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Spring Examinations 2009/
Exam Code(s) 3BI, 1EM1, 1SD121, 1MF121, 1APE1, 1APE
Exam(s) B.E. Industrial Engineering Erasmus Higher Diploma in Software Design & Development M.Sc in Software Design & Development M.Applied Science (Enterprise Systems)
Module Code(s) IE
Module(s) Computer Integrated Manufacturing
Paper No. 1
Repeat Paper
External Examiner(s) Prof. J. Antony
Internal Examiner(s) Dr. David O Sullivan
Dr. Paul Folan
Instructions: Answer any 5 questions.
All questions will be marked equally.
Duration 3 hours
No. of Pages Cover + 6 pages
Course Co-ordinator Dr. David O Sullivan
Requirements:
MCQ
Handout
Statistical Tables
Graph Paper
Log Graph Paper
Other Material
- Answer each of the following questions in relation to computer integrated manufacturing and related mathematical models and metrics. Use illustrations and mathematical models to describe your answers throughout.
(a)
(i) What is computer integrated manufacturing?
(ii) What elements should a strategy for automation implementation consider?
(iii) Define the difference between processing operations and assembly operations.
(3 marks each)
(b)
Upon investigating a certain batch manufacturing plant, a researcher determined the following data:
The average part produced was processed sequentially through 4 machines on average. 25 new batches of parts were launched on a weekly basis. The average operation time was 8 minutes. The average setup time was 4 hours. The average batch size was 16 parts. The average non-operation time per batch was 12 hours per machine. There are 20 machines in the plant working in parallel. Each of the machines can be set up for any type of job processed in the plant. The plant operates an average of 75 production hours per week. Scrap rate is negligible.
Based upon this data, you are asked to determine:
(i) The Manufacturing Lead Time for an average part.
(ii) The Production Capacity.
(iii) The Plant Utilization (per week).
(11 marks)
- Answer each of the following questions in relation to industrial control systems and hardware for automation and process control. Use illustrations and mathematical models to describe your answers throughout.
(a)
(i) Outline briefly the two types of control systems that are possible.
- Robot moves back to the pick-up position. Time to perform operation is 1.7 seconds.
The activities are performed sequentially as listed. After every 30 workparts, the cutting tools in the machine must be changed. This irregular cycle takes 3.0 minutes to accomplish.
The uptime efficiency of the robot is 97%; and the uptime efficiency of the machine tool is 98%, not including interruptions for tool changes. These two efficiencies are assumed not to overlap (i.e., if the robot breaks down, the cell will cease to operate, so the machine tool will not have the opportunity to break down; and vice versa).
Downtime results from electrical and mechanical malfunctions of the robot, machine tool, and fixture.
Determine the hourly production rate, taking into account the lost time due to tool changes and the uptime efficiency.
(12 marks)
- Answer each of the following questions in relation to storage systems and automatic identification and data capture. Use illustrations and mathematical models to describe your answers throughout.
(a)
(i) What is automatic identification and data capture?
(ii) Name the two forms of linear bar codes.
(iii) What is the major barcode standard that informs the use of barcodes made by most of contemporary industry?
(iv) In radio frequency identification (RFID) technology, what is the difference between a passive tag and an active tag?
(2 marks each)
(b)
A single carousel storage system is located in a factory making small assemblies. It is 15 metres long and 2 metres wide. The pick and deposit time is 0.85 minutes. The speed at which the carousel operates is 0.8 metres per second. The storage system has a 95% utilization. Determine the hourly throughput rate.
(12 marks)
- Answer each of the following questions in relation to material transport systems. Use illustrations and mathematical models to describe your answers throughout.
(a)
(i) What is ‘material handling’?
(ii) What is the unit load principle?
(iii) What is the difference between a hoist and a crane?
(2 marks each)
(b)
A planned fleet of forklift trucks has an average travel distance per delivery equal to 500 feet loaded, and an average empty travel distance equal to 350 feet. The fleet must make a total of 60 deliveries per hour. Load and unload times are each 0.5 minutes and the speed of the vehicles is 300 feet per minute. The traffic factor for the system is 0.85, availability is 0.95, and worker efficiency is 90%.
Determine:
(i) Ideal cycle time per delivery.
(ii) The resulting average number of deliveries per hour that a forklift truck can make.
(iii) How many trucks are required to accomplish the 60 deliveries per hour.
(14 marks)
- Answer each of the following questions in relation to inspection technologies. Use illustrations and mathematical models to describe your answers throughout.
(a)
(i) What different functions do measuring devices and gauges serve?
(ii) Describe how surface measurements of workparts are taken.
(iii) What is machine vision? List the three functions of machine vision.
(3 marks each)
(b)
A CNC machining centre has a programmed cycle time of 25.0 minutes for a certain part. The time to unload the finished part and load a starting work unit is 5.0 minutes. If loading and unloading are done directly onto the machine tool table and no automatic storage capacity exists at the machine, what are (i) the cycle time and (ii) hourly production rate?
If the machine tool has an automatic pallet changer added to it, so that unloading and loading can be accomplished while the machine is cutting another part, and the repositioning time is 30 seconds, what are (iii) the total cycle time and (iv) hourly production rate?
(8 marks)
