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