1
Q
What is a manufacturing system?
A
A collection of integrated equipment and human resources that performs processing and/or assembly operations on raw materials, parts, or sets of parts.
Manufacturing systems are essential for value-added work on parts and products.
2
Q
What are the main functions of a manufacturing system?
A
To perform processing and/or assembly operations on raw material, parts, or sets of parts.
3
Q
What types of equipment are integrated in a manufacturing system?
A
- Production machines and tools
- Material handling and work position devices
- Computer systems
4
Q
What role do human resources play in a manufacturing system?
A
Required either full time or periodically to keep the system running.
5
Q
What are the types of ‘production machines’?
A
- Manually operated
- Semiautomated
- Fully automated
6
Q
What examples of conventional machine tools are there?
A
- Lathes
- Milling machines
- Drill presses
7
Q
What are the tasks performed by a worker operating a manually operated machine?
A
- Engage feed
- Position tool
- Load/Unload materials
- Perform other tasks
8
Q
What is a semiautomated machine?
A
Machines that perform a portion of the work cycle under program control, with a worker tending to the remaining tasks.
9
Q
What are examples of semiautomated machines?
A
- CNC machines
- Other programmable machines
10
Q
What are fully automated machines?
A
Machines that operate without human attention for extended periods, though they may require periodic machine tending.
11
Q
What are 4 types of mechanical devices in a manufacturing system?
A
- Industrial robots
- Parts feeders
- Coil feeders
- Automatic pallet changers
12
Q
What is a workstation?
A
A place where specific tasks or operations are performed.
13
Q
What are the classifications of workstations?
A
- Manned Workstation
- Automated Workstation
14
Q
What is a manned workstation?
A
A workstation that has manually operated and semiautomated machines requiring a worker present during each cycle.
15
Q
What is an automated workstation?
A
A workstation that has fully automated machines and does not require a worker’s presence except periodically.
16
Q
What are the material handling functions in manufacturing operations?
A
- Loading work units each station
- Position work units at each station
- Unloading work units from the station
- Transporting work units between stations (only applicable to multiple workstations)
17
Q
What is a work holder?
A
A device that locates, orients, and clamps the part during processing.
18
Q
What are common work holders?
A
- Jigs
- Fixtures
- Chucks
19
Q
What types of work transport methods are there?
A
- Manual Transport
- Mechanized/Automated Transport
20
Q
What is fixed routing in work transport?
A
Work units flow between a sequence of stations, used when parts are identical or similar.
21
Q
What is variable routing in work transport?
A
Work units follow different sequences of stations depending on the product.
22
Q
What is a pallet fixture?
A
A work holder designed to be transported by material handling systems.
23
Q
What are the advantages of pallet fixtures?
A
- Ensures accurate positioning at the workstation
- Enables precise processing/assembly operations
24
Q
What is SMED?
A
Single Minute Exchange of Die, a methodology to reduce setup times to under 10 minutes.
25
What is the purpose of storage in material transport systems?
To ensure work is available at all times and prevent stations from being deprived of work.
26
What is the manning level equation?
Manning Level (M) = number of workers (w) / number of workstations (n)
27
What does the manning level (Mi) indicate?
The proportion of time that a worker spends at the station.
28
What are utility workers in manufacturing systems?
Workers not assigned to specific workstations who perform various supporting functions.
29
What are the two primary types of operations in manufacturing systems?
* Processing Operations
* Assembly Operations
30
What factors affect manufacturing operations?
* Types of materials processed
* Size/Weight of the part/product
* Part Geometry
* Part/Product Complexity
31
What are the advantages of increasing the number of workstations?
* Increased workload capacity
* Synergistic benefits of task distribution
* Higher production rates for complex produts
32
What are the types of workstation layouts?
* Fixed Routing Layouts
* Variable Routing Layouts
33
What is the significance of manufacturing flexibility?
The system's ability to adapt to changes in operating conditions and variations in parts or products.
34
What is the purpose of quick changeover in manufacturing systems?
To quickly load the correct part program or work instruction for each unit.
35
What does QCO stand for?
Quick Change Over
36
What are 'manually operated machines'?
Machines controlled/supervised by a human worker at all times. While the worker prodicdes control, the machien provides power.
37
What are the worker's tasks for 'Semiautmoted machines'?
1. Unload finished parts
2. Load new parts at the end of each cycle
38
True or False. Can workers tend to multiple stations at the same time?
True, if: the machine's work cycle is longer than the human tasks
39
What can a multiple workstations evovle into?
| HINT: There are 3 answers
1. Production lines
2. Assembly lines
3. Machine cells
40
What happens to a part after it has been unlaoded from its workstation?
| HINT: There are 2 answers
1. Placed into a container
2. Prepared for transport to the next workstation
41
When is 'Manual Transport' a viable option for moving parts?
## Footnote
1.How many parts per transport?
2.Weight of the part?
1. Either done individually or in batches
2. Suitable for small light parts
42
When are powered hoists/lift equipment needed?
When transporting heaveir loads, manually
43
Why is mechanized/automated transport used?
| HINT: There are 2 answers
1. Reduce labour effort
2. Increase efficiency
44
What are the 2 types of 'Work Routing'?
1. Fixed Routing
2. Variable Routing
45
List 3 examples of 'Fixed Routing'
1. Conveyor belts
2. Automatic guided vehicles
3. Flexible manufacturing systems (FMS)
46
Where is 'Fixed Routing' commonly used?
Production Lines
47
Where is 'Variable Routing' commonly used?
| HINT: There are 3 answers
1. Job shop production
2. Batch production/Machine cells
3. FMS
| FMS = Flexible Manufacturing System
48
What is the function of "upper portion" of 'Pallet Fixtrues'?
Holds the part accurately
49
What is the function of "lower portion" of 'Pallet Fixtrues'?
| HINT: There are 3 answers
1. Movement
2. Positioning
3. Clamping at each workstation
50
Where are 'pallet fixtures' commonly used?
1. Single machine cells with automatic pallet changers
2. Transfer lines
3. Automated assembly systems
51
List 3 functionalities for 'Modular Pallet Fixtures'
1. Designed with interchangeable/adjustable components
2. Can accommodate different part geometries
3. Ideal for FMS
| FMS = Flexible Manufacturing System
52
What are the 2 types of 'Alterante Work Transport' methods?
1. Without Pallet FIxtures
2. With Work Carriers
53
What is transporting "without pallet fixtures" mean?
Parts are moved directly by the handling systems
54
What is transporting "with work carrier" mean?
A work carrier is a container for holding parts during transport. They are NOT used to locate work units
55
List 3 examples of "transporting with work carriers"
1. Tote pans
2. Flat pallets
3. Wire baskets
56
Define "direct transport"
The work itself is moved by the transport system, without using pallet fixture/work carriers
57
On a scale from low to high, how feasible is 'direct transportation' for 'manually operated system"?
Highly feasible
58
What are the feasiblility limitations for 'direct transportation' in an 'automated system"?
1. Part geometry
2. Ability to move/locate/clamp the part
59
What is the role of 'human resources'?
To perform some/all of the value-added work on parts/products
60
List 2 examples of direct labour
1. Manual work directly on the part
2. Operating machines that perform the work
61
How is 'direct labour' incorporated into 'Automated Systems'?
| HINT: There are 3 answers
1. Loading/Unloading parts
2. Changing tools
3. Resharpening tools
62
Define 'Indirect Labour'
Workers who indirectly add value to the product by supporting/managing the system
63
List 5 examples of 'Indirect Labour'
1. Computer programs
2. Computer operator
3. CNC Part Programmers
4. Maintenance/Repair Personnel
5. Other technical/support roles
64
What factors are affected proportional the "number of workstations" (n) in a manufacturing system?
| HINT: There are 3 answers
1. Production rate
2. System reliability
3. Complexity
65
What are the two 'Classifications of Workstations'?
1. Single-station cell (n=1)
2. Multi-station system (n>1)
66
What does M=1 represent?
1 worker tends to 1 station at all times
67
What does M=0.25 represent?
1 worker tends to 4 stations simultaneously
68
What does M=4 represent?
4 workers tends to 1 station at the same time
69
True or False. When M≥1, more automation is required
False. More manual operations is required
70
True or False. When M<1, more automation is required
True
71
List the 4 functions of 'Utility Workers'
1. Relieving operators at workstation for breaks
2. Performing maintenance and repair tasks
3. Handling material transport
4. Managing tool changes
72
What type of machines are found in 'manned workstations'?
Manually Operated OR Semiautomated
73
What type of machines are found in 'automated workstations'?
Fully automated
74
Does a worker need to be present at all times in a 'Manned Workstation'?
Yes
75
Does a worker need to be present at all times in a 'Automated Workstation'?
No
76
What are the conditons that will allow 1 worker to attend multiple manned workstations?
| HINT: There are 2 conditions
1. The automatic work cycle time period is long enough
2. Worker’s task per cycle is short
77
What are the 3 Worker's Tasks when dealing with an Automated Workstation?
1. Maintenance
2. Loading/Unloading
3. Tool Changes
78
What are the 3 System-Level Automation Classifications?
1. Manned System
2. Automated System
3. Partially Automated/Hybrid System
79
What are the 5 'changes in operating conditions' in a manufactruing system?
1. Changes in production schedule
2. Rush orders
3. Late material orders
4. Broken tools
5. Equipment failure
80
What are the 3 'variations in parts/products' in a manufacturing system?
1. Design changes
2. Different starting material
3. Introduction of new part designs
81
True or False. Flexible systems can adapt with minimal disruption to performance.
True
82
What are the 3 Requirements of 'Mixed-Model Operation'?
1. Identification of Different Work Units
2. Quick Changeover of Operating Instructions
3. Quick Changeover fo Physical Setup
83
What are the 2 advantages of 'flexibility' in a manufacturing system?
1. Adaptability to product variety/operational changes
2. Reduced downtime due to batch change overs
84
What are the 7 disadvantages of 'flexibility' in a manufacturing system?
1. Higher risk of human error in manual system
2. Automated ID Systems must be integrated
3. Increased tooling/fixture variety required
4. More complex material handling to support varied part shapes
5. Inspection and quality control becomes more demanding
6. Inventory logistics for different part types becomes more difficult
7. Scheduling and coordination are significantly more complex
85
True or False. When achieving SMED, the work is divided into the follwing ares: Internal & External
True
86
What are the 8 steps of implementing SMED?
1. Separate internal from external setup operation
2. Converts internal to external setup
3. Standardize function, not shape
4. Use functional clamps or eliminate fasteners altogether
5. Use intermediate jigs
6. Adopt parallel operation
7. Eliminate adjustments
8. Mechanization
87
What are the 5 stages that will notify you when SMED Improvement occurs?
1. Ensure that external setup actions are performed while machine is running
2. Separate external and internal setup actions
3. Ensure that the parts all function and implement efficient ways of transporting the die and other parts
4. Convert internal setup actions to external
5. Improve all setup actions
Flexible Manufacturing
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Decks in class (11)
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