UNIT IV

1. Group Technology: Group Technology (GT) is a systematic approach to manufacturing that

organizes and processes similar parts together based on shared design or production
characteristics, aiming to improve efficiency and reduce waste.
2. Part Families:
• A part family is a collection of parts that are similar either in geometric shape and size or
in the processing steps required in their manufacture. The parts within a family are
different, but their similarities are close enough to merit their inclusion as members of the
part family.
• Example: In an automotive factory, cylindrical parts like shafts and rods are grouped into
one part family, while flat components like plates and brackets form another. Each family
is processed in specialized cells, improving efficiency.
3. Objectives of Group Technology (GT) are:
1. Improve Efficiency: Minimize setup times, material handling, and lead times by grouping
similar parts into part families.
2. Optimize Workflow: Streamline the production process by using machine cells, reducing
workflow interruptions.
3. Reduce Costs: Lower inventory levels, tooling requirements, and labour costs through
process standardization.
4. Increase Flexibility: Facilitate the efficient production of variety by managing parts
through grouping and classification.
5. Enhance Quality: Improve product consistency by standardizing processes and tools
within manufacturing cells.
6. Enable Lean Manufacturing: Support waste reduction, better resource utilization, and
improved productivity through efficient layouts and part grouping.
4. FMS:
FMS is an automated production system that uses computer-controlled machines, robots, and
workstations to produce a variety of products with minimal downtime.
It is designed for flexibility, allowing quick changes between different product types, improving
efficiency in low-volume, high-variety production. It also includes a central control system to
manage operations and material handling systems for smooth workflows.
5. FMS APPLICATIONS:
1. Metal-Cutting Machining
2. Metal Forming
3. Assembly
4. Joining-Welding (arc, spot), Glueing
5. Surface Treatment
6. Inspection
7. Testing

6. Lean Manufacturing: Lean manufacturing is a production philosophy that focuses on

minimizing waste (anything that doesn’t add value) while maximizing productivity. It involves
continuous improvement (Kaizen), optimizing the use of resources, and improving process flow
to deliver high-quality products with less time, effort, and cost.
7. Components of a Flexible Manufacturing System (FMS)
1. Workstations:
• Load/Unload Stations: Interface for loading raw parts and unloading finished parts,
communicating with the system to ensure proper handling.
• Machining Stations: CNC machines (e.g., CNC machining centers, turning centers)
perform operations like milling and turning with automatic tool changers.
• Assembly Stations: Industrial robots or component placement machines perform
automated assembly in high-variation environments.
• Inspection Stations: Coordinate measuring machines (CMM) and machine vision
systems are used for quality control during production.
2. Material Handling and Storage System:
This system moves parts between stations and stores them temporarily, ensuring efficient
operation. Key functions include:
• Random Movement: Parts are flexibly routed between workstations, adapting to
machine availability.
• Handling Various Part Types: Modular pallet fixtures handle non-rotational parts,
while robots manage rotational parts.
• Temporary Storage: Small part queues are maintained at each station to maximize
machine utilization.
• Computer Control: The central computer directs parts, manages routing, and
optimizes production flow.
3. Computer Control System: The central computer coordinates all components,
managing part flow, scheduling, and ensuring synchronization across the FMS.
4. Human Role: Humans are needed to load/unload parts, set tools, maintain equipment,
program CNC machines, and oversee system operations.
8. System Based Design and Manufacturing Attributes:
Two categories of part similarities can be distinguished by:
1. Design attributes are concerned with part characteristics such as geometry, size, and
material.
2. Manufacturing attributes are concerned with the processing steps required to make a part.
Design Attribute Description
1. Basic External Shape Defines the outer geometry of the part, determining its form
and fit.
2. Basic Internal Shape Describes the internal features like holes or cavities, critical
for functionality.
3. Rotational/ Rectangular Differentiates cylindrical and rectangular parts, affecting
Shape design and manufacturing processes.
4. Length-to-Diameter Ratio Important for the stability and functionality of rotational parts.
5. Material Type Specifies the material for performance, durability, and
manufacturability.
6. Part Function Defines the role of the part in the system, guiding design
requirements.
7. Tolerances Sets permissible dimensional variations, ensuring
compatibility and quality.
8. Surface Finish Specifies the surface texture or smoothness, affecting
aesthetics and performance.
 Manufacturing Attribute Description
1. Major Processes Primary methods like casting, machining, or forming
used in manufacturing.
2. Minor Operations Secondary operations, such as polishing or heat
treatment, to enhance quality.
3. Operation Sequence Defines the order of operations, ensuring efficient
and effective production.
4. Machine Tool Specifies the equipment required for production,
affecting precision and speed.
5. Production Cycle Time Time needed to complete one production cycle,
critical for efficiency.
6. Batch Size Number of parts produced per run, influencing cost
and inventory.
7. Annual Production Total quantity manufactured annually, guiding
resource and capacity planning.
8. Fixtures Required Jigs or fixtures used to hold the part securely during
manufacturing.

9. Lean v/s Agile Manufacturing:

Point Lean Manufacturing Agile Manufacturing

1. Focus Focuses on eliminating waste and Focuses on flexibility and
improving efficiency. responding quickly to market
changes.
2. Production Push-based (production based on Pull-based (production based on
Approach forecasted demand). actual customer demand).
3. Efficiency Emphasizes reducing waste, Emphasizes quick changes in
improving flow, and standardizing production based on fluctuating
processes. demand.
4. Inventory Low inventory (just-in-time) to Higher inventory levels to handle
reduce waste and storage costs. unpredictable demand.
5. Customization Limited customization due to focus High customization to meet
on efficiency and standardization. changing customer needs.
6. Lead Time Longer lead times due to focus on Shorter lead times due to
batch processing and efficiency. flexibility and quick adaptation.
7. Risk Reduces risk by creating Manages risk by enabling quick
Management predictable, stable processes. changes to meet market demands.
8. Best for High-volume, predictable Low- to medium-volume, custom
production environments. or rapidly changing demand
environments.
Example Toyota (Automotive Industry) uses Zara (Fashion Industry) uses Agile
Lean Manufacturing principles such Manufacturing to rapidly adapt to
as just-in-time inventory for large- changing fashion trends, offering
scale production of vehicles. quick turnaround and
customization based on customer
demand.
10. Describe the Coding System:
1. Hierarchical Structure: A structured coding system with a tree-like hierarchy where each
level adds specificity.
• Structure: Sequential structure where codes progress from general to specific.
• Code Length: Fixed length, with each digit or position representing a specific
characteristic.
• Interpretation: Easy to interpret: each digit corresponds to a predefined level in the
hierarchy.
• Advantages:
• Clear and systematic.
• Easy to decode.
• Well-suited for standardized systems.
• Disadvantages:
• Inflexible; hard to modify for new or unexpected features.
• Can become unwieldy for very detailed classifications.
• Best Use Cases:
• Systems with stable and well-defined part characteristics.
• Applications requiring standardization, like inventory management.
• Key Features:
• Organized and logical.
• Attributes depend on the hierarchy.
2. Chain-Type Structure: A flat coding system where each code segment independently
represents an attribute.
• Structure: Non-sequential, with each code segment having no dependency on the previous
ones.
• Code Length: Can be fixed or variable length, depending on the attributes included.
• Interpretation: Requires attribute lookup, as there is no natural order in the sequence.
• Advantages:
• Flexible and adaptable.
• Easy to add new attributes.
• Disadvantages:
• Less intuitive for decoding.
• No inherent relationship between attributes.
• Best Use Cases:
• Environments with highly variable or frequently updated attributes, such as custom
manufacturing.
• Key Features:
• Flexible and attribute-driven.
• No dependency between attributes.
3. Hybrid Structure: Combines a hierarchical structure for major categories with chain-type for
details.
• Structure: Sequential for high-level classification; independent for detailed attributes.
• Code Length: Flexible code length, adapting based on combined hierarchical and chain-
type parts.
• Interpretation: Easier for major categories but requires extra effort for detailed attributes.
• Advantages:
• Balances structure and flexibility.
• Ideal for complex and evolving systems.
• Disadvantages:
• Complex to design and maintain.
• Requires careful planning to avoid confusion.
• Best Use Cases: Systems combining both standardization and flexibility, like large-scale
manufacturing or supply chains.
• Key Features: Combines hierarchy for primary classifications with flexibility for detailed
attributes.
 UNIT I
1. Automation: The word ‘Automation’ is derived from Greek words “Auto” (self) and “Matos”
(moving). Automation therefore is the mechanism for systems that “move by itself”. Automation
is a set of technologies that results in operation of machines and systems without significant
human intervention and achieves performance superior to manual operation
2. Single Spindle and Multi-Spindle automation (any 4 points for 2 marks):

3. Objectives of the use of flow line automation:

• To reduce labour costs
• To increase production rates
• To reduce work-in-process
• To minimize distances moved between operations
• To achieve specialization of operations
• To achieve integration of operations
4. Transfer machine: It is an automated system that moves a workpiece through multiple
stations to perform sequential machining operations, optimizing efficiency for high-volume
production.
5. Industry 4.0: The fourth industrial revolution, integrating technologies like AI, robotics, and
IoT to create smart manufacturing systems.
1. Smart Manufacturing: Real-time data exchange and analytics optimize production.
2. Increased Automation: AI, robotics, and machine learning automate tasks.
3. Interconnected Systems: Seamless communication between machines, devices, and
humans.
6. Role of Automation in Industry: Process Optimization: Reduces errors, increases speed;
Increased Productivity: Frees labor for high-value tasks; Improved Quality: Enhances precision,
reduces variability; Cost Reduction: Minimizes labor costs, waste; Enhanced Safety: Automates
hazardous tasks.
7. Ten Strategies of Automation:
The ten strategies of automation and production systems aim to enhance efficiency, flexibility,
and control in manufacturing processes.
1. Specialization of Operation: Focuses on dividing tasks into specialized operations to
increase precision and efficiency.
2. Combined Operation: Merges multiple processes into a single operation to reduce
handling time and costs.
3. Integration of Operation: Coordinates various operations into a seamless system for
smoother workflows.
4. Simultaneous Operation: Executes multiple processes concurrently to save time.
5. Increased Flexibility: Adapts systems for diverse product requirements and quick
reconfiguration.
6. Improved Material Handling & Storage: Optimizes the movement and storage of
materials to streamline production.
7. Online Inspection: Uses real-time quality control to detect and address issues during
production.
8. Process Control & Optimization: Implements automated control systems to improve
process performance.
9. Plant Operation Control: Focuses on centralized management of overall plant activities
for higher efficiency.
10.CIM (Computer-Integrated Manufacturing): Integrates computer systems to automate
and optimize production comprehensively.
8. Automated Flow Line:
An automated flow line is a production system where workpieces move sequentially through
several automated stations, each performing specific tasks. Key features include:
1. Automatic Transfer: Work handling devices like conveyors move parts between stations.
2. Sequential Workflow: Parts enter as raw materials and progress step-by-step until
finished.
3. Buffer Zones: Temporary storage prevents delays between stations.
4. Quality Checks: Inspection stations ensure product quality at intermediate stages.
5. Manual Tasks: Some stations handle tasks that are uneconomical or difficult to automate.

It is ideal for high-demand, stable products requiring consistent quality and reduced labour.
Merits Demerits
• High Efficiency: Speeds up production and • High Initial Cost: Expensive to set up and
reduces time. implement.
• Consistent Quality: Ensures uniformity with • Limited Flexibility: Not ideal for frequent
minimal defects. product changes.
• Reduced Labor Costs: Lowers dependency on • Risk of Downtime: A breakdown halts the entire
manual labor. line.
9. Types of Automation and Their Objectives
1. Fixed Automation: Fixed automation refers to systems where the sequence of operations
is rigidly defined by the equipment configuration, typically for high-volume production
of a single product.
• Objectives:
• Achieve maximum production efficiency through predefined processes.
• Minimize unit production costs for high-demand, standardized products.
• Provide consistent product quality by eliminating variability in operations.
• Features:
• High initial investment for custom-engineered equipment.
• High production rates.
• Relatively inflexible for product changes.
• Applications: Used for producing products with very high demand rates and
volumes, such as in automotive manufacturing or consumer goods.

2. Programmable Automation: Programmable automation uses equipment capable of

producing multiple product configurations by changing the sequence of operations via
reprogramming and physical setup changes.
• Objectives:
• Provide versatility to produce different products or parts.
• Support low-to-medium production volumes efficiently.
• Enable cost-effective batch production for variable product designs.
• Features:
• High investment in general-purpose equipment.
• Flexibility to reprogram and adjust for different product configurations.
• Suitable for batch production, though downtime occurs during setup and
reprogramming.
• Applications: Includes numerically controlled (NC) machines, industrial robots,
and batch-based production processes.

3. Flexible Automation: Flexible automation is an advanced form of programmable

automation that allows rapid changeovers between products with no production
downtime.
• Objectives:
• Achieve seamless production of multiple product varieties without
interruptions.
• Support dynamic manufacturing environments requiring frequent design
changes.
• Minimize downtime to maximize production efficiency across varying
product demands.
• Features:
• High investment for custom-engineered systems.
• Continuous production of variable product mixes.
• Medium production rates with high adaptability to product design changes.
• Eliminates downtime during reprogramming and physical setup changes.
• Applications: Suitable for industries that produce customized products or require
just-in-time manufacturing, such as electronics or aerospace components.
 UNIT II
1. Applications of CNC:
➤ Precision Machining: High accuracy in operations like turning, milling, drilling, & contouring.
➤ Mass Production: Ideal for batch production and high-volume manufacturing.
➤ Customization: Easily adapt to produce customized and complex geometries.
➤ Flexible Manufacturing: Handles frequent design changes and diverse operations efficiently.
➤ Automation: Automates auxiliary functions like tool changes, spindle control, and coolant flow.
➤ Prototyping: Rapid and accurate production of prototypes during product development.
➤ 3D Contouring: Creation of intricate shapes for industries like aerospace and medical.
➤ Engraving: Detailed etching and carving on metals, wood, and plastics.
➤ Tool and Die Making: Precision manufacturing of molds, dies, and jigs.
➤ Sheet Metal Processing: Cutting, bending, and shaping sheet metal components.
2. What are the programming languages used in NC/CNCs:
• G-Code: Directs CNC machine movements, defines tool paths, and controls feed rates,
speeds, and operation sequences.
• M-Code: Controls auxiliary machine functions such as spindle on/off, tool changes,
coolant control, and other machine-specific operations.
• APT: Uses parametric and geometric descriptions to define tool paths for complex
shapes, automating machining operations and improving efficiency.
3. Discuss the turning and milling operation carried out using CNC machines:

Aspect CNC Turning CNC Milling

Workpiece The workpiece rotates on a The workpiece remains stationary
Movement spindle, allowing the cutting tool while the cutting tool rotates.
to shape it.
Tool Movement A stationary single-point cutting A multi-point cutting tool moves
tool removes material. along multiple axes.
Part Shape Suitable for cylindrical parts like Ideal for complex shapes, slots,
shafts, bolts, and bushings. holes, and cavities.
Axes of Operation Operates on 2 to 4 axes; Operates on 3 to 5 axes for
advanced machines offer more precise and intricate geometries.
flexibility.
Applications Best for symmetrical parts, Suitable for pocketing,
threading, boring, and facing. contouring, drilling, and 3D
designs.
Material Removal Material is removed from the Material is carved from a solid
outer surface of a spinning block.
workpiece.
Production Speed Faster and more cost-effective Slower and more expensive for
for simple cylindrical designs. complex shapes.
Machine Type Uses CNC lathes or turning Uses CNC milling machines or
centres. machining centers.
 ASSIGNMENT (UNIT III & V)
1. Types of Grippers:
1. Mechanical Grippers
2. Hooks and Scoops
3. Magnetic Grippers
4. Vacuum Grippers
5. Expandable Bladder Type Grippers
6. Adhesive Grippers
2. Differentiate between robot sensors and position sensors.
Aspect Robot Sensors Position Sensors
Purpose Enable robots to perceive and Track the location or position of a
interact with their environment. robot's parts.
Types Proximity, Vision (Cameras), Encoders, Potentiometers, LVDT, GPS
Force/Torque, Temperature,
Sound, Touch
Function Detect obstacles, environmental Provide feedback on the position,
conditions, and feedback for tasks. orientation, or movement of robot
components.
Scope of Use Broad range of sensory functions Specialized for measuring spatial
(light, sound, force, etc.). location or movement.
Examples Obstacle detection, environmental Joint position tracking, robot
monitoring, tactile feedback. navigation, movement control.
3. Short notes on 3D Printing (also known as Additive Manufacturing):
• Definition: 3D printing, or Additive Manufacturing (AM), creates objects layer by layer
from a digital model.
• Process: Unlike traditional manufacturing, it adds material layer by layer, allowing for
complex and intricate designs.
• Materials Used: Includes plastics (e.g., PLA, ABS), metals (e.g., titanium, aluminum),
ceramics, and bioprinting materials.
• Key Features:
• Enables rapid prototyping and customization.
• Reduces material waste.
• Capable of creating complex geometries.
• Applications:
• Aerospace: Lightweight parts and components.
• Healthcare: Prosthetics, implants, and medical models.
• Automotive: Prototypes and parts.
• Consumer Products: Custom items such as fashion, jewelry, and gadgets.
• Benefits:
• Speeds up production cycles.
• Cost-effective for low-volume or small-scale production.
4. Machine Vision:

Definition: Machine Vision is the technology and process by which machines use cameras,
sensors, and computational algorithms to interpret visual data for automated inspection,
analysis, and decision-making. It simulates human vision for industrial and automation
purposes. It works in the following stages:
1. Image Acquisition: A camera captures images of the object, with appropriate
illumination provided by light sources for clarity.
2. Digitization: The captured image is digitized into a pixel-based format suitable for
computer analysis.
3. Processing and Analysis: Specialized algorithms process the digital image to extract
relevant features like dimensions, defects, shapes, or patterns.
4. Decision-Making: The interpreted data is used to make automated decisions, such as
rejecting defective parts or guiding robotic operations.
The system operates in a feedback loop, where new data is continuously captured,
analysed, and acted upon.
Applications:
• Assembly Verification: Confirms proper positioning of components.
• Defect Detection: Identifies flaws like cracks or scratches in manufacturing.
• Dimension Measurement: Ensures accurate product sizing and tolerances.
• Robotics Guidance: Aids robotic arms in precise tasks like assembly.
• Barcode Reading: Scans and verifies barcodes for sorting and tracking.
5. Automated Material Handling and Storage System
An Automated Material Handling and Storage System (AMHSS) is an integrated setup of
machinery, robotics, and control systems designed to efficiently manage the movement, storage,
and retrieval of materials in industrial and warehouse settings. It enhances productivity, reduces
manual labor, and ensures safety in operations.
Key Components:
1. Conveyor Systems: Transport goods between workstations, storage areas, and production
lines seamlessly.
2. Automated Guided Vehicles (AGVs): Mobile robots navigate through predefined paths
to transfer materials.
3. Robotic Arms: Perform tasks such as loading, unloading, sorting, and palletizing.
4. Storage Racks with AS/RS: Automated storage and retrieval systems use cranes or
robotic systems to store and retrieve items efficiently.
5. Control Systems: Centralized software ensures synchronized material flow and optimizes
system performance.
Working Principle
1. Material Identification: Sensors, RFID, or barcode readers identify items to be handled.
2. Transportation: Conveyors, AGVs, or robotic arms move goods between production
lines and storage.
3. Storage: Materials are stored in racks using AS/RS systems, maximizing space utilization
and accessibility.
4. Retrieval: Goods are retrieved automatically based on production demands or order
requirements.
5. System Coordination: A control unit integrates and manages all operations, ensuring
accuracy and efficiency.
Applications: Manufacturing: Automating material flow between production stages;
Warehousing: Efficient storage, retrieval, and inventory management; E-commerce: Rapid
order picking and sorting for delivery; Pharmaceuticals: Precise handling of delicate products;
Automotive Industry: Managing heavy components in assembly lines.
6. Sensors:

7. Additive manufacturing: is a process of creating objects by adding material layer by layer

based on digital models. It includes various techniques such as 3D printing and is commonly
used in industries like aerospace, automotive, and healthcare for rapid prototyping and custom
production.
8. Stereolithography: Stereolithography (SLA) is an additive manufacturing process and one of
the earliest methods used in 3D printing. It is based on the principle of photopolymerisation,
where a liquid resin is solidified layer by layer using a laser or ultraviolet (UV) light.
Components:
1. Liquid Material (Resin): A vat filled with a photosensitive liquid resin serves as the raw
material for the 3D object.
2. Laser Scanner: A UV laser or light source selectively cures (solidifies) the resin in
specific areas according to the cross-sectional design of the object.
3. Computer Control System: The laser's movement is directed by a computer system,
which uses the 3D CAD model of the object to guide the laser's path for each layer.
4. Z Stage: The build platform (Z stage) is positioned within the resin vat. It moves
downward incrementally after each layer is cured, allowing the next layer to be formed on
top of the previous one.
5. 3D Object Formation: As the process repeats layer by layer, the 3D object is gradually
built up, emerging from the resin vat.
Key Characteristics:
• High Precision: Objects are produced with fine details and smooth surface finishes,
making it ideal for prototypes and detailed models.
• Material Limitation: It uses photopolymer resins, which can be brittle and less durable
compared to other materials.
• Post-Processing: The cured object may require additional steps, such as cleaning to
remove excess resin and UV curing to strengthen it.
9. FDM: Fused Deposition Modeling (FDM) is an additive manufacturing process where a
thermoplastic material is melted and extruded through a nozzle to create 3D objects layer by
layer.
Process:
1. Material Feeding: Filament from a material spool is fed into a heated nozzle, where it
is melted.
2. Layer Deposition: The nozzle deposits the melted material on the build platform
according to the cross-sectional design of the object.
3. Layer Fusion: Layers are added one at a time and fuse together while in a melted state.
4. Support Material: Additional material is deposited to support overhanging features,
which is removed post-printing.
Key Features:
• Accuracy: Builds objects layer by layer for complex geometries.
• Cost-Effective: Suitable for prototyping and small-scale production.
• Versatility: Uses materials like PLA, ABS, and PETG.