PRT401I/101/0/2012

Tutorial Letter 101/0/2012

Production Technology IV PRT401I Year Module
Department of Mechanical and Industrial Engineering
This tutorial letter contains important information about your module.

Bar code

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CONTENTS
1 1.1 2 2.1 2.2 3 3.1 3.2 3.3 4 4.1 4.2 4.3 5 5.1 5.2 6 7 8 8.1 8.2 8.2.1 8.2.2 8.3 8.4 9 10 11 12 INTRODUCTION AND WELCOME .................................................................................. 3 Tutorial matter ................................................................................................................... 3 PURPOSE OF AND OUTCOMES FOR THE MODULE ................................................... 3 Purpose ............................................................................................................................. 3 Outcomes .......................................................................................................................... 3 LECTURER AND CONTACT DETAILS ........................................................................... 6 Lecturers ........................................................................................................................... 6 Department ....................................................................................................................... 7 University .......................................................................................................................... 7 MODULE RELATED RESOURCES ................................................................................. 8 Prescribed books .............................................................................................................. 8 Recommended books ....................................................................................................... 8 Electronic Reserves (e-Reserves) .................................................................................... 8 STUDENT SUPPORT SERVICES FOR THE MODULE .................................................. 9 Study guide................................................................................................................8 Online resources...............................................................................................................9 MODULE SPECIFIC STUDY PLAN ................................................................................. 9 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING ....................... 9 ASSESSMENT ................................................................................................................. 9 Assessment plan ............................................................................................................... 9 General assignment numbers ......................................................................................... 10 Unique assignment numbers .......................................................................................... 10 Due dates of assignments............................................................................................... 10 Submission of assignments ............................................................................................ 11 Assignments ................................................................................................................... 11 EXAMINATIONS............................................................................................................. 11 OTHER ASSESSMENT METHODS ............................................................................... 12 FREQUENTLY ASKED QUESTIONS ............................................................................ 12 ANNEXURE A: ASSIGNMENTS.....................................................................................13 ORDER FORM..............................................................................................18

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INTRODUCTION AND WELCOME

Dear Student Welcome to the module, Production Technology IV (Code PRT401I), offered by the Industrial Engineering section in the School of Engineering at UNISA. This module is part of the qualification, Diploma in Engineering: Industrial. This is your first tutorial letter (TL); read it carefully before you start studying. It provides you with an overview and specific information about this module. You should use it as a guideline to your studies in this course. This tutorial letter also provides you with general administrative information as well as specific information about the subject. Read it carefully and keep it safe for future reference. We trust that you will enjoy this course. The purpose of this module is to provide the student with the practical and theoretical knowledge to do research for an Engineering Project. 1.1 Tutorial matter

Some of this tutorial matter may not be available when you register. Tutorial matter that is not available when you register will be posted to you as soon as possible, but is also available on myUnisa.

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2.1

PURPOSE OF AND OUTCOMES FOR THE MODULE

Purpose After completing this module a learner must be able to plan the implementation of production technology, equipment, materials handling, and information technology and evaluate alternatives, and how to manage the project.

2.2

Outcomes At the end of this module the student must be able to undertand: 1. Flexible Manufacturing systems and Understand the various manufacturing technologies used in industry. Relate competitiveness, quality and cost. The role of computers in manufacturing, CAD and CAM applications.

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2.

Introduction to flexible manufacturing systems Identify examples of flexible manufacturing systems Identify the FMS project structure and management Identify components, processes and materials handling systems in FMS. Applications of computer simulation for feasibility study of FMS. Financial justification for implementing FMS Process of installation and commissioning of FMS Identify factors affecting the development of FMS Just in Time systems Integrating JIT with MRPII systems Integration of JIT with CIM Automated manufacturing processes Automated materials handling and storage systems Computer integrated manufacturing enterprise.

3. Nontraditional machining processes Understand the classification of nontraditional machining processes Be able to describe, identify uses, tooling used and operations performed and advantages and limitations of the following processes o Ultrasonic machining o Abrasive jet machining o Electrochemical machining o Chemical milling o Electro discharge machining

4. Understand the principles, applications and implementation of the following sensing techniques in automated manufacturing processes o o o o 5. o o o o o Discrete sensing Continuous sensing Bar codes Symbology Understand the principles, applications of bar code technology Medium and printer selection Bar code scanners Bar code readers Bar code printers Shop floor control using bar codes

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o Radio frequency identification system(RDFI) 6. Understand the principles and application of Programmable logic controllers (PLCs) o Computer process control. 7. o o o o o o 8. o o 9. o o o o o CIM software which supports JIT The common elements in CIM and JIT systems People involvement Demand pull Total quality Control (TQC) JIT vendor interface Support for the focused factory Understand the application of technology in manufacturing Types of technology and impact of life cycle effect on technology. Material processing technology NC, CNC, AGVs, robots Understand and identify the application Information technology in manufacturing Transaction processing Automatic identification systems Management information systems Decision support systems Artificial intelligence and expert systems

10. Computer integrated manufacturing and the computer integrated enterprise o Data base and data base management o CIM data base o Data base models o Network and relational data base o Integration and implementation issues o Requirements for integrated manaufacturing data o System architechture o Functional architechture o Control architechture o Data achitechture o Steps in implementing CIM. 11. Automated material handling and storage systems o Advantages of AGVs o Automated storage and retrieval systems (AS/RS) o The main components of AS/RS o Benefits of AS/RS

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12. Robot applications o Classification and reach of robots o Cartesian, cylindrical, polar or spherical robots, articulated robots, SCARA robots o Classification based on control system o Point to point o Continuous path control o Controlled path computed trajectory o Robot reach or work place envelope o Major components and functions of robots o Drive system o Control system o Sensors o Robot grippers o Robot programming o Robot applications 13. Lasers in industry o How lasers work o Types of lasers o Laser application o Laser beam welding and machining 14. Rapid prototyping techniques o How rapid prototyping works o Types of rapid prototyping o rapid prototyping applications

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3.1

LECTURER AND CONTACT DETAILS

Lecturers Your lecturer is: Mr Steadyman Chikumba E-mail : chikus@unisa.ac.za Mondays to Fridays from 09h00 to 13h00

Availability:

Please adhere to these hours only. Functions of the Lecturer: Enquiries about technical content.

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Set assignments. Mark assignments. Set examination papers. Mark examination papers

Under no circumstances, should the lecturer be contacted with regard to examination dates, results or receipt of assignment or assignment marks. 3.2 Department You may contact the Department of Mechanical and Industrial Engineering by post, e-mail, telephone, or online through myUnisa. Please refer to the booklet: My studies @ Unisa Departmental Address: Department of Mechanical and Industrial Engineering Unisa (Florida Campus) Private Bag X6 Florida 1710 Phone: 011 471 2963 Use the general E-mail address: nkambule@unisa.ac.za Find our Department on the Internet at the online address:

http://www.unisa.ac.za Always state your STUDENT NUMBER and your Module Code PRT401I correspondence and enquiries. Whenever you contact the Department of Mechanical and Industrial Engineering, ensure that the first thing you mention after greeting is your subject code! It does not help to say you are a student in Industrial Engineering, lecturers deal with modules. 3.3 University in all

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If you need to contact the University about matters not related to the content of this module, please consult the publication My studies @ Unisa that you received with your study material. This brochure contains information on how to contact the University (e.g. to whom you can write for different queries, important telephone and fax numbers, addresses and details of the times certain facilities are open).Always have your student number at hand when you contact the University.

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4.1

MODULE RELATED RESOURCES

Prescribed books 1. TITLE: Systems Approach to Computer Integrated Design and Manufacturing AUTHOR: Nanua Singh PUBLISHER: John Wiley & Sons, Inc ISBN NO: ISBN 0-471-58517-3 2. TITLE: Implementation of Flexible Manufacturing Systems AUTHOR: Greenwood NR PUBLISHER: Basingstoke: Macmillan Educational ISBN: 047 0209321 NOTE: This Book can only be purchased through UNISA Press. Please use the form in Annexure B to order your text book

4.2

Recommended books ElMaraghy, Hoda A. (Ed.) , Manufacturing Systems , Changeable and Reconfigurable Manufacturing Systems Series: Springer Series in Advanced Manufacturing Mikell P. Groover Automation, Production Systems and Computer Integrated Manufacturing , 3rd Edition, Prentice Hall N. Nise, Control Systems, Wiley B Wu Manufacturing systems Design and Analysis John J. Craig Introduction to Robotics: Changeable and Reconfigurable, Pearson Electronic Reserves (e-Reserves)
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4.3

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There are no electronic reserves for this module.

STUDENT SUPPORT SERVICES FOR THE MODULE

Important information appears in your my Studies @ Unisa brochure.

5.1

Study Guide There is a study guide in this module. The student is encouraged to buy the prescribed book as soon as they register for the module.

5.2

On line resources All course materials are available on myUnisa https://my.unisa.ac.za under the module course code under Materials. Discussion forums are set up by your lecturer and available for discussions with your peers https://my.unisa.ac.za Some additional electronic resources are available from the Library site (via www.unisa.ac.za). You may electronically post or upload your assignments in line with the guidelines explained in the booklet : My studies @ Unisa.
DO NOT EMAIL ASSIGNMENTS TO LECTURERS. DO NOT FAX ASSIGNMENTS. DO NOT SEND ASSIGNMENT IN FRAGMENTS, BUT SUBMIT THE COMPLETE ASSIGNMENT.

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skills.

MODULE SPECIFIC STUDY PLAN

Use your my Studies @ Unisa brochure for general time management and planning

MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING

There are no practicals for this module.

ASSESSMENT
Your assignments will each receive a % mark, as per the table below. These marks are independent of the exam credit value. In order to qualify for sitting the examinations, you have to submit all three assignments.

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You will find your 2 (TWO) assignments for this subject in Annexure A at the back of this tutorial letter. All TWO Assignments are compulsory. Please submit all three assignments, duly completed, to UNISA before the closing dates stated in this section. The mark for Production Technology IV (PRT401I) is calculated as follows: The year mark contributes to 10% of final mark The examination mark contributes to 90% of the final mark 8.1 Assessment plan The year mark is based on all the assignment marks obtained and their contribution towards the final year mark are as shown in the table below:
CONTRIBUTION TOWARDS FINAL SUBJECT MARK 5% 5% = 10%

ASSIGNMENT NUMBER 1 (Compulsory) 2 (Compulsory) TOTAL

CONTRIBUTION TOWARDS YEAR MARK 50 % 50 % = 100 %

8.2

General assignment numbers Assignments are numbered consecutively per module, starting from 01. Only Arabic numerals are used: for example, Assignment 01, 02, 03. For detailed information and requirements as far as assignments are concerned, see my studies @ Unisa, which you received with your study package.

8.2.1 Unique assignment numbers Unique numbers for assignments are shown below: Unique Numbers Assignment 1 Assignment 2 8.2.2 Due dates of assignments
THE CUT-OFF SUBMISSION DATES FOR THE ASSIGNMENTS ARE : 306741 260633

Assignment 1 Assignment 2

28 May 2012 3September 2012

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8.3

Submission of assignments You will find your two assignments for this subject in Annexure A. You are required to submit two (2) assignments to UNISA before the closing dates stated in this section. The year mark is based on all the assignment marks obtained and their contribution towards the final year mark For detailed information and requirements as far as assignments are concerned, see the brochure my Studies @ Unisa that you received with your study material. To submit an assignment via myUnisa: Go to myUnisa. Log in with your student number and password. Select the module. Click on assignments in the menu on the left-hand side of the screen. Click on the assignment number you wish to submit. Follow the instructions. IT IS VERY IMPORTANT TO CONSIDER THE FOLLOWING POINTS: No late assignment submissions will be accepted. Keep a clear copy of the assignment for your own reference. This is important, as assignments do get lost. Submissions of assignments must be in accordance to the myStudies@Unisa handy guide. It is your responsibility to check whether Unisa has received your assignment.

8.4

Assignments The three assignments which include the final portfolio submission are attached as Annexure A.

EXAMINATIONS
There is a 3 hour written examination. Students can also be referred to the myStudies@Unisa brochure for general examination guidelines and examination preparation guidelines. Please note that students receive admission to the examinations on the submission of their first assignment.

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OTHER ASSESSMENT METHODS

None

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FREQUENTLY ASKED QUESTIONS

The my Studies @ Unisa brochure contains an A-Z guide of the most relevant study information. Ensure that you have received the Unisa booklet: My studies @ Unisa and that you have familiarised yourself with its contents. Take special note of Unisas online internet facility: myUnisa, and ensure that you register, if possible. It has many benefits, inter alia that you can communicate with your fellow students on subject matters or submit assignments.

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ANNEXURE A ASSIGNMENTS
ASSIGNMENT 1 (unique no: 306741)

QUESTION 1 1.1 1.2 1.3 Discuss how the creativity matrix compares with Hayes Wheelwright Model. (8) Explain the importance of the Interdependence of costs, quality and delivery time in production processes. (6) Discuss twelve death signs of a growing manufacturing company. (12) [26] (10) (5)

QUESTION 2 2.1 2.2 2.3 2.4 2.5 2.6 What are the various types of machine cells? Classify a component using MICLASS system. What factors are considered in selecting a classification and coding system? (5) What is cell formation? What are the objectives of cell formation? Compare the features of horizontal and vertical machining centers. Discuss the importance of the following statements in the APT: 2.6.1 Geometric statements 2.6.2 Cutter motion statements 2.6.3 Auxilliary statements 2.6.4 Post processor statements 2.7 2.8 Define canned cycle? How does a canned cycle reduce program length? (2) (2) (2) (2) (4) [46] QUESTION 3 3.1 3.2 Discuss the machining features on nontraditional machining. (5) (5) (5)

Discuss how the solid model based CAD data is used for NC programming. (4)

Explain the principle and application of jet based technologies in manufacturing. (10) 3.3 Discuss the monitoring and modeling of AWJ process. (10) [25] QUESTION 4 4.1 Explain the two configurations of Direct Numerical Control. (6)

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4.2 4.3 4.4

Discuss the steps of part programming using Standard APT (Automatically programmed tools) language. (8) Explain the role of the post processor in part programming. Explain CAD/CAM based part programming. (5) (6) [29]

QUESTION 5 5.1. 5.2 5.3. 5.4 5.6 5.7 5.8 5.9 What are the components of Flexible Manufacturing System? Discuss the types of flexibilities an FMS can offer. What are the FMS performance reports? Explain how they are used. Discuss the operational issues of FMS. Explain the structure of FMS application software systems. Discuss the purpose of Simulation Software in an FMS. What is a Kanban? What for it is used in FMS? Explain. Write short notes on the following: (a) Flexible workforce (b) Role of Preventive Maintenance in FMS. QUESTION 6 Write short notes on the following principle, industrial applications and how control is achieved. 6.1 AS/RS (6) 6.2 AGVs (6) [12] QUESTION 7 7.1 7.2 7.3 7.4 7.5 Explain about the Robot Anatomy and configuration. Explain about homogeneous Transformations in Robotics kinematics. Discuss in detail about the grippers and their types. Explain the Image processing and Image data Reduction. Write about segmentation and object recognition in detail. (10) (5) (8) (10) (5) (3) (3) [46] (10) (5) (5) (5) (5) (5) (5)

[38] TOTAL MARKS = [222]

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ASSIGNMENT 2 (Unique no 260633) QUESTION 1 Carry out a study on how your organization designs, selects processes and manufactures new product and service offerings. Discuss how concurrent engineering can be implemented within your organisations context. (20) [20] QUESTION 2 The project must basically be focused on the application of nontraditional manufacturing methods and technologies including rapid prototyping. The student is tasked to identify a problem at a typical company and justify how nontraditional manufacturing methods or RP can be a solution to the problem. The application areas include: a) Direct production of engineering metal, ceramic, and polymer components or parts by rapid prototyping or nontraditional manufacturing methods, production of tooling (rapid tool making) such as molding dies, fixtures by nontraditional manufacturing methods or rapid prototyping for use in further manufacturing operations 1. Title page This should include the project title and the name of the authors of the report. The project should be based on application of nontraditional manufacturing methods or Rapid Prototyping technology at a typical company in South Africa. You should formulate its project title. The title must reflect the goals or aims of the project. 2. Abstract The abstract is a very brief summary of the report's contents. It should be about half a page long. Somebody unfamiliar with your project should have a good idea of what it's about having read the abstract alone and will know whether it will be of interest to them. Trends in Rapid prototyping can also be cited. 3. Acknowledgements It is usual to thank those individuals who have provided particularly useful assistance, technical or otherwise, during your project.

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4. Contents page This should list the main chapters and (sub)sections of your report. Choose self-explanatory chapter and section titles and use double spacing for clarity. If possible you should include page numbers indicating where each chapter/section begins. Try to avoid too many levels of subheading - three is sufficient. 5. Introduction This is one of the most important components of the report. It should begin with a clear statement of what the project is about so that the nature and scope of the project can be understood by a lay reader. It should summarise everything you set out to achieve, provide a clear summary of the project's background, relevance and main contributions. The introduction should set the scene for the project and should provide the reader with a summary of the key things to look out for in the remainder of the report. When detailing the contributions it is helpful to provide pointers to the section(s) of the report that provide the relevant technical details. The introduction itself should be largely non-technical. Aims and objectives of the project should be clearly stated. 6. Background The company background should be clearly stated. This section may include the main processes, particular machines that are to be studied and citation of the problem which will be solved should be explicitly clear. The background section of the report may also set the project into context by relating it to existing published work which you read at the start of the project when your approach and methods were being considered. There are usually many ways of solving a given problem, and you shouldn't just pick one at random, so explain why Rapid Prototyping is appropriate to achieve the objectives. The background section can be included as part of the introduction but is usually better as a separate chapter, especially if the project involved significant amount of prior research. 7. Methodology Outline the procedure that is undertaken to collect, store, analyze and present information as part of a research process to achieve the desired objectives. This section should briefly exhibit steps undertaken to identify the problem, how the design was done, how the model
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was

printed,

de-powdering

and

infiltration,

and

statement

to

indicate

that

recommendations were finally made. 8. Body of report (the title for this section depends on the project undertaken) This is the central part of the report and can have more than one chapter detailing the technical work undertaken during the project. 9. Recommendations Give recommendations for correct nontraditional manufacturing methods or RP techniques that could be used. 10. Conclusions and Future Work The project's conclusions should list the things which have been learnt as a result of the work you have done. 11. Bibliography This consists of a list of all the books, articles, manuals etc. used in the project and referred to in the report. You should provide enough information to allow the reader to find the source. SUBMISSIONS Paper of about up to 2000 words Hand written papers will not be accepted. And working models (optional) (100) [100] Total marks = [120]

UNISA 2012

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ORDER FORM
TO: The Business Section, Unisa Press, PO Box 392, UNISA, 0003 FAX NO: (012) 429-3449 /REFERENCE TEL NOS: (012) 429-3515 / (012) 429-2976 / (012) 429-3448/ (012) 4293368 / (012) 429-2953 NB: Please note that the University no longer banks with ABSA bank. The new bank is Standard bank, see bank account details below PRICE: (PUBLICATION IS SUBJECT TO AVAILABILITY, AND PRICE MAY INCREASE) Please send me the following Unisa publication: (ITEM NO ) SA price: Overseas prices: Other countries in Africa: (VAT AND POSTAGE INCLUDED) US$ R ; UK ; } (all these prices INCLUDE AIRMAIL)

STUDENT NO: Name: Address:

TEL NO:

Postal code: PAYMENT OPTIONS: Choose between the following 5 options (indicate with an x) 1a) Direct Payment for South African students: Banking details as follows: Standard Bank, Sunnyside, Type of Account: Deposit; Name of Account: UNISA Student deposits; Account no: 096R. Branch Code: 010645. For reference on the Bank deposit slip, please print your student no, space and the allocation no 5400380438 on the deposit slip and fax deposit slip to (012) 429-3449. This is an example of the Reference on the Bank deposit slip: Direct Payment for Foreign students: (Please contact Unisa Press on 012 429 3448 / 2976 e-mail: Thearl@unisa.ac.za). 2) 3) Postal order for R ______________, made payable to Unisa, is attached My Unisa study fees account has been paid in full AND has a credit available that will cover the cost of this order. I therefore authorise Unisa Press to debit my study fees account with the amount owing (not applicable for NFSAS students). NFSAS students

1b)

4)

Signed _______________________________________ Date __________________________

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