after perfect line balancing. e. Allows using less skilled workers.

Process Layout: Represents the functional layout. The main feature of this type of layout is that similar machines or similar kinds of processes are kept in a group in a department. The specialized department works for all types of production. This type of layout is generally employed for industries engaged in job-order production and non repetitive kinds of maintenance or manufacturing. All the machines have to be arranged according to their functions. Figure shows process layout:

Q.P.Code: GT-6795

[Page 24 of 27]

Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

The following are the advantages of process layout: a. Provide better utilization of available equipments. b. Require less number of machines. c. Provide better product quality because the supervisors and workers attend to one type of d. Machines and operations. e. Varieties of jobs coming as different job orders make work more interesting for the workers/operators. f. Reduces capital investment.

5. Master Production Schedule Master production schedule is used as: It serves as a basis for production schedule as it provides overall data. It shows the production requirements against the available plant/resource's capacity and tries to establish relationship between customer's order and sales estimate. It provides relevant statistics and records to the production manager so that arrangements can be made to meet the delivery and commitments ensuring the maximum utilization of plant capacity in an efficient and logical manner. It is a time table showing the overall starting and the finishing time of each major part of the production process.

Q.P.Code: GT-6795

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Prepared by Prof. A.V.Javir

Rajend Mane College of Engineering and Technology, AMBAV ra (Devrukh)-415804

Information Technology University of Mumbai Sem-V (Rev) Winter 2010 (10-WIN-IT-V-REV-MPPS)

MANUFACTURING PROCESS PLANNING & SYSTEM

6. Ergonomics: Ans: Definition: Ergonomics is the study of human abilities and characteristics that affects the design of equipment systems and jobs. The terms ergonomics and human factors can be used interchangeably. The latest formal definition of Ergonomics given by International Ergonomics Association Executive Council. August 2000 is as: "Ergonomics (or human factors) is the scientific discipline concerned about the understanding of human interactions and other elements of a system. and a profession that applies theory. Principles, data and methods to design to optimize human well-being and overall system performance." Following are the important ergonomic considerations: I. Physical factors: Refers to ambient conditions; objects (tools. furniture. etc.) 2. Biological factors: Refers to body dimensions. body capabilities. and physiological processes 3. Psychological factors: Refers to mental workload. information processing. training. And motivation 4. Work factors: Refers to job demands (time. rate. etc.) and job design 5. Organizational factors: Refers to the organization type/climate and management systems Ergonomics needs a mature and sensitive ability to listen and consult carefully with the people who may have to use the system or product being developed or changed. They work at different interfaces where the user contacts the product or system physically mentally, or otherwise. The aim of ergonomics is to develop a comfortable. Safe and thus a productive work system. by incorporating human factors such as thinking and data into the plan. This means designing a product or process to use the capabilities of a person. But at the same time respecting their limitations.

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