ME-461, Manufacturing

Technology, Lecture 1
Date: 20/05/2016
Instructor: Shantanu
Bhattacharya

Manufacturing Systems
Approach
Definition of Manufacturing Technology:
Manufacturing technology provides the tools that enable production of all
manufactured goods. These master tools of industry magnify the effort of
individual workers and give an industrial nation the power to turn raw materials
into the affordable, quality goods essential to todays society.
Manufacturing technology provides the productive tools that power a growing,
stable economy and a rising standard of living. Thus manufacturing process really
represents adding value to a raw material and creation of wealth.
Replenish
Sales
fluctuations

Output

Manufacturing
Facility Add
Value

Raw materials cost and

availability
Business
environment

Input

Social Pressure

Manufacturing
System
comprising of
manufacturing
processes

Production rate,
quality and
delivery
Profit
Reputation

Resources and
plans

Wealth

Manufacturing
Process is the key
to wealth
generation

Manufacturing Enterprise
For a manufacturing enterprise of the twenty first century business environment
the customer is the king.
The business environment is characterized mainly by products of increasing
variety and lower demand.
This has led to the empowerment of Customer individualism as a central theme
of all businesses.
This necessitates the manufacturing of highly customized products sometimes
customized to the needs and necessities of individual customers.
Historically the 1970s were dominated by the cost of product as a main lever
to obtain competitive supremacy.
Later 1980s were dominated by the low cost, high performance, high
quality product.
Currently, the customer takes high quality and low cost to be granted and is
more focused to other factors like:
1.Finding out his exact product expectation and requirement
(customization)
2.Reduced delivery lead times.
3.Environmental issues like reduced waste generation etc.

Manufacturing Enterprise
So the current focus of any manufacturing enterprise is to
develop a mechanism to understand the customer
needs and develop internal mechanisms to respond
to the changing needs quickly and inexpensively.
So most of the factories follow the reverse direction
thinking that build products from customer needs
and expectations.
In other words we can say that a future successful
manufacturing organization will be a virtual corporation
that is instantaneously responsive to customer
needs. (Industry consortium on twenty first century
manufacturing , Goldman and Priess)

Manufacturing Enterprise
We know how the various
functional organs of any
manufacturing enterprise
such as finance, sales and
marketing, design and
manufacturing and human
resources receives feedback
about product, product
attributes and market
segments.
That is also one of the
reasons why customer plays a
pivotal role.
Corporate objectives such as growth in market share, profitability,
workforce stability, and other financial measures associated with any
manufacturing enterprise emanate from the study of the market place.

What can marketing identify which would

help the manufacturing enterprise?
Range of products, product market segment, product ideas to
satisfy customer needs.
Can a company deliver the kinds of products needed to satisfy the
order winning criteria such as cost, quality, lead time and so on?
The answer to this question would lie in product design and
manufacturing which explores the various design and process options
as well as assesses the infrastructure to see if they can satisfy the
order winning criteria.
Obviously , the human resources, technology, finance, and
business processes in the company play a major role in answering
this question and their interaction with manufacturing is very
important.
So, a manufacturing strategy is really a collaborative decision making
that should satisfies everybodys needs an necessities and is also a
way to achieve congruence between corporate strategy, marketing
goals and manufacturing capabilities of an enterprise.

A historical perspective of Design

1.

Design and manufacturing are core activities for realizing a marketable

and profit making product.
2.
The figure below shows the evolution of mechanical CAD/CAM systems
over the past three decades. CAD technology emerged to facilitate
representation completeness.
3. First there was the development of 2-D
drafting in 1960s which extended to 3D
models principaly initiated by the
wireframe based modeling systems.
However, it was not possible to
represent higher order geometry data
such as surfaces.
4. In 1970 surface based models were
developed which evolved surface data
for boundary representations although
this was not sufficient to represent solid
or volume enclosure information.
5. All solid modeling schemes have an
inherent weakness in that they provide
a low level representation of parts in
terms of only providing geometric and
topological data constituting the model
6. This led to a slightly higher order modeling of parametric and variational design which
finally emerged as knowledge based engineering system that captures a lot of additional
non geometric product information like engineering rules, part dependences,
manufacturing constraints etc.

Modern manufacturing

Definitionaly modern manufacturing is a series of interrelated

activities and operations involving design, material selection,
planning, production, quality assurance, management, and
marketing of discreet consumer and durable goods.
Manufacturing can be classified into continuous and discreet
product production processes and we will be principally focusing on
the discreet production technology.
The modern manufacturing being very sensitive to the customer
want and need and the market environment is a combination of
attributes of mass production and job shop production.
Such systems having attributes from both are known as flexible
manufacturing systems.
They rely heavily on CNC equipment, AGVS, ROBOTS and group
technology approaches which rely heavily on similarities in part
production by virtue of their design attributes and manufacturing
features.

A historical perspective of
modern manufacturing

The concept of a factory and productivity improvement is really attributed

to the father of modern day economics , a Scotish national Adam Smith
whose famous work on the division of labor entitled
An Inquiry into the Nature and Causes of the Wealth of Nations. was one
of the first treatises in 1776 on modern day economics and capitalism.
Development of the flow assembly line system for engine manufacturing
by Henry Ford in 1913 was a giant leap towards the modern day
manufacturing.
Some other philosophers like Frant Gilbreth who developed the concept
of motion study and elimination of wasteful motions and Henry Gantt
who devloped a systematic graphing procedure for preplanning,
scheduling of activities and progress review and schedule updating.
In the area of machines G.C. Devol developed a controller device in
1946 that could record electrical signals magnetically and play them back
to operate a mechanical machine. A no. of interesting developments have
taken place since then in the area of machine tools.

Numerically Controlled
Machines: A historical
Perspective

The first successful numerical machine tool was developed at MIT under
a subcontract from Parsons Corporation, Michigan on Air force funding in
1950.
Automatic tool changers and indexing worktables were added in 1960s.
During this period the concept of DNC (direct numeric control) in which
several NC machines are linked to a main computer was developed.
Control system development in 1971 was the next milestone which lead
to the development of microcontroller controlled NC machines also
called CNC machines.
The major advantage of a CNC machine was in its ability to store part
programs and also interact with other controllers or central computer
which led to the development of distributed NC systems wherein several
CNC machines would be connected to a central host computer.
The power of the NC machines were further enhanced in 1980 by
making them capable of carrying hundreds of tools, having multiple
spindles and controlling movements upto 6 axis.

Material Handling Systems

Material handling is an integral part of any manufacturing
system.
Manufacturing system performance can be significantly
improved by using computer controlled material flow , which
reduces waiting time and work in process inventory compared
with manual loading and unloading and manual material
handling systems.
To this end the development in floor mounted and over head
roller conveyors, stacker cranes and automated guided vehicles
have contributed substantially to smooth material flow in
factory floors.
Through a system of PLCs, computer network, material handling
systems, material storage systems and machine tools can be
integrated to configure an automated manufacturing system.

ROBOTICS

The word was satirically used for the first time in the play
Rossums Universal Robots written by Karel Capek in 1921
and indicated forced labor.
Since then robotics has really witnessed a series of
technological changes.
The technology for the current generation of industrial
robots was developed simulataneously by C.W. Kenward in
Great Britain in 1954 and G.C. Devol in United States.
The first computer type robot programming language was
developed a Stanford Research Institute in 1973 wherein
the language AL was developed.
Nowadays robots are used for a variety of applications like
painting, welding, material handling and assembly.

Objectives of this course

The main goal of the above collaborative decision is to formulate a
design and manufacturing plan which is prinicipally built
considering aspects like product and process definition and
capability, manufacturing planning and control, and factory
automation strategies.
In doing so it is very important to have a thorough understanding of the
concepts of design and manufacturing technology and
management and also other functional areas like finance,
marketing and sales, personal etc.
The focus of this course would be limited to the design and
manufacturing technologies enabling the functioning of a successful
manufacturing enterprise.
Accordingly we would discuss some concepts of Computer aided
design, Computer aided process planning, Computer aided
manufacturing, quality engineering, automated material
handling, manufacturing planning and control, Lean
manufacturing and Flexible manufacturing.

Topics to be covered
(Computer Aided Design,
CAD)
1.

2.
3.
4.

5.
6.
7.

The Product Design Process

Problem identification, Preliminary ideas, refinement process,
analysis process, decision process, Implementation process
Computer Aided Design
A brief history of CAD
CAD/CAM system
Mainframe based systems, Minicomputer based systems,
Workstation based systems, Microcomputer based systems
CAD system Input-Output Devices
Selection of CAD/ CAM systems
Computer graphics and transformations
Geometric transformation, homogeneous representation,
Composition of transformations

Topics to be covered
(Geometric Modeling)
1.
2.
3.
4.

Introduction to geometric modeling.

Why is knowledge of geometric Modeling Necessary?
Geometric Modeling Approaches
Wireframe Modeling
Limitations of wireframe modeling, Wireframe Entities,
Analytic curves, Representation of curves, Nonparametric
representation of curves, Parametric representation of
curves, Synthetic curves, Parametric representation of
Synthetic curves, Hermite cubic spline, Bezier curves, BSpline, Rotational B-Spline and non uniform rotational BSpline curves, Curve manipulations.
5. Surface modeling
Surface entities, surface representations

1.

2.
3.

4.

5.
6.

Topics to be covered
(Computer Aided Process
Planning)

Overview of manufacturing processes

Turning Operations, Drilling Operations, Milling Operations, Grinding
Operations
What is Process Planning?
Basic steps in developing a Process Plan
Analysis of part requirements, Selection of Raw work-piece,
Determining manufacturing operations and their sequences,
selection of machine tools, Selection of tools, work-holding devices,
inspection equipments etc., determining machining conditions and
manufacturing times.
The principle process planning approaches
Manual experience based planning methods, computer aided
process planning method.
Variant and generative process planning systems.
Feature recognition in computer aided process planning

Topics to be covered
(Automated material handling and storage
systems)
1.
2.
3.
4.

5.

6.

What is a material handling system?

Principles of material handling
Material Handling Equipment
Automated Guided Vehicle Systems
The components of an AGVS, The types of AGVS, AGVS Guidance
Systems, AGVS steering control, AGVS routing, AGVS control
systems, Interface with other Subsystems, AGVS load transfer, AGVS
design features, System design of automated guided vehicle
systems, advantages of AGVSs over other material handling
systems, applications of AGVSs.
Automated storage and retrieval systems
Functions of storage systems and definitions of AS/RS
AS/RS components and terminology used
Why an AS/RS ,Types of AS/RS, Design of AS/RS
Conveyors.

Topics to be Covered
(Quality Engineering)
Quality engineering, Statistical Process Control
and automated inspection systems:
1. Understanding the meaning of Quality.
2. Dimensions of Quality.
3. Quality Costs (Prevention costs, Appraisals cost,
Internal failure cost, External failure cost)
4. Framework for quality improvement.
5. Failure mode effect analysis.
6. Improving product quality during the production
phase.
7. Automated Inspection (on-line/ in- process and
post process inspection method).

Topics to be Covered
(Japanese Manufacturing
Systems)

Just in Time manufacturing systems

1. Toyota production system: An overview (components of the Toyota Production system,
Three Ms)
2. Pull versus Push systems.
3. Types of Kanban (withdrawal kanban, production kanban, flow of withdrawal and
production kanbans and their interactions, preconditions for operating kanbans)
4. Kanban planning and control models (determining the number of kanbans: a
deterministic model, a probabilistic cost model for determining optimal number of
kanbans, relationship between JIT manufacturing, setup time and cost).
5. Signal Kanban , Express kanban, Emergency kanban, through kanban.
6. Level schedules for mixed model assembly lines (a mathematical model to obtain level
schedules).
7. Alternate JIT systems (periodic pull system, constant work in process system, long pull
system).
8. Just in time purchasing.
9. Total quality control and JIT (TQC responsibilities, Principles of Quality, Quality culture)
10. Barriers to JIT implementation.
11. Potential benefits of JIT implementation.

Topics to be Covered
(Manufacturing planning and control systems)
1.
2.
3.
4.
5.
6.

A basic framework for a manufacturing planning and Control system.

Demand management (demand forecasting)
Aggregate production planning (a mathematical model).
Master production schedule.
Rough cut capacity planning.
Material requirements planning (product structure and bill of materials,
Independent versus dependent demand, parts explosion, gross
requirements of component items, Common use items, on hand inventory,
scheduled receipts and net requirements).
7. MRP lot sizing.
8. Capacity planning.
9. Order release.
10.Shop floor control (bar code systems for shop floor, operations scheduling,
job sequencing and priority rules, comparison of various scheduling rules)

Evaluation Criteria and

Method

Evaluation Criteria:
1 Midterm, Final examination and
Term paper.
S.No.

Criteria

Midterm

30 marks

Final Exam

40 marks

Term paper

30 marks

Total Lecture Hours = 40 to be shared by Dr.

Ramkumar and Dr. Shantanu Bhattacharya

Important points
Attendance in classes is very
important for continuity of
understanding. Topics discussed are
related and understanding of one
topic may depend on prior learnt
topics and whatever is covered in the
class would be thoroughly evaluated
in the term paper.
No duplication of each others work is
permissible in assignments. Grading
will be done based on originality of
the answers as per instructor

Books and references

Computer integrated design and manufacturing,
Nanua Singh, John Wiley and sons, Inc.
Statistical Quality Control by Eugene L. Grant and
Richard S. Leavenworth, Tata Mcgraw Hill
Publishing Company Limited, New Delhi.
Elementary Statistical Quality Control, Irving W.
Burr, Marcel Dekker Inc.

Computer aided design

A large no. of factors are responsible for the
success of any engineering organization.
Engineering design of products and processes is
one of the most critical factors for success.
Understanding of the design process and the
computer aided design tool CAD is required to
realize a producible product design.
Computer graphics play an important role in
the product development process by generating
presenting and manipulating geometric models.

A brief history of CAD

Automotive and aerospace industries have been at
the forefront of development of CAD technology.
Its origin however can be traced back to Ivan
Sutherlands thesis in 1963 describing a system called
sketch pad.
The system known as sketch pad is now known as
interactive graphics and was developed under the
SAGE (semi automatic ground environment) project.
It helped change the radar information into computer
integrated pictures and allowed the flexibility of
choosing the information by pointing a light pen at
the desired location on the cathode ray tube display.

CAD/CAM systems

A wide variety of CAD/CAM systems are currently avialable.

Essentially a CAD system comprises of three major
components: Hardware, which includes computer and
input/output devices, application software, and the
operating system software.
The operating systems software act as the interface
between the hardware and
the CAD application software
The classification scheme we use in this
system.
section is based on hardware of the system.
More specifically, we classify systems by the
host computer that drives the system.
Generally, CAD/CAM systems are classified
into four types:
1.Mainframe Based systems
2.Minicomputer based systems
3.Workstation based systems
4.Microcomputer based systems

Input output devices

Introduction to Geometric
Transformation
Computer graphics plays an important
role in the product development process
by generating, presenting, and
manipulating geometric models of objects.
During the product development process,
for proper understanding of designs, it is
necessary not only to generate geometric
models of objects but also to perform such
manipulations on these objects as
rotation, translation and scaling.

Introduction to Geometric
transformation
Essentially, computer graphics is concerned with
generating, presenting and manipulating models of
an object and its different views using computer
hardware, software and graphic devices.
Usually the numerical data generated by a computer
at very high speeds is hard to interpret unless one
represents the data in graphic format and it is even
better if the graphic can be manipulated to be
viewed from different sides, enlarged or reduced in
size.
Geometric transformation is one of the basic
techniques that is used to accomplish these graphic
functions involving scale change, translation to
another location or rotating it by a certain angle to
get a better view of it.

Geometric Transformation
Two dimensional transformation:

2-D transformation

Example : In the figure above, suppose the initial coordinates of vertices A,B,C are
(1,3), (4,5), and (5,3.5), respectively. Determine the coordinates of new vertices A, B
and C after translating the triangle by a distance D= [7, -2]T (where T represents
transpose). Verify that the lengths of the edges of the triangle are unchanged.

2-D transformation

2-D transformation
Scaling

Example: From the figure on the right, show that

the length of the edge AB is equal to three times
that of AB after scaling the object uniformly by
factor 3.

2-D transformation
Rotation:
Rotation in 2D space is defined as moving
any point (x,y) of an object to a new position
by rotating it through a given angle about
some reference point. Positive angles are
measured counterclockwise from x to y. The
mathematical expression for the rotating
transformation is not as obvious as the
formulas for translation and scaling

2-D transformation
(Rotation)

Example: Determine the new position of

object A placed on a round holding table
after the table has been rotated by 35 deg.
Solution:

3-D transformation
3-D transformations are similar to 2-D transformations in both definition
and derivation. We provide 3-D transformations in matrix form as
follows:
Translation: In this case we translate a point V(x,y,z) by (dx, dy, dz) to
point V(x,y, z). This can be expressed in matrix form as

Homogeneous
transformation

Although the 2D and 3D transformations

presented in the previous sections have
obvious geometric meaning it is not efficient or
economical to implement them on a computer.
This is because translation involves the
addition of matrices whereas scaling and
rotation involves multiplication.
It is however possible to implement a scheme
involving only multiplication which would
simplify the transformation process.

Homogeneous
Transformation

Composition of
Transformation
In practice, series of transformations may have to
be applied to an object.
The techniques for combining series of
transformation are very useful in these cases.
The final process of composition is accomplished
by multiplying [H] matrix of various compositions.
The process is also known are compounding or
concatenation of [H].
V= [Hn] [Hn-1] . [H1] V

Where n refers to the nth transformation in sequence.