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SACA 101 Study Guide
Can you give three examples of advanced manufacturing tools and techniques? - correct answer Industrial Robotics Modeling and Simulation Advanced Manufacturing Do you know the role of product design in Advanced Manufacturing? - correct answer To produce a product with the best form, fit, and function possible. Can you name three impacts of computers on Advanced Manufacturing besides automation? - correct answer Modeling and Simulation Production Efficiency Product Consistency Can you name three benefits of factory automation? - correct answer Relieve humans from undesirable work Improve quality Increase flexibility Can you describe how a CNC machine works? - correct answer A CNC (Computer numerical control) machine is a type of motion controller that can coordinate the speed and positioning of multiple axes at the same time to cut complex features into the metal part. Do you know the difference between an additive and a subtractive manufacturing process? - correct answer Additive manufacturing, often referred to as 3D printing, adds successive layers of material to create an object. Subtractive manufacturing removes material to create an object. Can you name two types of robots? - correct answer Industrial Robot
Mobile Robot Do you know the function of a PLC? - correct answer A PLC is a general-purpose industrial computer that has been designed to wire directly to input and output devices. It is programmed to control different type of machines and processes. Besides alarm screens and error messages, do you know what else an HMI is used for? - correct answer An operator can troubleshoot many problems directly from the HMI panel. Can you name some Software and New Emerging Technologies in Advanced Manufacturing? - correct answer CAD (Computer Aided Design) CAM (Computer Aided Machine) The Internet of Things (IoT) Cloud Computing 3D Printing Do you know the four industrial revolutions and the cause and benefits of each? - correct answer 1. Mechanization 1760-
- Mass Production 1850-
- Automation 1960-
- Smart Automation 2000-Present Can you name some components and applications of Industrial Internet of Things (IIoT)? - correct answer Machine to Machine Communication Internet Access and Control Smart Devices and Data Machine Learning Big Data and Analysis Data Storage
Do you know how machine interlocks and emergency stop controls effect an operation? - correct answer A machine interlock prevents a machine from operating without the proper guards in place. All emergency stop controls are designed to shut down a machine if an operator is immediately in danger. Can you differentiate value added and non value added activities? - correct answer Value-added activities transform or shape material and information that meets customer requirements. example: cutting metal to make a part shape, or adding paint to a product's surface. Non-value-added activities take time resources or space, but do not add to the value of the product or service. example: product inspection, or rework. Do you know what each S in 5S stands for? - correct answer
- sort
- straighten
- shine
- standardize
- sustain Can you describe the 8 deadly wastes? - correct answer 1. excess inventory
- overproduction (more product than the next process or customer needs)
- excess motion (movement by a team member that doesn't add value)
- over processing (putting extra effort into a process that doesn't add value to the customer)
- transportation (any movement of the product within the facility)
- waiting
- underutilized people
- nonconforming product (any product that doesn't meet design specifications)
Can you explain line balancing? - correct answer Line balancing spreads the workload across workstations based on the speed of processing to avoid bottlenecks and excess capacity. Line balancing allows the company to identify under-used and overworked staff. Can you explain the operation of two types of transistors used in electronic sensors?
- correct answer 1. The PNP transistor provides a high signal at it's output when the sensor is energized, or has detected the presence of an object.
- the NPN transistor operates the opposite of the PNP transistor. when the sensor is off, the voltage at the sensor's output terminal is high, the sensor's output terminal is zero volts when the sensor is energized. Can you state the 5 characteristics that affect inductive proximity sensor operation?
- correct answer 1. target material
- target size
- target distance
- sensor head size
- sensor mounting Can you state 5 characteristics that affect capacitive proximity sensor operation? - correct answer 1. target material
- target size
- target distance
- sensor head size
- sensor mounting Can you transfer robot program files between a PC and robot controller? - correct answer Robot program files and points files are often transferred between PC software and the robot controller via a serial or ethernet connection. some robots allow the user to transfer files using a thumb drive.
6.complete safety training
- lockout/tagout when doing maintenance robot programing safety rules
- robot must be in teach mode
- a slow jogging speed must be set
- another worker must observe the robot and press emergency stop if needed
- carry teach pendant so you have immediate access to the emergency stop button Can you power up and power down a servo robot? - correct answer Power up:
- remove lockout/tagout on the robot's circuit breaker and turn on the circuit breaker
- turn on the robot controller, which also powers the teach pendant
- select the teach pendant options on the controller and the teach pendant so they communicate with each other
- enable the drivers if they are not automatically enabled
- home the robot if it does not have absolute encoders
- verify that all screens appear with no faults Power down:
- move the robot arm to where it is to be positioned while not in use
- turn off the power switch
- apply the lockout/tagout Can you use a teach pendant to jog a servo robot? - correct answer Hit the jog button then press different buttons to get it to move. Can you read and interpret ladder diagram detached symbology? - correct answer The parts of the relay symbol are detached because each part of the relay is wired to different parts of the circuit. Can you interpret the operation of a relay performing control logic? - correct answer The relay uses its normally open and normally closed contacts to perform control logic by causing outputs to be on or off based on input positions.
Can you interpret the operation of a seal-in circuit? - correct answer A seal in circuit uses a relay to latch itself after the input turns off. can you read and interpret a basic ladder diagram? - correct answer do you know the six elements of control logic? - correct answer
- AND - turns on the output only if all inputs are actuated.
- OR - turns on the output if anyone of the inputs are actuated.
- NOT - turns on the output if its one input is not actuated.
- NOR - turns off the output if any of the inputs are actuated.
- NAND - turns off the output only if all the inputs are actuated.
- Memory - uses an input tied to an output to keep the output energized after main input is no longer pressed. can you explain the operation of MEMORY logic? - correct answer Memory logic is used to keep an output energized after the input signal that turned it on has been removed. Can you state common types of injuries and accidents? - correct answer Repetitive motion, strains, sprains, cuts, abrasion, and hearing loss. Do you know seven types of PPE? - correct answer 1. Eye Protection
- Ear Protection
- Head Protection
- Hand and Arm Protection
- Foot Protection
- Lung Protection
- Protective clothing Can you state the elements of an emergency action plan? - correct answer Contact Information
- Radiation
- Light
- Biological
- Electrical
- Mechanical do you know electrical power and its units? - correct answer electric power is the rate at which electricity is converted into some other usable form like heat or mechanical energy. electric power is measured in watts in SI units and it is abbreviated as W. one watt of energy is consumed when one volt pushes one amp through a circuit. can you calculate the power in a simple circuit? - correct answer Power(W) = Current(A) * voltage(V) do you know the operation of a fuse and circuit breaker and how to replace or reset them? - correct answer Fuses are used in applications where an over-current problem rarely occurs. Fuses cannot be fixed or reset, they must be replaced. Circuit breakers are used where an over-current condition occurs more often. Circuit breakers can be reset and reused, they do not need to be replaced. do you know the resistance characteristics in series and parallel circuits? - correct answer the more resistors there are in series, the higher the overall resistance. the equivalent resistance of a parallel load actually decreases as more branches are added. can you use Ohm's law to analyze a circuit? - correct answer Ohm's law: E = I * R
can you define continuity and state its importance? - correct answer Electrical continuity means there's a complete path for current to flow in a circuit. Sometimes, a lack of continuity is desired, such as when a light switch is set to off. However, if a wire or a component doesn't have continuity when it should, it prevents current flow and circuit operation. can you state Kirchhoff's circuit laws? - correct answer Voltage Law: the sum of voltage sources and voltage drops around any loop in a circuit must add up to zero. Current Law: the current into any point in a circuit must equal the current out of the same point. do you know the basic characteristics of series and parallel circuits? - correct answer Series: current is constant throughout the circuit. Voltage decreases as the electricity passes through each load. Parallel: the current that flows through each branch is different. The voltage across each branch is the same. do you know two types of ammeters? - correct answer analog and digital can you use a DMM to measure current and voltage? - correct answer The DMM has to replace a wire to measure current. To measure voltage, touch and hold the probes to the desired point in the circuit. Do you know the GHS and HCS communication standards? - correct answer GHS uses pictograms to convey potential hazards in the workplace. There are 9 pictograms as follows:
- Toxic Substances
can you state the pneumatic safety rules? - correct answer
- wear proper PPE.
- avoid exposure to the pressurized air.
- secure pressurized hoses and devices.
- use proper pressure when cleaning.
- use pressure-rated containers. Can you interpret the HazCom labeling and other hazardous material identification systems? - correct answer HazCom includes pictograms but also requires: Chemical Identifierss Signal Word Hazard Statements Precautions Emergency Contact Information Can you state what a Safety Data Sheet does? - correct answer Safety Data Sheets provide one place with information about proper handling, storage, PPE, and disposal of each chemical. Do you know the guidelines for handling, storing and shipping hazardous materials?
- correct answer A key for handling hazardous materials is PPE and having plans for spills and accidents. When storing them, labeling, storing with like materials, using the original storage container, and keeping away from heat and open flame. Do you know the DOT Hazardous Material Identification System? - correct answer Colors: Orange-Explosive Green-Non-Flammable Gas Red-Flammable Blue-Water Reactive Yellow-Oxidizer
White-Health Hazard Do you know the elements of a fire? - correct answer Fuel, Heat, & Oxygen. Do you know four types of fires and how to select a fire extinguisher for each type? - correct answer A. Ordinary Flammable Fires B. Flammable and Combustible Liquid C. Energized Electrical D. Combustible Metals CO2 Extinguishers are for B & C. Dry Chemical are for A, B, & C. Dry Powder are for D. Halon Extinguishers are for B & C. Do you know how to use a fire extinguisher? - correct answer Pull the pin, aim at the base of the fire, pull the trigger, and sweep the area the fire occupies until extinquished. Can you state the electrical safety guidelines? - correct answer Use grounded equipment Don't overload equipment Use approved equipment Do not use damaged cords Run cords properly Turn equipment off Do you know how to maintain a safe work station? - correct answer Work stations should be organized, reduce physical and mental strain on the employee using it, have assigned spaces for all tools and consumables, waste should have proper disposal containers, kept as clean as possible, and have been through hazard assessment regularly to reduce accidents in the workplace.
