ME2402 COMPUTER INTEGRATED MENUFACTURING

(Questions & Answers)

1. List any four reasons for using a CAD system.

To increase the productivity of the designer
To improve the communication
To create a database for engineering
To improve the quality of design

2. What are the components of a CAD system?

Geometric modelling,
Design analysis and optimisation,
Design review and evaluation,
Documentation and drafting

3. List any two benefits of CIM.

Tangible benefits Intangible benefits
Higher profits Improved customer service
Improved quality Greater Flexibility
Shorter time to market with new products Greater responsiveness
Shorter flow time Improved competitiveness
Shorter vendor lead time Safer working environment
Reduced inventory levels Higher employee morale
Improved schedule performance More opportunities for upgrading skills

4. What are the various network topologies?

The five basic network topologies are: Star, Tree, Bus, Ring and Hybrid.

5. State the role of GT in CAD/CAM integration.

GT applications provide a common database for effective integration of CAD and
CAM, which leads to successful implementation of CIM. Foe the effective integration
of CAD and CAM, one needs to integrate the information used by all the departments
in a shop such as design, manufacturing, quality, etc.,
Group technology provides a means to structure and save information about parts,
such as design and manufacturing attributes, processes, and manufacturing
capabilities that is amenable to computerization and analysis. It provides a common
language for the users. Integration of many types of part - related information would
be virtually impossible without group technology; consequently, group technology is
an important element of CAD/CAM integration.

6. List any two benefits of CAPP.

The benefits of implementing CAPP include the following:
 Improved rationalization and standardization of plans
Increased productivity
Reduced time to production
Increased integration of design and manufacturing
Elimination of human error
Reduced product cost

7. Mention any two methods used to collect data from the shop floor.
1. Manual data input techniques
a. Job traveller
b. Employee time sheet
c. Operation tear strips
d. Prepunched cards
2. Data collection terminals
a. Push button keyboards
b. Keyboard based terminals
3. Automated input techniques
a. Optical bar code readers
b. Magnetic card readers
c. Magnetised or bar-coded readers

8. Write any two applications of FMS.

The applications of FMS are realised in the following areas: Machining; Assembly;
Forging; Sheet metal press working; Welding; Plastic injection moulding; Textile
machinery manufacturing and Semiconductor component manufacture.

9. Define Lean manufacturing.

Lean manufacturing may be defined as an adaptation of mass production in which
workers and work cells are made more flexible and efficient by adopting methods that
reduce waste in all forms.

10. What are the components of DDC?

1. Transducer, sensors and associated instrumentation.
2. Actuators (Process interface devices)
3. Digital computer
4. Analog-to-digital convertor (ADC)
5. Digital-to- Analog convertor (DAC)
6. Input and output multiplexers
 May/June 2012

1. What are the drawing features of CAD package?

Geometric modelling features
Editing or manipulation features
Display control features
Drafting features

2. What are the advantages of solid modelling?

Mass properties of physical model can be calculated easily.
Solid models are unambiguous models.
Cross sectional views of model can be easily found.
It can be used for interference/clearance checking of moving parts.

3. What is the difference between automation and CIM?

Automation may be defined as the process of having machines follow a
predetermined sequence of operations with little or no human labour, using
specialised equipment and devices that perform and control manufacturing processes.
CIM is the automated version of manufacturing process where the three major
manufacturing functions: product design and process design; production planning and
control; and production process- are replaced by the automated technologies. CIM
represents the logical evaluation of the automation concept.

4. What is meant by asynchronous data transfer?

In asynchronous data transfer, data is sent one byte (or character) at a time. Each
string of bits making up the byte is bracketed, or marked off, with special control bits.

5. Mention the benefits of GT.

Reduce part proliferation
Help design standardization
Provide manufacturing feed back
Reduce lead time
Reduce delays
Reduce set-up time
Improve product quality
Increased productivity
Improved accuracy in estimation of costs
Greater standardization and variety reduction
Reduced set up times
Better product delivery (Helps to implement just-in-time (JIT) manufacturing)
Reduced cost of purchasing
Improved plant efficiency
6. What is CAPP?
CAPP refers to computer aided process planning. CAPP is used to overcome the
drawbacks of manual process planning. CAPP is the application of computer to assist
the human process planer in the process planning function.

7. List the different stages of shop floor control.

1. Order release
2. Order scheduling, and
3. Order Progress.

8. State the functions of computer control system of FMS.

The functions that are performed by the FMS computer control system includes:
1. Workstation/ processing station control,
2. Distribution of control instructions to workstations,
3. Production control,
4. Material handling system control.

9. Define Agile manufacturing.

Agile manufacturing is an enterprise level manufacturing strategy of introducing new
products into rapidly changing markets, and an organisational ability to thrive in a
competitive environment characterised by continuous and sometimes unforeseen
changes.

10. What are the inputs to MRP system?

1. Master production Schedule
2. Bill of materials file, and
3. Inventory record file.

Nov/Dec 2012
1. What is meant by geometry and topology?
Geometry is concerned with size, shape, and relative position of figures.
Topology is a branch of geometry that concerns only connectness (i.e., connectivity of
edges, vertices, etc.)

2. List any four rules of dimensioning.

1. Dimensions should be placed in views where the features dimensioned are
shown true shape.
2. Dimensioning to hidden lines should be avoided wherever possible.
3. Dimensioning should not be duplicated.
4. Each dimension should be so clearly so that it can be interpret in only one
way.

3. Mention the benefits of CIM.

Refer Nov/Dec 2011 Part-A Question No: 3

4. Differentiate between LAN model and MAN model.

A local area network (LAN) is a privately owned communications network used
within a geographical area.
A metropolitan area network (MAN) is a communication network covering a
geographic area the size of city or suburb.

5. What is meant by monocode and polycode structures?

Hierarchical structure (or mono-code), in which the interpretation of each successive
symbol depends on the value of the preceding symbols. Whereas the chain-type
structure (or poly-code), the interpretation of each successive symbol does not depend
on the preceding symbols & the symbol in the sequence is always the same.

6. List out the techniques available for the formation of cell in GT.
1. Part Family grouping
a. Classification and coding
b. Cluster analysis
2. Machining grouping
a. Cluster analysis
b. Graph theory
c. Combinational analysis
3. Machine-part family grouping
a. PFA
b. Rank order clustering

7. Difference between dedicated FMS and random order FMS.

A dedicated FMS is designed to produce a limited variety of part configurations. A
random order FMS is more flexible and capable of producing large variety of parts.

8. State the purpose of primary and secondary material handling system.

The primary material handling system establishes the basic layout of the FMS and is
responsible for moving work-parts between workstations in the system.
The secondary material handling system transfer work parts from the primary system
to the machine tools or other processing stations.

9. Write down the three phases of SFC.

Order release;
Order scheduling; and
 Order progress.

10. What is meant by procurement lead time?

The procurement lead time is the interval between the initiation of procurement
action and the receipt into the supply system of the material procured.

May/June 2013

1. Distinguish between reflection and scaling transformation.

Scaling an object tends to change its size and repositions the object relative to the
coordinate origin.
Reflection is a transformation in which the direction of one axis is reversed and it
produces a mirror image of an object.

2. What is sculptured surface?

Refer Nov/Dec 2012 Part-A Question No: 2

3. What is communication network? List its types.

A communication network is a collection of equipment and physical media that
interconnects two or more computers.
Types may be internal or external communication.

4. What is MAP model?

MAP is manufacturing automation protocol and these standards are essentially an
application specific subset of the ISO protocols designed to meet the needs of factory
automation.

5. What is main difference between Hierarchical codes and attribute codes

structures?
Refer Nov/Dec 2012 Part-A Question No: 5

6. What is CMPP system?

The CMPP stands for Computer Managed process planning and is a commercial
generative process planning system capable of automatically making process
decisions.

7. Distinguish between on-line and off-line data collection systems.

In an online system, the data are entered directly into the plant computer system and
are immediately available to the order progress module.
In an offline data collection system, the data are collected temporarily in a storage
device or in a standalone computer system to be entered and processed by plant
computer in a batch mode.
8. List some important advantages of implementing FMS.
1. Increased machine utilization.
2. Reduced inventory.
3. Reduced manufacturing lead time.
4. Greater flexibility in production scheduling.
5. Improved product quality.

9. What do you mean by fixed order quality model?

Q model or EOQ model is the inventory system to determine how much quantity to
order and when to order. In this system, the size of the order (order quantity) is
predetermined and fixed, but the time of its placement (ordering time) is allowed to
vary depending upon the fluctuation in demand.

10. What is direct digital control?

DDC is a computer process control system in which certain components in a
conventional analog control system are replaced by the digital computer.
1. What are the advantages to be gained by the adaptation of CAD?
Increased design productivity.
Shorter lead time.
Flexibility in design.
Improved design analysis.
Fewer design errors.
Greater accuracy in design calculation.
Better visualization of drawings.
Faster new products design.
Standardization of design, drafting and documentation procedures.

2. Specify the range of applications for which typical geometric modelling

information is used.
Process planning, tool design, production planning, and CNC programming,
inspection, assembly, costing and vendor development

3. Differentiate IGES and GKS graphics standards.

GKS (Graphical Kernel System) is an ANSI and ISO standard.GKS standardizes two-
dimensional graphics functionality at a relatively low level.
IGES stands for INITIAL GRAPHICS EXCHANGE SPECIFICATION. IGES is a
popular data exchange standard.

4. Differentiate Modulation and Demodulation.

Refer Nov/Dec 2012 Part-A Question No: 5

5. Explain OPTIZ coding system.

This classification and coding system was developed by H. Opitz in 1970 at Aachen
Technology University in West Germany. The coding system uses the following
digital sequence:
1 2 3 4 5 6 7 8 9 AB C D
The basic code consists of nine digits that can be extended by additional four digits.
The first five digits are called the form code and indicate the design or the general
appearance of the part and hence assist in design retrieval.
Later, 4 more digits were added to the coding scheme, in order to increase the
manufacturing information of the specific work part. These last four digits are also
called supplementary code. All four are integers, and respectively represent:
Dimensions, Material, Original shape of raw stock, and Accuracy of the work part.
The extra four digits, A, B, C, and D, called the secondary code, are used by the
specific organization to include those characters that are specific to the organization.

6. Define Group Technology.

Group Technology is a manufacturing philosophy that exploits similarities in the
design, fabrication, and assembly attributes of products. GT is a manufacturing
philosophy in which similar parts are identified and grouped together to take
advantage of their similarities in manufacturing and design.

7. Mention the importance of SFC systems.

Shop floor control deals with managing the work-in-process. This consists of
the release of production orders to the factory, controlling the progress of the orders
through the various work stations, and getting the current information of the status of
the orders.
8. What are the inputs and outputs of MRP?
Inputs to MRP system
1. Master production Schedule
2. Bill of materials file, and
3. Inventory record file.
Outputs to MRP system
1. Order release notice.
2. Report of planned order releases.
3. Cancellation notices.
4. Exception reports.

9. Describe CIM data transmission methods.

1. Serial data transmission
a. Synchronous data transfer
b. Asynchronous data transfer
2. Parallel data transmission

10. List different types of production monitoring systems.

1. Data Acquisition systems.
2. Data Logging systems, and
3. Multilevel scanning.