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Tutorial Letter 101/0/2012Production Technology IV

Year Module

Department of Mechanical and Industrial

Engineering

This tutorial letter contains important

information about your module.

Bar code

PRT401I

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CONTENTS

1 INTRODUCTION AND WELCOME .................................................................................. 31.1 Tutorial matter ................................................................................................................... 32 PURPOSE OF AND OUTCOMES FOR THE MODULE ................................................... 32.1 Purpose ............................................................................................................................. 32.2 Outcomes .......................................................................................................................... 33 LECTURER AND CONTACT DETAILS ........................................................................... 63.1 Lecturers ........................................................................................................................... 63.2 Department ....................................................................................................................... 73.3 University .......................................................................................................................... 74 MODULE RELATED RESOURCES ................................................................................. 84.1 Prescribed books .............................................................................................................. 84.2 Recommended books ....................................................................................................... 84.3 Electronic Reserves (e-Reserves) .................................................................................... 85 STUDENT SUPPORT SERVICES FOR THE MODULE .................................................. 95.1 Study guide................................................................................................. ...............8

5.2 Online resources...............................................................................................................9

6 MODULE SPECIFIC STUDY PLAN ................................................................................. 97 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING ....................... 98 ASSESSMENT ................................................................................................................. 98.1 Assessment plan ............................................................................................................... 98.2 General assignment numbers ......................................................................................... 108.2.1 Unique assignment numbers .......................................................................................... 108.2.2 Due dates of assignments............................................................................................... 108.3 Submission of assignments ............................................................................................ 118.4 Assignments ................................................................................................................... 119 EXAMINATIONS ............................................................................................................. 1110 OTHER ASSESSMENT METHODS ............................................................................... 1211 FREQUENTLY ASKED QUESTIONS ............................................................................ 1212 ANNEXURE A: ASSIGNMENTS.....................................................................................13

13 ORDER FORM..............................................................................................18

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1 INTRODUCTION AND WELCOME

Dear Student

Welcome to the module, Production Technology IV (Code PRT401I), offered by the

Industrial Engineering section in the School of Engineering at UNISA.

This module is part of the qualification, Diploma in Engineering: Industrial. This is

your first tutorial letter (TL); read it carefully before you start studying. It provides

you with an overview and specific information about this module. You should use it

as a guideline to your studies in this course.

This tutorial letter also provides you with general administrative information as well

as specific information about the subject. Read it carefully and keep it safe for future

reference. We trust that you will enjoy this course.

The purpose of this module is to provide the student with the practical and theoretical

knowledge to do research for an Engineering Project.

1.1 Tutorial matter

Some of this tutorial matter may not be available when you register. Tutorial matter that is

not available when you register will be posted to you as soon as possible, but is also

available on myUnisa.

2 PURPOSE OF AND OUTCOMES FOR THE MODULE

2.1 Purpose

After completing this module a learner must be able to plan the implementation of

production technology, equipment, materials handling, and information technology

and evaluate alternatives, and how to manage the project.

2.2 Outcomes

At the end of this module the student must be able to undertand:

1. Flexible Manufacturing systems and

Understand the various manufacturing technologies used in industry.

Relate competitiveness, quality and cost.

The role of computers in manufacturing, CAD and CAM applications.

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Introduction to flexible manufacturing systems

Identify examples of flexible manufacturing systems

Identify the FMS project structure and management

Identify components, processes and materials handling systems in FMS.

Applications of computer simulation for feasibility study of FMS.

Financial justification for implementing FMS Process of installation and commissioning of FMS

Identify factors affecting the development of FMS

2. Just in Time systems

Integrating JIT with MRPII systems

Integration of JIT with CIM

Automated manufacturing processes

Automated materials handling and storage systems

Computer integrated manufacturing enterprise.

3. Nontraditional machining processes

Understand the classification of nontraditional machining processes

Be able to describe, identify uses, tooling used and operations performed and

advantages and limitations of the following processes

o Ultrasonic machining

o Abrasive jet machining

o Electrochemical machining

o Chemical milling

o Electro discharge machining

4. Understand the principles, applications and implementation of the following sensing

techniques in automated manufacturing processes

o Discrete sensing

o Continuous sensing

o Bar codes

o Symbology

5. Understand the principles, applications of bar code technology

o Medium and printer selection

o Bar code scanners

o Bar code readers

o Bar code printers

o Shop floor control using bar codes

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12. Robot applications

o Classification and reach of robots

o Cartesian, cylindrical, polar or spherical robots, articulated robots, SCARA robots

o Classification based on control system

o Point to pointo Continuous path control

o Controlled path computed trajectory

o Robot reach or work place envelope

o Major components and functions of robots

o Drive system

o Control system

o Sensors

o Robot grippers

o Robot programming

o Robot applications

13. Lasers in industry

o How lasers work

o Types of lasers

o Laser application

o Laser beam welding and machining

14. Rapid prototyping techniques

o How rapid prototyping works

o Types of rapid prototyping

o rapid prototyping applications

3 LECTURER AND CONTACT DETAILS

3.1 Lecturers

Your lecturer is: Mr Steadyman Chikumba

E-mail : chikus@unisa.ac.za

Availability: Mondays to Fridays from 09h00 to 13h00

Please adhere to these hours only.

Functions of the Lecturer:

Enquiries about technical content.

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Set assignments.

Mark assignments.

Set examination papers.

Mark examination papers

Under no circumstances, should the lecturer be contacted with regard to examination

dates, results or receipt of assignment or assignment marks.

3.2 Department

You may contact the Department of Mechanical and Industrial Engineering by post,

e-mail, telephone, or online through myUnisa.

Please refer to the booklet: My studies @ Unisa

Departmental Address:

Department of Mechanical and Industrial Engineering

Unisa (Florida Campus)

Private Bag X6

Florida

1710

Phone: 011 471 2963

Use the general E-mail address: nkambule@unisa.ac.za

Find our Department on the Internet at the online address:

http://www.unisa.ac.za

Always state yourSTUDENT NUMBER and your Module Code PRT401I in all

correspondence and enquiries.

Whenever you contact the Department of Mechanical and Industrial Engineering,

ensure that the first thing you mention after greeting is your subject code! It does not

help to say you are a student in Industrial Engineering, lecturers deal with modules.

3.3 University

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If you need to contact the University about matters not related to the content of this module,

please consult the publication My studies @ Unisa that you received with your study

material. This brochure contains information on how to contact the University (e.g. to whom

you can write for different queries, important telephone and fax numbers, addresses and

details of the times certain facilities are open).Always have your student number at hand

when you contact the University.

4 MODULE RELATED RESOURCES

4.1 Prescribed books

1. TITLE: Systems Approach to Computer Integrated Design and

Manufacturing

AUTHOR: Nanua Singh

PUBLISHER: John Wiley & Sons, Inc

ISBN NO: ISBN 0-471-58517-3

2. TITLE: Implementation of Flexible Manufacturing Systems

AUTHOR: Greenwood NR

PUBLISHER: Basingstoke: Macmillan Educational

ISBN: 047 0209321

NOTE: This Book can only be purchased through UNISA Press. Please use the form in

Annexure B to order your text book

4.2 Recommended books

ElMaraghy, Hoda A. (Ed.) , Manufacturing Systems , Changeable and

Reconfigurable Manufacturing Systems Series: Springer Series in Advanced

Manufacturing

Mikell P. Groover Automation, Production Systems and Computer Integrated

Manufacturing , 3rd Edition, Prentice Hall

N. Nise, Control Systems, Wiley

B Wu Manufacturing systems Design and Analysis

John J. Craig Introduction to Robotics: Changeable and Reconfigurable, Pearson

4.3 Electronic Reserves (e-Reserves)

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There are no electronic reserves for this module.

5 STUDENT SUPPORT SERVICES FOR THE MODULE

Important information appears in yourmy Studies @ Unisa brochure.

5.1 Study Guide

There is a study guide in this module. The student is encouraged to buy theprescribed book as soon as they register for the module.

5.2 On line resources

All course materials are available on myUnisa https://my.unisa.ac.za under the

module course code under Materials. Discussion forums are set up by your lecturer

and available for discussions with your peers https://my.unisa.ac.za

Some additional electronic resources are available from the Library site (viawww.unisa.ac.za).

You may electronically post or upload your assignments in line with the guidelines

explained in the booklet : My studies @ Unisa.

DO NOT EMAIL ASSIGNMENTS TO LECTURERS. DO NOT FAX ASSIGNMENTS. DO

NOT SEND ASSIGNMENT IN FRAGMENTS, BUT SUBMIT THE COMPLETE

ASSIGNMENT.

6 MODULE SPECIFIC STUDY PLAN

Use yourmy Studies @ Unisa brochure for general time management and planningskills.

7 MODULE PRACTICAL WORK AND WORK INTEGRATED LEARNING

There are no practicals for this module.

8 ASSESSMENT

Your assignments will each receive a % mark, as per the table below. These marks

are independent of the exam credit value. In order to qualify for sitting the

examinations, you have to submit all three assignments.

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You will find your 2 (TWO) assignments for this subject in Annexure A at the back

of this tutorial letter. All TWO Assignments are compulsory. Please submit all three

assignments, duly completed, to UNISA before the closing dates stated in this

section. The mark for Production Technology IV (PRT401I) is calculated as follows:

The year mark contributes to 10% of final mark

The examination mark contributes to 90% of the final mark

8.1 Assessment plan

The year mark is based on all the assignment marks obtained and their contributiontowards the final year mark are as shown in the table below:

8.2 General assignment numbers

Assignments are numbered consecutively per module, starting from 01. Only Arabic

numerals are used: for example, Assignment 01, 02, 03. For detailed information

and requirements as far as assignments are concerned, see

my studies @ Unisa, which you received with your study package.

8.2.1 Unique assignment numbers

Unique numbers for assignments are shown below:

8.2.2 Due dates of assignments

THE CUT-OFF SUBMISSION DATES FOR THE ASSIGNMENTS ARE :

Assignment 1 28 May 2012

Assignment 2 3September 2012

ASSIGNMENT

NUMBER

CONTRIBUTION

TOWARDS YEAR MARK

CONTRIBUTION

TOWARDS FINAL SUBJECT

MARK

1 (Compulsory) 50 % 5%

2 (Compulsory) 50 % 5%

TOTAL = 100 % = 10%

Unique Numbers

Assignment 1 306741

Assignment 2 260633

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8.3 Submission of assignments

You will find your two assignments for this subject in Annexure A. You are required

to submit two (2) assignments to UNISA before the closing dates stated in this

section. The year mark is based on all the assignment marks obtained and their

contribution towards the final year mark

For detailed information and requirements as far as assignments are concerned, see

the brochure my Studies @ Unisa that you received with your study material.

To submit an assignment via myUnisa:

Go to myUnisa.

Log in with your student number and password.

Select the module.

Click on assignments in the menu on the left-hand side of the screen.

Click on the assignment number you wish to submit.

Follow the instructions.

IT IS VERY IMPORTANT TO CONSIDER THE FOLLOWING POINTS:

No late assignment submissions will be accepted.

Keep a clear copy of the assignment for your own reference. This is important, as

assignments do get lost.

Submissions of assignments must be in accordance to the myStudies@Unisa

handy guide.

It is your responsibility to check whether Unisa has received your assignment.

8.4 Assignments

The three assignments which include the final portfolio submission are attached as

Annexure A.

9 EXAMINATIONS

There is a 3 hour written examination. Students can also be referred to the

myStudies@Unisa brochure for general examination guidelines and examination

preparation guidelines. Please note that students receive admission to the

examinations on the submission of their first assignment.

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10 OTHER ASSESSMENT METHODS

None

11 FREQUENTLY ASKED QUESTIONS

The my Studies @ Unisa brochure contains an A-Z guide of the most relevant studyinformation.

Ensure that you have received the Unisa booklet: My studies @ Unisa and that you

have familiarised yourself with its contents. Take special note of Unisas online

internet facility: myUnisa, and ensure that you register, if possible. It has many

benefits, inter alia that you can communicate with your fellow students on subject

matters or submit assignments.

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12 ANNEXURE A ASSIGNMENTS

ASSIGNMENT 1 (unique no: 306741)

QUESTION 1

1.1 Discuss how the creativity matrix compares with Hayes Wheelwright Model. (8)

1.2 Explain the importance of the Interdependence of costs, quality and delivery time in

production processes. (6)

1.3 Discuss twelve death signs of a growing manufacturing company. (12)

[26]

QUESTION 2

2.1 What are the various types of machine cells? (10)

2.2 Classify a component using MICLASS system. (5)

2.3 What factors are considered in selecting a classification and coding system?

(5)

2.4 What is cell formation? What are the objectives of cell formation? (5)

2.5 Compare the features of horizontal and vertical machining centers. (5)

2.6 Discuss the importance of the following statements in the APT:

2.6.1 Geometric statements (2)

2.6.2 Cutter motion statements (2)

2.6.3 Auxilliary statements (2)

2.6.4 Post processor statements (2)

2.7 Define canned cycle? How does a canned cycle reduce program length? (4)

2.8 Discuss how the solid model based CAD data is used for NC programming. (4)

[46]

QUESTION 3

3.1 Discuss the machining features on nontraditional machining. (5)

3.2 Explain the principle and application of jet based technologies in manufacturing.

(10)

3.3 Discuss the monitoring and modeling of AWJ process. (10)[25]

QUESTION 4

4.1 Explain the two configurations of Direct Numerical Control. (6)

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4.2 Discuss the steps of part programming using Standard APT (Automatically

programmed tools) language. (8)

4.3 Explain the role of the post processor in part programming. (5)

4.4 Explain CAD/CAM based part programming. (6)

[29]

QUESTION 5

5.1. What are the components of Flexible Manufacturing System? (10)

5.2 Discuss the types of flexibilities an FMS can offer. (5)

5.3. What are the FMS performance reports? Explain how they are used. (5)

5.4 Discuss the operational issues of FMS. (5)

5.6 Explain the structure of FMS application software systems. (5)

5.7 Discuss the purpose of Simulation Software in an FMS. (5)

5.8 What is a Kanban? What for it is used in FMS? Explain. (5)

5.9 Write short notes on the following:

(a) Flexible workforce (3)

(b) Role of Preventive Maintenance in FMS. (3)

[46]QUESTION 6

Write short notes on the following principle, industrial applications and how control isachieved.

6.1 AS/RS (6)

6.2 AGVs (6)

[12]

QUESTION 7

7.1 Explain about the Robot Anatomy and configuration. (10)

7.2 Explain about homogeneous Transformations in Robotics kinematics. (5)

7.3 Discuss in detail about the grippers and their types. (8)

7.4 Explain the Image processing and Image data Reduction. (10)

7.5 Write about segmentation and object recognition in detail. (5)

[38]

TOTAL MARKS = [222]

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ASSIGNMENT 2 (Unique no 260633)

QUESTION 1

Carry out a study on how your organization designs, selects processes and manufactures

new product and service offerings. Discuss how concurrent engineering can be

implemented within your organisations context. (20)

[20]

QUESTION 2

The project must basically be focused on the application of nontraditional manufacturing

methods and technologies including rapid prototyping. The student is tasked to identify a

problem at a typical company and justify how nontraditional manufacturing methods or RP

can be a solution to the problem. The application areas include:

a) Direct production of engineering metal, ceramic, and polymer components or parts

by rapid prototyping or nontraditional manufacturing methods, production of tooling (rapid

tool making) such as molding dies, fixtures by nontraditional manufacturing methods or

rapid prototyping for use in further manufacturing operations

1. Title page

This should include the project title and the name of the authors of the report. The project

should be based on application of nontraditional manufacturing methods or Rapid

Prototyping technology at a typical company in South Africa. You should formulate its

project title. The title must reflect the goals or aims of the project.

2. Abstract

The abstract is a very brief summary of the report's contents. It should be about half a page

long. Somebody unfamiliar with your project should have a good idea of what it's about

having read the abstract alone and will know whether it will be of interest to them. Trends in

Rapid prototyping can also be cited.

3. Acknowledgements

It is usual to thank those individuals who have provided particularly useful assistance,

technical or otherwise, during your project.

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4. Contents page

This should list the main chapters and (sub)sections of your report. Choose self-explanatory

chapter and section titles and use double spacing for clarity. If possible you should include

page numbers indicating where each chapter/section begins. Try to avoid too many levels

of subheading - three is sufficient.

5. Introduction

This is one of the most important components of the report. It should begin with a clear

statement of what the project is about so that the nature and scope of the project can be

understood by a lay reader. It should summarise everything you set out to achieve, provide

a clear summary of the project's background, relevance and main contributions. The

introduction should set the scene for the project and should provide the reader with a

summary of the key things to look out for in the remainder of the report. When detailing the

contributions it is helpful to provide pointers to the section(s) of the report that provide the

relevant technical details. The introduction itself should be largely non-technical. Aims and

objectives of the project should be clearly stated.

6. Background

The company background should be clearly stated. This section may include the main

processes, particular machines that are to be studied and citation of the problem which willbe solved should be explicitly clear. The background section of the report may also set the

project into context by relating it to existing published work which you read at the start of the

project when your approach and methods were being considered. There are usually many

ways of solving a given problem, and you shouldn't just pick one at random, so explain why

Rapid Prototyping is appropriate to achieve the objectives. The background section can be

included as part of the introduction but is usually better as a separate chapter, especially if

the project involved significant amount of prior research.

7. Methodology

Outline the procedure that is undertaken to collect, store, analyze and present information

as part of a research process to achieve the desired objectives. This section should briefly

exhibit steps undertaken to identify the problem, how the design was done, how the model

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was printed, de-powdering and infiltration, and a statement to indicate that

recommendations were finally made.

8. Body of report (the title for this section depends on the project undertaken)

This is the central part of the report and can have more than one chapter detailing the

technical work undertaken during the project.

9. Recommendations

Give recommendations for correct nontraditional manufacturing methods or RP techniques

that could be used.

10. Conclusions and Future Work

The project's conclusions should list the things which have been learnt as a result of the

work you have done.

11. Bibliography

This consists of a list of all the books, articles, manuals etc. used in the project and referred

to in the report. You should provide enough information to allow the reader to find the

source.

SUBMISSIONS

Paper of about up to 2000 words

Hand written papers will not be accepted.

And working models (optional)

(100)

[100]

Total marks = [120]

UNISA 2012

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ORDER FORM

TO: The Business Section, Unisa Press, PO Box 392, UNISA, 0003

FAX NO: (012) 429-3449 /REFERENCE TEL NOS: (012) 429-3515 / (012) 429-2976 / (012) 429-3448/ (012) 429-

3368 / (012) 429-2953

NB: Please note that the University no longer banks with ABSA bank. The new bank is Standard bank, see bank

account details below

PRICE: (PUBLICATION IS SUBJECT TO AVAILABILITY, AND PRICE MAY INCREASE)

Please send me the following Unisa publication: (ITEM NO )

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Africa:

R

STUDENT NO: TEL NO:

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Address:

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PAYMENT OPTIONS: Choose between the following 5 options (indicate with an x)

1a) Direct Payment forSouth African students: Banking details as follows: Standard Bank, Sunnyside, Type ofAccount: Deposit; Name of Account: UNISA Student deposits; Account no: 096R. Branch Code: 010645. Forreference on the Bank deposit slip, please print your student no, space and the allocation no 5400380438 on the

deposit slip and fax deposit slip to (012) 429-3449.

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Direct Payment for Foreign students: (Please contact Unisa Press on 012 429 3448 / 2976 e-mail:

Thearl@unisa.ac.za).

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3) My Unisa study fees account has been paid in full AND has a credit available that will cover the cost of thisorder. I therefore authorise Unisa Press to debit my study fees account with the amount owing (not applicable for

NFSAS students).

4) NFSAS students

Signed _______________________________________ Date __________________________