GROUP 7 ADVANCED MANUFACTURING SYSTEM TASK 2 PRESENTATION

GROUP 7ADVANCED MANUFACTURING SYSTEMTASK 2 PRESENTATIONAbdul Rahman B Mohd sapawiRyan RaymondFaffa Zamizza Bt ZamriMohammad Shukery B YusofPART A: Manufacturing of Ultra-Precise Metal MouldProblem Our company has just been awarded a contract to manufacture ultra-precise metal moulds but we have no experience in producing it.

Solution-Propose a new process flow -Propose a new plant layout-Propose a new quality control system-Propose a new tool condition monitoring technique

Process Flow

1. Customer OrderThe mould will be made according to specifications provided by the customer.2. DesignGroup of design experts will develop the design of the mould.The design will be analyze and go through all the checklist parameter.

3. Raw MaterialChoose a material that allow us to get the job done quickly and efficiently as possibleCharacteristics that need to be consider = hardness, machinability, resistance to corrosion4. Manufacturing Process

Vertical CNC Milling MachineTo turn the material into desired dimensionCNC Surface GrinderTo produce a smooth finish on the mould surface5-Axis CNC Milling MachineTo make the mould component shape (cavity, holes,pins)5. InspectionTo make sure the mould meet the quality requirements (the method will be further explain in the next section)6. StorageTo store the finished product Use Automated Storage/Retrieval Systems7. Delivery- The completed metal mould will be deliver to the customerInspectionAutomated Vision InspectionFlexible, Convertibility, Low costOperate similar as human vision

Position of InspectionInput Material InspectionTo prevent any defective input material to go through the machining process.Finished Product InspectionTo prevent any defective product to be package and deliver to costumer.

Method of Automated Machine Vision Inspection SystemFirst Step: Acquisition of mold imageSecond Step: Image ProcessingThird Step: Decision-making process

Output of systemPass: Object go through the next processFail: Object rejected and go to rejected product section

Quality Control Systems

Online Inspection & MonitoringReal time process (online) mode to prevent and increase quality of production during the process.Offline Inspection& MonitoringCollected data used to perform statistical analysis(Taguchi Method) to enhance the productivity.

Taguchi Method

Specific Loss Function- To reduce the variance of production. Supply specific target for production to reduce any losses.

Taguchi Method

Offline Quality Control- Eliminate variation in production during the mold designing process.- Specific parameter of mold design to minimize variance during removal process.Design of Experiment- Designing an experiment theories that aimed to allow greater understanding of variations of the product.

Tool Condition MonitoringSensor-less condition monitoringMonitored machine tools utilizing the existing sensors and signals in the machine tool.

AdvantagesAdditional complexity is kept to minimumReducing the cost of condition monitoring system

Internal Drive SignalsUsing non-intrusive Hall Effect sensors to measure the internal drive signals (spindle motor and feed drive current) to indirectly measuring the cutting force.Using spindle power consumption signal and feed drive current signals to estimate tool wear in high speed milling.

Online and Offline Monitoring

Plant Layout-Company annual production = 8000-10 000 units of metal mould (medium production)

Cellular Manufacturing Each cell is specialize in production of a given similar parts. Cellular manufacturing is an application of group technology. Similar parts are identified and group together to take advantage of their similarities Processing steps for each group will be the same

Flexible Manufacturing System (FMS)

Decentralized Automation ConclusionAll of the recommendations in this proposal are very useful in order for us to start producing ultra-precise metal mould.Automation system should be implemented to get a product with high quality.Our product will be much more competitive in the market and we will be able to become one of the most highly in demand manufacturer of our very own products.

Advanced Manufacturing System

Task 2 part B

Obsolete and New Product

Obsolete and New ProductAvailable in 3 size only8-, 5 - and 3 -inch Consist of flat, circular plates made of metal or plastic and coated with iron oxide.Information are magnetically imprinted on the coatingCapacity:High Density: 1.44 MBSuperdisk: 240 MB

The manufacturing Process

Automated: Disk, Semi-auto: Jacket, CaseManual: Assembly

All process in one plant.Small-size, light weight, hot-swappable and rewritable.Consist of flash memory and USBTransfer rate of data: USB 1.1 (500Kbps-10Mbps), USB 2.0 (25Mbps -400Mbps) and USB 3.0 (> 4.8Gbps)Information are store in the flash memory.Capacity:from 32MB to 64GB

The manufacturing Process(Lexar)Almost all process are automated except the assembly of the parts.

Memory Chips produce in USA (Micron Tech. Company)Assembly plant in Asia.

USB flash drives has a higher storage capacity.Most of the latest computer does not support floppy disk.The rise of file sharing and media file which encouraged the use of files that more than floppy disk can support.USB flash drives has a much faster transfer rates.USB flash drives has a more attractive design.

Reason for changes