KJEI’s

TRINITY POLYTECHNIC, PUNE

Sr. No. 25 &27, Near Bopdeo Ghat, Kondhawa Saswad Road, Dist. Pune.
DEPARTMENT OF MECHANICAL ENGINEERING

Program: Diploma in Mechanical engineering Program Code:- ME

Scheme:- I Semester:- 5
Course:- Advanced Manufacturing Processes CourseCode:- 22563

Q. State any two examples of fixed automation. W-19 2M

Q. Describe fixed and programmable automation. W-19 4M
Q.Compare hard automation and soft automation stating one application of each. S-22 4M
Fixed Automation:
Examples:
a. Transfer lines used in automotive industry.
b. Automatic assembly machines or systems installed for assembly without need of human being.
c. Industrial robots installed or fixed for performing repetitive operations.
Fixed Automation (Hard automation) Programmable Automation
Fixed automation refers to the use of special purpose In programmable automation, the production equipment is
equipment to automate a fixed sequence of processing or designed with the capability to change the sequence of
assembly operations. operations to accommodate different
Each of the operation in the sequence is usually simple, product configurations.
involving perhaps a plain linear or rotational motion or an The operation sequence is controlled by a program, which is a
uncomplicated combination of two. It is relatively difficult to set of instructions coded.
accommodate changes in the product design. New programs can be prepared and entered into the
Advantages: equipment to produce new products.
1. Low unit cost Advantages:
2. Automated material handling 1. Flexible to deal with design variations.
3. High production rate. 2. Suitable for batch production.
Disadvantages: Disadvantages:
1. High initial Investment 1. High investment in general purpose
2. Relatively inflexible in accommodating product changes. equipment
Examples: 2. Lower production rate than fixed
Transfer Lines, Assembly lines, Industrial Robot etc. automation.
Example: Numerical controlled machine tools, industrial robots
and programmable logic controller
Q.Define Robotics. State the components of Robotics manipulator W-19 2M
Robotics is a branch of engineering that involves the conception, design, manufacture and operation of robots.
Components of Robots:
1. Manipulator:
2. End effector:
3. The Locomotion Device:
4. The Controller:
5. The Sensors:
Q. Justify the need of Group Technology in today’s manufacturing situation. W-19 4M
Group Technology:
 Group technology is an approach to organizing manufacture which can be applied in any industry (machining, welding,
foundry, press work, forging, plastic molding, etc.) where small-batch variety production is used.
 The basic approach enables all aspects of manufacturing, from design, through estimating and planning, to production, to be
rationalized.
 It forms the basis for the development of computeraided procedures and flexible automation.
 Group technology is a manufacturing philosophy or principle whose basic concept is to identify and bring together related or
similar parts and processes, to take advantage of the similarities which exist, during all stages of design and manufacture.
Advantages of Group Technology:
The following are the advantages of introducing GT in manufacturing:
1. Work in progress and finished stock levels are reduced.
2. Simplified estimating, accounting and work management.
3. Improved plant replacement decisions, and.
4. Improved job satisfaction, morale, and communication.
5. Short throughput times because machines are closed together.
6. Better quality because the group complete parts and the machines are closed together under one foreman.
7. Lower material handling costs because machines are closed together under one foreman.
8. Better accountability because of machines complete parts.
9. The foreman can be made responsible for costs, quality, and completion by the due date.
10. Training for promotion since GT provides a line of succession because a group is a minidepartment.
11. Automation GT is the first evolutionary step in automation.
12. Reduced set up time since similar parts brought together on the same.
13. Morale and job satisfaction since most workers prefer to work in groups.
14. The output is improved due to improved resource utilization.

Q.Select a engineering product manufactured by applying group technology principles. Write its part S-22 4M
classification and coding.
Parts classification and coding :
GT is a manufacturing philosophy in which similar part are identified and grouped together to take advantage of their similarities in
manufacturing and design.

Parts classification and coding

Coding: assignment of a symbol (or a set of symbols) to represent information.
Classification: a protocol that is used to separate a large group of objects into separate sub-groups.
Large manufacturing system can be decomposed into smaller subsystems of part families based on similarities in part.

Part classification as per Attributes

1. Part design attributes and
2. Part manufacturing attributes
3. Both design and manufacturing attributes

Coding methods
Coding methods are employed in classifying parts into part families
Coding refers to the process of assigning symbols to the parts
The symbols represent design attributes of parts or manufacturing features of part families
The variations in codes resulting from the way the symbols are assigned can be grouped into three distinct type of codes:
– Monocode or hierarchical code
– Polycode or chain-type
– Hybrid or mixed code
Example of Coded Part:

Pneumatic actuators are widely used in Robotics

As pneumatic actuators fulfil all necessary requirements of Robotics like-
 It converts energy formed by compressed air at high pressure into either linear or rotary motion.
 It gives quickly respond in operation which is necessary in Robotics.
 Pneumatic cylinders provide more force & speed per unit size than any other actuator.
 Force speed of pneumatic actuator is easily adjustable & is independent of each other.
 It is most economical when the scale of deployment matches the capacity of the compressor.
 Cost of pneumatic actuator is less as compared to other actuators.
Cellular manufacturing
 It is one of the main tools of Lean Manufacturing, helps to create a concept known as single or onepiece flow.
 Equipment and the workstations are arranged in sequences to allow for a smooth flow of materials and components through
the process.
 The cell is made up of workers and the equipment required performing the steps in creating the product.
 The layout of the equipment and the workstations is determined by the logical sequence of production.
 By grouping similar products into families that can then be processed on the same equipment in the same sequence, cellular
manufacturing offers companies the flexibility to give customers the variety they require.
 Factories converted to cellular manufacturing benefit by the reduction of overproduction and waste, shorter lead time,
improved quality and productivity, improved teamwork and communication.
 The main requirement of Cellular Manufacturing is to ensure that all equipment required for production is operating at 100%
efficiency at all times.
 Through short daily inspections, cleaning, lubricating, and making minor adjustments, minor problems can be detected and
corrected before they become a major problem that can shut down a production line.
 The basic concept of cellular manufacturing is the integration of management practices with technological advances. To be
truly successful requires a thorough understanding of the causes and elimination of waste at all levels, and that means both
operations and processes.
 There are several important considerations involved in order to achieve the best benefits:
 Reduction of lead time
 Utilization of available space
 Maximizing flexibility
 Emphasizing teamwork
 Improving communications
 Productivity and quality improvement