Problem Statement
Proposed Solution
Key Considerations
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion Design TeamJonathan Correia, Sean Heckathorne, Jeff Quinn
Flexible Manufacturing System Classroom Laboratory
Questions
Project NeedProject Need
► Current Manufacturing Systems and Current Manufacturing Systems and Techniques (MIMU530) lab Techniques (MIMU530) lab experiments do not adequately experiments do not adequately relate classroom theory to practice relate classroom theory to practice or expose students to a broad or expose students to a broad enough range of manufacturing enough range of manufacturing techniques.techniques.
Problem Statement
Proposed Solution
Key Considerations
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion
Questions
Project StatementProject Statement► To create a set of laboratory experiments that To create a set of laboratory experiments that
satisfy the need to integrate classroom teachings satisfy the need to integrate classroom teachings with laboratory practices.with laboratory practices.
► Understand the demands and expectations of Understand the demands and expectations of laboratory objectives and formulate strategies to laboratory objectives and formulate strategies to satisfy them.satisfy them.
► Design a flexible manufacturing system to introduce Design a flexible manufacturing system to introduce students to a practical application of traditional and students to a practical application of traditional and state of the art manufacturing techniques.state of the art manufacturing techniques.
Problem Statement
Proposed Solution
Key Considerations
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion
Questions
Our GoalsOur Goals► Design a set of lab experiments to allow
students to demonstrate knowledge of course objectives
► Research and recommend lab configurations and equipment that satisfy the demands of the lab procedures
► Identify and address missing links and voids within the equipment configurations that require unique solutions
Problem Statement
Proposed Solution
Key Considerations
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion
Questions
Project BenefitsProject Benefits► Creation of a set of pedagogically sound laboratory Creation of a set of pedagogically sound laboratory
exercises to be used in the MIMU530 courseexercises to be used in the MIMU530 course
► Integration of classroom theory and hands-on practiceIntegration of classroom theory and hands-on practice
► Addition of problem solving aspect to lab experienceAddition of problem solving aspect to lab experience
► Recommendation of equipment and configurations to Recommendation of equipment and configurations to satisfy demands of long-term laboratory needssatisfy demands of long-term laboratory needs
► A specification for Phase I laboratory development - A specification for Phase I laboratory development - definition of equipment and operating procedures required definition of equipment and operating procedures required for implementationfor implementation
► Design of enabling technologies for implementation of Design of enabling technologies for implementation of Phase IPhase I
Problem Statement Proposed Solution
Key Considerations
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion
Questions
OverviewOverview► Demonstrate and understand practical Demonstrate and understand practical
measure and calculation of process measure and calculation of process performance metricsperformance metrics WIP, cycle time, MLT, utilization, production rateWIP, cycle time, MLT, utilization, production rate
► Analyze the process performance and Analyze the process performance and recommend improvementsrecommend improvements
► Gain understanding of manufacturing Gain understanding of manufacturing configurations and how they relate to configurations and how they relate to process performanceprocess performance Storage buffers, batch vs. flow, product Storage buffers, batch vs. flow, product
customization (pull), lean manufacturingcustomization (pull), lean manufacturing
Problem StatementProposed Solution
Lab Experiments
Laboratory Reports
Entire Solution
Phase I Solution
Conclusion
Questions
ProceduresProcedures► Lab 1 – Effects of Storage Buffers in Assembly Lab 1 – Effects of Storage Buffers in Assembly
LinesLines
► Lab 2 – Effects of Batch Production in Assembly Lab 2 – Effects of Batch Production in Assembly LinesLines
► Lab 3 – Effects of Customization in Assembly Lab 3 – Effects of Customization in Assembly LinesLines
► Lab 4 – Applying Lean Tools to an Assembly LineLab 4 – Applying Lean Tools to an Assembly Line
Problem StatementProposed Solution Lab Experiments
Final Phase Solution
Entire Solution
Phase I Solution
Conclusion
Questions
Layout Decision MatrixLayout Decision Matrix
Problem StatementProposed SolutionLab Experiments
Final Phase Solution
Entire Solution
Phase I Solution
Conclusion
Questions
““U” Shaped LayoutU” Shaped Layout
Problem StatementProposed SolutionLab Experiments Final Phase Solution
Entire Solution
Phase I Solution
Conclusion
ConveyorsCNC MachinesRobotsRobot Reach
Questions
DesignDesign
Problem StatementProposed SolutionLab ExperimentsFinal Phase Solution
Phase I Solution
Phase I Solution
Conclusion
Conveyor System Sections
WorkersQuestions
DesignDesign
Problem StatementProposed SolutionLab ExperimentsFinal Phase Solution
Phase I Solution
Phase I Solution
Conclusion
Questions
Conveyor BridgeConveyor BridgeProblem StatementProposed SolutionLab ExperimentsFinal Phase SolutionPhase I Solution
Enabling Technologies
Conclusion
Questions
2.75” GapConveyor
Conveyor
Conveyor Drive Shaft
Support Plates
Timing Pulleys and Belt
Conveyor
ConveyorConveyor
Conveyor
4X Sealed Bearing
•4X ½-20 SHCS
•½” Spacers
Support CalculationsSupport Calculations
Problem StatementProposed SolutionLab ExperimentsFinal Phase SolutionPhase I Solution Enabling Technologies
Conclusion
Questions
Tourque = lbsftRPM
HP 81.3
84.45
5252*)301
(5252*
Timing Belt Length = "50912.506081.2*22
955.955.2
2
21
L
CC
Stress Analysis = approx. 2.4e+5
AccomplishmentsAccomplishments
Problem StatementProposed SolutionLab ExperimentsFinal Phase SolutionPhase I SolutionEnabling Technologies
Conclusion
► Four lab experiments written and ready for Four lab experiments written and ready for implementation at the next course offeringimplementation at the next course offering
► Final phase system design in placeFinal phase system design in place
► Phase I design refined and ready for Phase I design refined and ready for implementationimplementation
► Conveyor gap solution designed and ready Conveyor gap solution designed and ready for testing and implementationfor testing and implementationQuestions
Future ConsiderationFuture Consideration
Problem StatementProposed SolutionLab ExperimentsFinal Phase SolutionPhase I SolutionEnabling Technologies Conclusion
► Purchase of Phase I equipment for implementationPurchase of Phase I equipment for implementation
► Continue research into machines that will satisfy Continue research into machines that will satisfy laboratory objectiveslaboratory objectives
► Research computer programs to control machine Research computer programs to control machine automationautomation
► Build prototype of conveyor bridge and test in the Build prototype of conveyor bridge and test in the systemsystem
► Maintain laboratory experiment objectives while Maintain laboratory experiment objectives while altering the procedure to include new machinesaltering the procedure to include new machines
Questions
??Problem StatementProposed SolutionLab ExperimentsFinal Phase SolutionPhase I SolutionEnabling TechnologiesConclusion
Questions