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PRT401I/101/0/2015

Tutorial letter 101/0/2015 PRODUCTION TECHNOLOGY IV PRT401I Year Module Mechanical and Industrial Engineering
Tutorial letter 101/0/2015
PRODUCTION TECHNOLOGY IV
PRT401I
Year Module
Mechanical and Industrial Engineering
IMPORTANT INFORMATION:
This tutorial letter contains important information
about your module.

CONTENTS

Page

1

INTRODUCTION

3

2

PURPOSE OF AND OUTCOMES FOR THE MODULE

3

2.1

Purpose

3

2.2

Outcomes

3

3

LECTURER(S) AND CONTACT DETAILS

6

3.1

Lecturer(s)

6

3.2

Department

6

3.3

University

7

4

MODULE-RELATED RESOURCES

7

4.1

Prescribed books

7

4.3

Electronic Reserves (e-Reserves)

7

5

STUDENT SUPPORT SERVICES FOR THE MODULE

7

5.1

Study Guide

7

5.2

On line resources

7

6

MODULE-SPECIFIC STUDY PLAN

8

7

MODULE PRACTICAL WORK AND WORK-INTEGRATED LEARNING

8

8

ASSESSMENT

8

8.1

Assessment plan

8

8.2

General assignment numbers

8

8.2.1

Unique assignment numbers

8

8.2.2

Due dates for assignments

8

8.3

Submission of assignments

9

8.4

Assignments

9

9

OTHER ASSESSMENT METHODS

9

10

EXAMINATION

9

11

FREQUENTLY ASKED QUESTIONS

9

12

SOURCES CONSULTED

10

13

CONCLUSION

10

14

ADDENDUM A: ASSIGNMENTS

11

PRT401I/101

1

INTRODUCTION

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, Bachelor of Technology 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 of statistics and quality control.

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

1.

Flexible Manufacturing Systems

Understand the various manufacturing technologies used in industry.

Relate competitiveness, quality and cost.

The role of computers in manufacturing, Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) applications.

Introduction to flexible manufacturing systems

Identify examples of flexible manufacturing systems (FMS).

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 (JIT)

Integrating JIT with Material Requirements Planning II (MRPII) systems

Integration of JIT with computer integrated manufacturing (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

o

Radio frequency identification system (RDFI)

6.

Understand the principles and application of programmable logic controllers (PLCs)

o

Computer process control.

7.

CIM software which supports JIT

o

The common elements in CIM and JIT systems

o

People involvement

o

Demand pull

o

Total Quality Control (TQC)

o

JIT vendor interface

o

Support for the focused factory

8.

Understand the application of technology in manufacturing

o

Types of technology and impact of life cycle effect on technology.

o

Material processing technology Numerical Control (NC), computer numerical control (CNC), Automatic Guided Vehicles (AGVs), robots

9.

Understand and identify the application Information technology in manufacturing

o

Transaction processing

o

Automatic identification systems

o

Management information systems

o

Decision support systems

o

Artificial intelligence and expert systems

PRT401I/101

10. Computer integrated manufacturing and the computer integrated enterprise

o

Data base and data base management

o

CIM data base

o

Data base models

o

Network and relational data base

o

Integration and implementation issues

o

Requirements for integrated manaufacturing data

o

System architechture

o

Functional architechture

o

Control architechture

o

Data achitechture

o

Steps in implementing CIM.

11. Automated material handling and storage systems

o

Advantages of AGVs

o

Automated storage and retrieval systems (AS/RS)

o

The main components of AS/RS

o

Benefits of AS/RS

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 point

o

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 and rapid prototyping applications

3

LECTURER(S) AND CONTACT DETAILS

3.1 Lecturer(s)

Your lecturer is: Mr Steadyman Chikumba

E-mail :

Availability:

Please adhere to these hours only.

Mondays to Fridays from 09h00 to 13h00

Functions of the Lecturer:

Enquiries about technical content.

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 your STUDENT 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

PRT401I/101

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

Title: Automation, Production Systems and Computer-Integrated Manufacturing

Author: Mikell P. Groover,

Edition: 2008 or later

Publisher: Pearson Education

ISBN: 0-13-207073-1

4.2

Recommended books

Fred E. Meyers. Matthew P. Stephens Manufacturing Facilities Design and Material

Handling (3 rd Edition), PEARSON EDUCATION

EB Magrab, SK Gupta, FP McCluskey, P Sandborn (2009) Integrated Product and

Process Design and Development, 2 nd Edition, CRC Press, ISBN 1420070606

4.3

Electronic Reserves (e-Reserves)

There are no electronic reserves for this module.

5 STUDENT SUPPORT SERVICES FOR THE MODULE

5.1 Study Guide

Your Study Guide is the first and main source of tuition to be studied in totality! a printed copy will be sent to you (with an electronic copy online on myUnisa). Certain aspects in the text book are elaborated on, explained, or omitted in the study guide.

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

(via

Some

www.unisa.ac.za).

additional

electronic

resources

are

available

from

the

Library

site

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 your my Studies @ Unisa brochure for general time management and planning skills.

7 MODULE PRACTICAL WORK AND WORK-INTEGRATED LEARNING

There is no practical and work integrated learning in this module.

8 ASSESSMENT

8.1 Assessment plan

ASSIGNMENT

CONTRIBUTION TOWARDS YEAR MARK

CONTRIBUTION TOWARDS FINAL SUBJECT MARK

NUMBER

1 (Compulsory)

50

%

10%

2 (Compulsory)

50

%

10%

TOTAL

= 100 %

= 10%

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 as follows

Unique Numbers

Assignment 1

Compulsory

559372

Assignment 2

Compulsory

560126

8.2.2 Due dates for assignments

THE CUT-OFF SUBMISSION DATES FOR THE ASSIGNMENTS ARE :

Assignment 1

4 May 2015

Assignment 2

21 August 2015

8.3 Submission of assignments

PRT401I/101

You will find your two assignments for this subject in Addendum 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 “services and procedures” handy guide.

It is your responsibility to check whether Unisa has received your assignment by contacting the call centre two (2) weeks after submission.

8.4 Assignments

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

tutorial letter. All two assignments are compulsory.

9 OTHER ASSESSMENT METHODS

None

10 EXAMINATION

A 3 hour examination will be scheduled for this module. 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.

11 FREQUENTLY ASKED QUESTIONS

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

The table below explains fully where to find anything for this course. Please ensure that you read and understand this section very well.

Ensure that you have received the Unisa booklet: My studies @ Unisa and that you have familiarised yourself with its contents. Take special note of Unisa’s 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.

12 SOURCES CONSULTED

Tompkins, J.A , Facilities Planning, 3 rd Edition, John Wiley and Sons, NY

Groover, Mikell P. 2008. Automation, Production Systems and Computer Intergrated Manufacturing. 3rd edition., Pearson International. London

13 CONCLUSION

After reading your tutorial letter make sure you purchase the prescribed book and get access to library resources before attempting assignments. Good luck.

 

PRT401I/101

14

ADDENDUM: ASSIGNMENTS

QUESTION 1

1.1 Explain the concept of mass customisation.

(2)

1.2 Explain three mass customized product strategies.

(6)

1.3 Explain the challenges faced when deploying mass customization manufacturing

 

system.

(10)

1.4

Discuss the characteristics of layout scenarios, which can be analyzed by

simulation.

(10)

 

[28]

 

QUESTION 2

2.1 With examples and block diagrams explain the configuration and functioning of a typical continuous control system in your workplace.

(16)

2.2 Explain the concept of polling in computer process control.

(4)

[20]

 

QUESTION 3

The installation of an FMS involves coordinating the various activities which include siting,

 

machine layout, project management, safety considerations, computer systems,

integration and commissioning. Discuss in detail these activities in FMS installation

process.

(20)

[20]

 

QUESTION 4

A company hires you as an engineer and they have a storage space problem. The director has heard about ASRS. Explain the practical major components of this system and how it can benefit the company.

(20)

[20]

 

QUESTION 5

Discuss the level of automation in your organisation under following headings:

 

5.1 Programme of instructions to direct the process.

(5)

5.2 Control system to actuate the instructions

(5)

5.3 Safety monitoring

(5)

5.4

Maintenance repair and diagnostics

(5)

 

[20]

QUESTION 6

Discuss the inspection technologies in an environment you familiar with. Highlight the following:

6.1 Hardware elements

(10)

6.2 Control, accuracy and reliability

(10)

6.3 Processes and products

(10)

[30]

TOTAL MARKS = [138]

QUESTION 1

ASSIGNMENT 2

PRT401I/101

1.1 Identify and discuss sensing techniques used in industry, they principles and applications.

(8)

1.2 Discuss the manufacturing planning and control activities in industry.

(6)

[14]

QUESTION 2

Explain how you would use any rapid prototyping techniques to a manufacture a product of your choice. Highlight the following;

2.1 The product sketch and cost considerations.

(10)

2.2 The current process and its weaknesses.

(10)

2.3 The rapid prototyping process including literature search

(10)

[30]

QUESTION 3

Explain how you would use any non-traditional manufacturing techniques to a manufacture a product of your choice. Highlight the following;

3.1 The product sketch and cost considerations.

(10)

3.2 The current process and its weaknesses.

(10)

3.3 The non-traditional process including literature search.

(10)

3.4 Process control considerations.

(10)

[40]

QUESTION 4

4.1 Discuss the classification and control of robots.

(12)

4.2 Choose one robot and explain in detail how you can install, implement and control in an environment of your choice. Highlight the type of arms, sensor and gripper for this application.

(20)

[32]

©

UNISA 2015

[TOTAL MARKS = 102]