Benha University

FACULTY OF ENGINEERING IN SHOUBRA / CAIRO

Mechanical Engineering Dept. Prod. Eng. Section (3rd Year)

Questions of Sheets and Solved Examples on:

Integrated Design Course

1. Define the following expressions:
- Integrated Design
- Weakest element in machine design.

2. Give a classification for the mechanical failure modes in machines.

3. Explain the following:

- The roll of Value Engineering in Mechanical Engineering.
- Group Technology in Machine Elements Design.

4. What are the items of the maintenance Plan?

5. Explain how you can check the spare Parts Supply Chains.

6. Give a layout of a Maintenance Workshop designed to repair the

mechanical equipment of an industrial plant applying the CMMS in
maintenance planning and scheduling.

7. What will be the best offer submitted by three contractors to maintain an

industrial machine realizes 20,000 LE daily profit and it needs
maintenance by contracting three offers are:

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 Contractor Cost ( LE) Time (days)
8. Explain A 4000 4 3
B 6000 3
C 10,000 1
applications of Group Technology (GT) in industry for Standard
or special families of Products.
Keys of answer:
- Classifications
- Coding
- GT Manufacturing Cells (see Slides)

9. Technology development growth

10. Product Life Cycle

11. Explain the Multi Stage Integrated Manufacture Job Plan

12. Explain the role of CMMS in increasing maintenance performance.

13. What are the maintenance activities may be covered by the most CMMS
in practice?

14. What is the maintenance systems applied in industry?

15. Explain the principals of the Total Predictive Maintenance

16. Explain how can you perform a Product Cost Estimation for an Optimum Design

17. Explain the main types of failure probability in mechanical equipment.

18. Explain the following expressions:

- Design theories and philosophers
- The role of Integrated Design in Product Life Cycles
- Forecasting of Technological growth and development

19. Explain the Value Engineering analysis procedure in the following two cases:
- For already produced Standard wooden door for a flat.
- Multi Stage Integrated Manufacture Job Plan for a welded sheet metal

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 standard flat door of high quality and reliability.

20. Explain the main types of failure probability in mechanical equipment.

21. Explain the role of CMMS in increasing maintenance performance.

22. How can you calculate the replacement asset value (RAV)? . If the annual
maintenance cost is 700,000 L.E. and the Maintained Assets Replacement
Value is 20,000,000 L.E. Calculate the (RAV).

23. Give a classification of Engineering Materials

24. Design a coding system for two Technological Groups of bolts and Studs
shown in Figure below if the bolts and stud have the same pitch
and thread dimensions and bolts made from mild and studs made from
hardened steels .

BOLT Nomenclature: Nominal bolt thread diameter (d), Total Length (L),
Threaded Length (b), Pitch (p), Big diagonal (e), Smaller diagonal (s), Hex. Bolt
head height (k).

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 Stud Nomenclature: Nominal bolt thread diameter (d), Total Length (L),
Threaded Pitch (p).

25. Explain methods applying for Improving Quality and Reliability by the
intigrated Dsign course you studied.

26. For the the celluar productive GT cell, shown in the Figure. Shown below
Determine the follwing:
- System Nodes
- System Reliability and its failure rate probability.
- The number of Modules Module
  

Lambda 1 Reliability 0.95

Lambda 2 Reliability 0.90
Lambda 3 Reliability 0.85
Lambda 4 Reliability 0.95

27- What are the differences between Machine Design and Optimum Process Design?
28- Explain the BEP Analysis and calculations
29- Explain the optimum Design
30- The Principle of selection of the optimum manufacturing Processes.

Solved Examples
1- Coding of a Washer in Design for GT

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 2- Explain the following:
- Integrated design
- Methods for integrated design

Answer

Engineering Reliability may be defined in the following ways:

 The idea that an item is fit for a purpose with respect to time
 The capacity of a designed, produced, or maintained item to perform as required
over time
 The capacity of a population of designed, produced or maintained items to
perform as required over specified time
 The resistance to failure of an item over time
 The probability of an item to perform a required function under stated conditions
for a specified period of time
 The durability of an object.

The Ideal and Optimum Design

Optimal designs offer three advantages over suboptimal experimental designs:

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 1. Optimal designs reduce the costs of experimentation by allowing statistical
models to be estimated with fewer experimental runs.
2. Optimal designs can accommodate multiple types of factors, such as process,
mixture, and discrete factors.
3. Designs can be optimized when the design-space is constrained, for example,
when the mathematical process-space contains factor-settings that are practically
infeasible (e.g. due to safety concerns).

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3- Explain the Classification and Coding System in Group

Technology (GT)
The Classification System in Group Technology (GT) is a
Hierarchical Systems depends on the types of products in the
families

Coding System in Group Technology (GT)

The Coding System in Group Technology (GT) is a Coding Systems are:

- Ahlphapitical coding A, CD, ……etc

- Neumerical coding 01, 456, …….etc
- Alphaneumeric coding A001, M987 ….etc

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4- What will be the best offer submitted by three contractors to maintain
an industrial machine realizes 20,000 LE daily profit and it needs
maintenance by contracting three offers are:

Contractor Cost ( LE) Time (days)

A 4000 4
Solution: B 6000 3
C 10,000 1
Cost of Contractor A = 20,000+
4*4000= 36,000 (LE)
Cost of Contractor B = 20,000+ 3*6000= 38,000 (LE)
Cost of Contractor C = 20,000+ 1*10,000= 21,000 (LE)

Contractor C is the best Offer

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 5- Product Cost Estimation for an Optimum Product
Design

Solution:
Product Cost = Total Product Cost (Ct) = Fixed Product Cost (Cf) +

Variable Product Cost (Cv)

6- Define the Weakest element in machine design.

Answer:

Weakest element in machine design:

In the design process which so called weakest element in machine construction when the
design phase is performed. In such case the designers take in their consideration about the
reliable and safe damage of the Machine or Equipment , the Designers considered the
failure theory which consider the theory of failure of the weakest element in machine
that to be damaged and faille first safely with minimum losses to be maintained easily .

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7- Explain the following:

- The roll of Value Engineering in Mechanical Engineering.
- Group Technology in Machine Elements Design.

Answer:

 The roll of Value Engineering in Mechanical Engineering.

Value engineering (VE) is systematic method to improve the "value" of goods or

products and services by using an examination of function. Value, as defined, is
the ratio of functions of quantitative and qualitative variables. Value can therefore
be increased by either improving the function or reducing the costs. It is a primary
tenet of value engineering that basic functions be preserved and not be reduced as
a consequence of pursuing value improvements.

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 The roll of Value Engineering in Mechanical Engineering is as follow to increase
mainly the qualitatin mechanical engineeringive value of the mechanical product
by applying the basics of optimum design:

- Neat and safe design

- Well manufactured

- Selecting good durable , suitable and valuable materials

 Group Technology in Machine Elements Design.

Group technology or GT is a manufacturing technique[1] in which parts having

similarities in geometry, manufacturing process and/or functions are manufactured in one
location using a small number of machines or processes. GT is based on a general
principle that many problems are similar and by grouping similar problems, a single
solution can be found to a set of problems, thus saving time and effort.

The group of similar parts is known as part family and the group of machineries used to
process an individual part family is known as machine cell. It is not necessary for each
part of a part family to be processed by every machine of corresponding machine cell.
This type of manufacturing in which a part family is produced by a machine cell is
known as cellular manufacturing. The manufacturing efficiencies are generally increased
by employing GT because the required operations may be confined to only a small cell
and thus avoiding the need for transportation of in-process parts.[2]

Group technology is an approach in which similar parts are identified and grouped
together in order to take advantage of the similarities in design and production.
Similarities among parts permit them to be classified into part families.

The advantage of GT can be divided into three groups:

1. Engineering
2. Manufacturing
3. Process Planning

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8- What is:
CMMS, CAD/CAM and MRP ?
Answer:
CMMS: Computerized maintenance management Systems
CAD/CAM and MRP: Integrated Computer Aided Design and Computerized
manufacturing Systems and Materials Requirement Planning

9- Explain the following:

- Engineering Reliability
- The Ideal and Optimum Design

Answer:
Engineering Reliability may be defined in the following ways:

 The idea that an item is fit for a purpose with respect to time
 The capacity of a designed, produced, or maintained item to perform as required
over time
 The capacity of a population of designed, produced or maintained items to
perform as required over specified time
 The resistance to failure of an item over time
 The probability of an item to perform a required function under stated conditions
for a specified period of time
 The durability of an object.

Readability Examples
Sample 1 --- a simple series system

In this sample, we only have two series modules.

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1. Input the configuration of the system

Nodes Nom=3 Modules Num=2

Input Node=1 Output Node=3

A=(1,2)
B=(2,3)

Input the numeric value of reliability for each module:

0.9, 0.8

Result:

System Reliability = Ra*Rb

Given Ra = 0.9, Rb = 0.8

Rsystem = 0.72

Failure Probability = (1- Rsystem ) = 0.28

Sample 2 --- a simple parallel system

In this sample, we only have two parallel modules.

1. Input the configuration of the system

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NodesNum=2       ModulesNum=2
InputNode=1      OutputNode=2
A=(1,2)
B=(1,2)

3. Input the numeric value of reliability for each module:

0.9, 0.8

Result
•   System Reliability = 1-(1-Ra)*(1-Rb) Given Ra = 0.9, Rb = 0.8
Rsystem = 0.98

Failure Probability = (1- Rsystem ) = 0.02

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The Ideal and Optimum Design

Optimal designs offer three advantages over suboptimal experimental designs:

4. Optimal designs reduce the costs of experimentation by allowing statistical

models to be estimated with fewer experimental runs.
5. Optimal designs can accommodate multiple types of factors, such as process,
mixture, and discrete factors.
6. Designs can be optimized when the design-space is constrained, for example,
when the mathematical process-space contains factor-settings that are practically
infeasible (e.g. due to safety concerns).

10- Explain how can you perform the Value Engineering analysis?

Key Terms:

- Quantitative analysis
- Qualitative analysis
- VE team

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END

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