SRI SAI RAM ENGINEERING

COLLEGE
(NBA Accredited & ISO Certified Institution)
SAI LEO NAGAR ,WEST TAMBARAM
CHENNAI -44

QUESTION BANK

ME 2402 - COMPUTER INTEGRATED

MANUFACTURING
(Mechanical Engineering – IV Year – VII
Semester)
Prepared by
Mr.S.RAJESH, Mr.G.SWAMINATHAN
 ME2402 COMPUTER INTEGRATED MANUFACTURING

OBJECTIVE:

To gain knowledge about the basic fundamental of CAD.

To gain knowledge on how computers are integrated at various levels of planning
and manufacturing understand computer aided planning and control and computer
monitoring.

UNIT I COMPUTER AIDED DESIGN

Concept of CAD as drafting and designing facility, desirable features of CAD package,
drawing features in CAD – Scaling, rotation, translation, editing, dimensioning, labeling,
Zoom, pan, redraw and regenerate, typical CAD command structure, wire frame modeling,
surface modeling and solid modeling (concepts only) in relation to popular CAD packages.

UNIT II COMPONENTS OF CIM

CIM as a concept and a technology, CASA/Sme model of CIM, CIM II, benefits of CIM,
communication matrix in CIM, fundamentals of computer communication in CIM – CIM
data transmission methods – seriel, parallel, asynchronous, synchronous, modulation,
demodulation, simplex and duplex. Types of communication in CIM – point to point (PTP),
star and multiplexing. Computer networking in CIM – the seven layer OSI model, LAN
model, MAP model, network topologies – star, ring and bus, advantages of networks in CIM

UNIT III GROUP TECHNOLOGY AND COMPUTER AIDED PROCESS

PLANNING
History Of Group Technology – role of G.T in CAD/CAM Integration – part families
classification and coding – DCLASS and MCLASS and OPTIZ coding systems – facility
design using G.T – benefits of G.T – cellular manufacturing.Process planning - role of
process planning in CAD/CAM Integration – approaches to computer aided process
planning – variant approach and generative approaches – CAPP and CMPP systems.
UNIT IV SHOP FLOOR CONTROL AND INTRODUCTION TO FMS
Shop floor control – phases – factory data collection system – automatic identification
methods – Bar code technology – automated data collection system.
FMS – components of FMS – types – FMS workstation – material handling and storage
system –FMS layout- computer control systems – applications and benefits.

UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER

MONITORING
Production planning and control – cost planning and control – inventory management –
material requirements planning (MRP) – shop floor control. Lean and Agile Manufacturing.
Types of production monitoring systems – structure model of manufacturing – process
control and strategies – direct digital control.

TEXT BOOK:
1. Mikell. P. Groover “Automation, Production Systems and Computer Integrated
Manufacturing”, Pearson Education 2001.
REFERENCES:
1. Mikell. P. Groover and Emory Zimmers Jr.,“CAD/CAM”, Prentice hall of India Pvt.
Ltd., 1998.
2. James A. Regh and Henry W. Kreabber, “Computer Integrated Manufacturing”,
Pearson Education second edition, 2005.
3. Chris McMahon and Jimmie Browne, “CAD CAM Principles, Practice and
Manufacturing Management”, Pearson Education second edition, 2005.
4. Ranky, Paul G., “Computer Integrated Manufacturing”, Prentice hall of India Pvt. Ltd.,
2005.
5. Yorem Koren, “ Computer Integrated Manufacturing”, McGraw Hill, 2005.
6. P N Rao, “ CAD/CAM Principles and Applications”, TMH Publications, 2007.
 SRI SAIRAM ENGINEERING COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
ME 2402-COMPUTER INTEGRATED MANUFACTURING
SEVENTH SEMESTER
QUESTION BANK

UNIT I

1. Define CIM.
CIM is the integration of the total manufacturing enterprising through the use of integrated
systems and data communications coupled with new managerial philosophies thatimprove
organisational and personal efficiency.

2. Is CIM a concept or a technology?

CIM is both a concept and technology. For top management, CIM is a concept, ablueprint for
success. For middle managers and line managers, CIM is a technology, a physicalrealization of
resources that are more capable and flexible.

3. What are the concepts of CIM?

Combination of separate applications, such as computer aided design (CAD), computer aided
engineering (CAE), computer aided manufacturing (CAM), robotics, and manufacturing resource
planning (MRP-II). Its objective is to streamline the manufacturing processes and to integrate them with
other business functions (such as accounting, financing, distributing, marketing).

4. List various components of CIM.

Computer Aided Design
Computer Aided Manufacturing
CNC machines.
Flexible manufacturing systems
Robotics
Automated material handling systems
Group Technology
Computer aided process planning
 Manufacture resource planning
Computer control systems

5. Define automation.
Automation maybe defined as the process of having machines follow a predeterminedsequence
of operations with little or no human labour, using specialised equipment and devicesthat perform and
control manufacturing process

6. What is the main objective of CIM?

The main aim of CIM is to use the advanced information processing technology into all areas of
manufacturing industry in order to Make total process more process more productive and efficient.
Increase product reliability.
Decrease the cost of production and maintenance relating to the manufacturing system as well
as to the product.
Reduce the number of hazardous jobs and increase the involvement of well educated and able
humans in the manufacturing ability and design.

7. What do you mean by “Islands of Automation”?

The individually automated workstations or processes are called as Islands of automation. In
other words the term represents the various technologies that facilitate manufacturing automation in
isolation, without having integrated with other manufacturing technologies.

8. Differentiate between the islands approach to automation and CIM.

The primary difference between the islands approach to automation and CIM is that the CIM is global
and the other is local. CIM represents the logical evolution of the islands of automation concept.

9. What is the role of CIM is manufacturing?

CIM is most closely associated with functions in manufacturing engineering such a
processplanning and numerical control (NC) part programming.

10. Define CAD and CAM.

CAD maybe defined as any design activity that involves the effective use if computer tocreate, modify
or document engineering design.
CAM may be defined as an effective use of computers and computer technology in theplanning,
management and control of the manufacturing function.

11. What do you mean by island of software?

When computer software is restricted in its ability to link to other computer softwares it
isknown as island of software.

12. What are the important applications of CIM in manufacturing planning?

Manufacturing planning
Manufacturing control

13. What are the important applications of CIM in manufacturing control?

The applications of computer process control are pervasive today in automated productionsystems.
Quality control includes a variety of approaches to ensure the highest possible quality levels inthe
manufactured product.
Shop floor control refers to production management techniques.

14. What is management?

Management is the process of making decisions and directing the activities of personnel
toachieve stated objective. The objectives are successfully met when efforts are organized
bycommunicating appropriate information for control and readjustment.

15. What is MAP?

Manufacturing automation protocol (MAP) is an implementation of the OSI model. It is
tahardware cum software implementable set of rules that facilitate information transfer
amongnetworked computers and computer based equipments.

16. What are the goals of automation in manufacturing industry?

Process Integration
Improve Productivity
Economize on floor space
Improve quality

17. Define EDI.

Electronic data interchange (EDI) may be defined as the electronic transfer from the computerto
computer (or application to application) of commercial or administrative transactions using anagreed
standard to structure the transaction or message data.

18. What are dedicated and open systems?

The dedicated system refers to a computer system that is dedicated for a specific
application/purpose/machine. Open systems enable any type of computer system to communicate with
any other.

19. What are the benefits of EDI?

Properly installed EDI offers benefits in terms of reduced data errors through the avoidance
of double entry of data, reduced costs through improved business processes, reduced lead time, better
service and customer support through faster and better business processes.

20. What are the key functions of a manufacturing company?

Marketing
Engineering
Production planning
Plant operations
Physical distribution
Business and financial management

21. What is production planning and production control?

Production planning is the preproduction activity. It is the predetermination of themanufacturing
requirements such as manpower, materials, machines and manufacturingprocess.
Production control, through control mechanism tries to take corrective action to match theplanned and
actual production.

22. What is meant by physical distribution?

It may be defined as the broad range of activities concerned with different movement
of finished products from the end of the production line to the customers. These activities include freight
transportation, inventory control, plant warehouse site selection, order processing, market forecasting
and customer service.

23. What are the responsibilities of facilities engineering?

The responsibilities of facilities engineering include plant automation, planning the installation
of new equipment, planning materials flow and related work handling equipments, planning inventory
staging space and arranging storage for materials and tools.

24. List the activities carried out by financial department of a manufacturing industry.
1. Company services
2. Payroll
3. Accounts payable, billing and accounts receivable
4. Cost accounting
5. Financial planning and management
6. Strategic planning

25. Specify the activities carried out by marketing department is manufacturing industry.
1. Doing market research

2. Forecasting demand and sales

3. Analysing sales, tackling the performance of products and of market segments

4. Arranging sales activities and advertising campaign

5. Developing and managing marketing channels

6. Managing sales personnel, sales plans and promotions

PART-B (16 MARKS)

1. Briefly explain the nature and role of the elements of CIM system.

2. Describe the basic activities that must be carried out in a factory to convert raw

materials into finished product.

3. Describe the changing manufacturing and management scenario after the

development of CIM.

4. What do you understand by term islands of automation? List and explain any six

islands of automation.

5. List some CIM hardware and CIM software and bring out the various benefits of

implementing a CIM system.

 UNIT II

1. Define Group Technology (GT).

Group Technology (GT) is a manufacturing methodology in which identical or similar
components grouped processed together during design, process planning and manufacturing
so that a wide variety of components can be manufactured, at the least expense of time, inventory, man
hours and material handling.

2. List out the stages in Group Technology.

Production planners to setup the GT database. Grouping the parts or components into part-families with
some similar characteristics. Re-design the shop-floor arrangement according to common shape,
function or manufacturingprocess and tooling.

3. Define Part family

Partfamily is defined as" collection of parts which are similar in terms of geometrics
hape, size, and similar processing steps required in manufacturing, so flow of
materials through the plant improves"

4. What are the methods available for solving problems in GT?5. List the general methods used for
grouping parts into families.
Visual Inspection
Parts classification and coding system
Production flow analysis.

6. What is PFA?
Production flow analysis (PFA) is a method for identifying part families and associated
machine groupings that uses the information contained on production route sheets rather on part
drawings.

7. List the steps involved in PFA.

Data Collection
Sortation of process routings
Preparation of PFA chart
Cluster analysis.
8. What are the 3 basic code structures used in GT applications?
1. Hierarchical codes
2. Attribute codes
3. Decision tree-codes.

9. What is the main difference between hierarchical code and attribute code structures?
In hierarchical structure, the interpretation of each symbol in the sequence depends on the value
of preceding symbols. Whereas in attribute/polycode structure, the interpretation of each symbol in the
sequence does not depend on the value of preceding symbols.

10. List any six coding systems that are widely recognised in industries.
1. Optiz classification system
2. MICLASS system
3. DCLASS system
4. KK-3 System
5. CODE system
6. CUTPLAN system

11. What is cellular manufacturing?

Cellular manufacturing (CM) is an application of GT in which dissimilar machines have
beenaggregated into cells, each of which is dedicated to the production of a part family.

12. List any four design considerations guiding the cell formation.

Parts/products to be fully completed in the cell.

Higher operator utilisation
Fewer operations than equipment
Balanced equipment utilisation in the cell.
13. What is Process planning?
Process planning consists of preparing a set of instructions that describe how to
fabricate apart or build an assembly which will satisfy engineering design specifications. Process
planning is the systematic determination of the methods by which product is to be manufactured,
economically and competitively.

14. List the activities associated with process planning

1. Analysing finished part equipments
2. Determining operating sequence
3. Selecting machines
4. Selecting material parameters
5. Calculating process times
6. Documenting process planning

15. What is meant by CAPP?

CAPP refers to computer aided process planning. CAPP is used to overcome the drawbacks
of manual process planning. With the use of computers in the process planning, one can reduce the
routine clerical work of manufacturing engineers. Also it provides the opportunity to generate rational,
consistent and optimal plans.

16. What are the approaches the CAPP will recognize?

Two approaches to CAPP are traditionally recognized: the variant approach and the
generative approach. Many CAPP systems combine both approaches.

17. Why CAPP systems are called as variant system?

The investment is less and the development time is shorter. Especially for medium sized
companies which want to establish their own research groups.
The development costs and hardware costs are lower. Especially for some small companies where the
products do not vary much and who still have process planners.

18. Give the main component of generative CAPP systems.

CAPP system contains of two main components. Manufacturing data base (part description,
machine tool library etc.) Decision logic (to represent the process planner)
19. What are the basic approaches of CAPP?
1. Retrieval (or variant) CAPP system
2. Generative CAPP system.

20. What are the results of Process Planning?

Routings which specify operations, operation sequences, work centres, standards, tooling and
fixtures. This routing becomes a major input to the manufacturing resource planning system
to define operations for production activity control purpose and define required resources for
capacity requirements planning purposes.
Process plans which typically provide more detailed, step-by-step work instructions including
dimensions related to individual operations, machining parameters, set-up instructions, and quality
assurance checkpoints.
Fabrication and assembly drawings to support manufacture (as opposed to engineering drawings to
define the part).

21. What are the factors should be considered in selection of tooling?

The type and amount of the material to be cut.
The surface finish required
The rigidity and shape of the part.
The capacity and condition of the available equipment
The required production volume (high volume jobs usually permit optimum speeds
and feedswhile lot jobs may use lower speeds to achieve completion of the lot without regrinding of
thecutting tool). The succeeding operations such as finish grinding and honing

22. What are the prerequisites for process planning?

1. Part list
2. Annual demand/ batch size
3. Accuracy and surface finish requirement
4. Equipment details
5. Data on cutting fluids, tools, jigs and fixtures, gauges.
6. Standard available stock sizes.
7. Machining data, data on handling and setup.
23. What is the weakness of PFA?
The weakness of production flow analysis (PFA) that the data used are derived from
production route-sheets. But the process-sequences have been prepared by different process lanners and
the difference is reflected on to these route-sheets.

24. List some commercial variant and generative CAPP software systems
Some of the commercial variant CAPP systems include CUTPLAN. COMCAPP V,
DCLASSand INTELLICAP.
Some of the commercial generative CAPP systems include AUTAP, CMPP, GENPLAN andLOCAM.

25. What is CMPP?

The CMPP stands for computer-managed process planning. It is a commercial
generativeprocess planning system capable of automatically making process decisions

PART-B (16 MARKS)

1. Explain about Optiz classification and coding system.

2. Define variant CAPP systems. Explain the general procedure for using one of the variant

CAPP systems.

3. Discuss about MICLASS and DCLASS classification and coding system.

4. Briefly discuss the various benefits of implementing a GT in a firm. Also bring out the

Advantages and limitations of using GT.

5. Explain in detail the process planning activities.

 UNIT III

1. Gives the major objectives of a Production Management Systems (PMS).

The two major objectives of a production management system (PMS) are planning and
controlling of the manufacturing operations. The Planning Stage deals initial Production planning,
development of master schedule, capacity planning, and MRP.

2. Define SFC.
Shop Floor Control (SFC) is defined as the important manufacturing activity that will control
flow of the product and materials on the factory flow involving the quantities, types of parts, schedule
dates, priorities and the status of jobs and orders.

3. What are the primary functions of SFC?

Functions of SFC system
→ Priority control and assignment of shop orders
→ Maintain information on work in process for MRP
→ Monitor shop order status information
→ Provide production output data for capacity control purposes

4. What are the phases of SFC?

The three phases or modules are:
1. Order Release
2. Order Scheduling
3. Order Progress

5. What is the purpose of FDS?

The purpose of the Factory Data Collection (FDS) system in shop floor control is to provide
basic data for monitoring order progress. In a computerized SFC system these data are submitted to the
order progress module for analysis and generation of work order status reports and exception reports.

6. What is an Automatic Data Capture (ADC) method?

Automatic Identification methods is also known as Automatic Data Capture (ADC) it is refers
to the technologies that provides direct entry of data into the computer or other control systems without
using a keyboards. These technologies require no human involvement in the data capture and entry
process.

7. What are the technologies used in ADC?

1. Optical
2. Magnetic type
3. Electromagnetic type
4. Smart card
5. Touch techniques
6. Biometric

8. What Bar code consists?

The bar code consists of a thick and narrow coloured bars separates thick and narrow spaces
separating the bars. The pattern of bars and spaces is co to represent alphanumeric characters.

9. What are the types of Bar code?

Bar codes divide into two basic types:
1) Linear, in which the encoded data are read using a linear sweep of the scan
2) Two-dimensional, in which the encoded data must be read in both directions

10. What is scheduling?

Operation scheduling is concerned with the problem of assigning specific jobs to specific
work centres on a weekly, daily, hourly basis. Operation scheduling = Machine loading + Job
sequencing

11. What is dispatching?

Dispatching is the function concerned with issuing the individual orders to the machine operators.

12. What are the phases of SFC?

Order Release
Order Scheduling
Order Progress
13. What is the philosophy of just in time?
It is a management philosophy that strives to eliminate sources of manufacturing waste
byproducing the right part in the right place at the right time.

14. What do you mean by priority control in PPC?

The term priority control is used in production planning and control to denote the function that
maintains the appropriate levels for the various production orders in the shop.

15. Define term machine loading and job sequencing.

Allocating orders to work centres is knows and machine loading Determining the priority in
which the jobs should be processed is termed as job sequencing.

16. What is the purpose of factory data collection system?

The purpose of the Factory Data Collection (FDS) system in shop floor control is to provide
basic data for monitoring order progress. In a computerized SFC system these data are submitted to the
order progress module for analysis and generation of work order status reports and exception reports.

17. What is FDS?

The factory data collection system consists of various paper documents, terminals and
automated devices throughout the plant for collecting data on shop floor operations.

18. What is DAS?

A data acquisitions system (DAS) is a computer system used to automatically collect data from
a process or piece of equipment. They either perform an analysis data or transmit the data to
another computer for processing and analysis.

19. Define FMS.

A Flexible Manufacturing System (FMS) is an individual machine or group of machines served
by an automated materials handling system that is computer controlled and has a tool handling
capability.
20. What are the Objectives of FMS?

To provide flexible manufacturing facility for pan family components.

To provide the benefits of grouping the operation in single location.
To provide the flexibility in producing small and medium parts.
To maximize the utilization of facilities.
To have a good management control.

21. What are the components of FMS?

1. Processing stations or workstations
2. Material handling and storage
3. Computer control system
4. Human labour

22. What are the FMS layout configurations?

1. In-line layout
2. Loop layout
3. Ladder layout
4. Open fie1d 1ayout
5. Robot-centred cell.

23. What are the functions of computers in FMS?

1. Workstation control
2. Distribution of control instructions to workstations
3. Production control
4. Traffic control
5. Shuttle control
6. Work piece monitoring
7. Tool control
8. Performance monitoring and reporting
9. Diagnosis
24. List any two advantages and disadvantages of FMS implementation.
Advantages
Faster, lower-cost changes from one part to another which will improve capital utilization.
Lower direct labour cost, due to the reduction in number of workers.
Disadvantages
Substantial pre-planning activity.
Expensive, costing millions of dollars.

25. List the applications of FMS.

1. Machining
2. Assembl y
3. Sheet-metal press-working
4. Forging
5. Plastic injection moulding
6. Welding
7. Textile machinery manufacture
8. Semiconductor component manufacture

PART B (16 MARKS)

1. Explain the component of FMS and FMS layout configuration.

2. Explain three phases of shop floor control.

3. Write an engineering brief about the various types of automatic identification technologies.

4. Write short notes on various materials handling equipment that are commonly found in a

FMS.

5. What is MRP? Explain the inputs to MRP and various MRP outputs. Also list the various

benefits of MRP.
 UNIT IV

1. Why are company models necessary?

They are necessary because they characterise a company in different ways to analyse the
various characteristics such as complexity of their operation, the large amount of data involved, their
cyclic operation, uncertain or variable behaviour of certain parts etc.

2. What are the specific characteristics that have to be incorporated in the CIM system models?
1. The complexity of their operation
2. The large amount of data involved
3. Their cyclic operation
4. Uncertain or variant behaviour of certain behaviour
5. Their changing nature to accommodate new markets
6. Involvement of humans as part of the system

3. What three forms of modelling tool are desirable to characterise company operation?
1. As a representation of the system
2. As a dynamic model
3. As a executable model

4. What are the IDEF modelling tools?

The acronym IDEF stands for Integrated CAM definition. The IDEF modelling tools cover
arrange of uses from function modelling to information, simulation, object-oriented analysis and design
and knowledge acquisition.

5. What are the types of IDEF models?

IDEF refers to a family of modeling language, which cover a wide range of uses, from
functional modeling to data, simulation, object-oriented analysis/design and knowledge acquisition.
Eventually the IDEF methods have been defined up to IDEF14:
6. Define E-R diagram.
A graphical representation of entities and their relationships to each other, typically
used in computing in regard to the organization of data within databases or information
systems. An entity is a piece of data-an object or concept about which data is stored.
7. What are ER diagrams?

The entity-relationship (ER) diagrams are used to capture the relationships between entities.

8. What is an activity cycle diagram?

Activity cycle diagram (ACD) is a modelling approach designed to represent the dynamics of a system.

9. Which IDEF tool is an extension of ER diagram for manufacturing information?

IDEF1 modelling tool is extension of ER diagram for manufacturing information. This is
because, as with ER diagram, in IDEF1 model the data is characterised in terms of entity classes.

10. Write about CIMOSA.

CIMOSA defines a model-based enterprise engineering method which categorizes
manufacturing operations into Generic and Specific (Partial and Particular) functions.

11. How does CIMOSA separate function?

1. The CIMOSA modelling Framework in which specific and generic functions are-clearly
separated.
2. The CIMOSA Integrating Infrastructure supporting execution of Generic functions and linking
specific functions. It is effectively the communication system which interconnects all of the
functions in the CIM system.

12. What do you mean by the term CIM architecture?

The term ‘CIM architecture’ often applied to a template which can be used for the design and
implementation of a CIM system.

13. What is the role of process planning in CIM architecture?

The process planning function can ensure the profitability or non profitability of a part being
manufactured because of the myriad ways in which a part can be produced.

14. What is data dictionary?

A data dictionary is a catalogue of all the data in the database. The dictionary may include cross-
reference information explaining which programs use which data and which department need which
reports.
15. Explain the terms ‘data repository’ and ‘data store’.
The data represented within a model needs to be stored and to be accessible by the users either
directly or through any application program. The interface between user applications and stored data
within CIM architecture can be conceptualised as a data repository. The data items themselves are
viewed as being held in a data store.

16. What is the function of repository?

The main function of the repository is to isolate applications from changes in the integration
methods, reducing the need for application maintenance.

17. What is production data management (PDM)?

PDM is concerned with the management of the life-cycle data of products

PART-B (16 MARKS)

1. Explain the components of a Local Area Network and network topologies.

2. Explain the CIMOSA model with a neat diagram. Describe product data management and
its advantages.

3. What is data communication? Identify and briefly explain the five components of a data
Communication system.

4. Compare the two methods of serial transmission. Discuss the advantages and
disadvantages of each.

5. Writes short notes on: Ethernet, token ring, and FDDI.

6. What is network management? Discuss the various functions of it.

 UNIT V

1. What are the two types of channel?

Two basic channel types are used in data communications. They are
i) Analog type
ii) ii) Digital type

2. List the characteristics of channel.

The channel characteristics are

i) Electronic noise
ii) Signal attenuation
iii) Analog channel capacity
iv) Digital channel capacity

3. What is channel bandwidth?

An analog signal can vary from a minimum to maximum frequency. The difference
between the lowest and the highest frequency of a single analog is the bandwidth of that
signal. The mathematical formula for frequency is,

Frequency = Wavelength * Velocity

4. What are two types of transmission mode?

There are three transmission modes available. They arc

i) Simplex
ii) Half-duplex
iii) Duplex.

They can be applied to both analog and digital channels.

5. What is modulation?

The process of varying amplitude or frequency or phase of the carrier signal in

Accordance with the instantaneous value of the information signal is known as modulation.
6. What is demodulation?

The process of separating the original information signal from the modulated carrier
signal is known as demodulation. It is the inverse process of modulation.

7. What are the reasons for using LAN?

1. LAN allows for decentralization of various data processing functions.

2 LAN allows departments to share hardware.

3. LAN allows for the electronic transfer of text.

4. LAN allows for communication between organizations.

5. LAN allows information to be shared.

8. What are the features of LAN?

i) Compatibility

ii) Protected Mode Operation

iii) Internetworking

iv)Growth Path and Modularity

v) System Reliability

9. Define topology and explain its classification.

The pattern of interconnection of nodes in a network is called topology. Topology can

also be defined as the geometric arrangement of workstations and the links among them.

The types of LAN topology are

i) Bus topology
ii) Ring topolgy
iii) Star topology
 iv) Mesh topology

10. What are the Advantages of LAN?

1. LAN is suited to any type of application.

2. It provides data integrity.
3. Any number of users can be accommodated.
4. A LAN can fit any site requirements.
5. It is flexible and growth-oriented.
6. LAN provides a cost-effective multi user computer environment.
7. Data transfer rates are above 10 Mbps.
8. It allows sharing of mass central storage and printers.
9. It allows file/record locking.

11. Define OSI.

Open systems interconnection (OSI) reference model is an international standards

organization (ISO) standard that specifies the conceptual structure of systems that are to
communicate with each other.

12. List out the layers of OSI model.

Seven layers in OSI model

i) Physical layer

ii) Data link layer

iii) Network layer

iv) Transport layer

v) Session layer

vi) Presentation layer

vii) Application layer

13. What are the functions of physical layers?

The physical layer consists of the hardware that drives the network and circuits.

14. What is the function of data link layer?

The data link layer handles the task of transferring information across the physical
link by sending blocks of data.

15. What is the function transport layer?

The transport layer provides transparent transfer of packets (data) to and from the
session layer without disruption.

16. What is the role of application in OSI model?

The application layer provides the user interface to the networking system.

17. What is gateway?

A gateway device is a special-purpose computer, a workstation with associated

software, or a software module that runs as a task in a mainframe. It is essentially a protocol
converter that facilitates the connection of two dissimilar network architectures. Gateways are
integration tools to permit end-to-end communications.

18. List the application protocols of TCP/IP.

A number of application protocols and user applications have been developed based
on TCP/IP. These include Telnet, FTP, Network File System (NFS), Simple Mail Transfer
Protocol (SMTP), and Simplified Network Management Protocol (SNMP).

19. How data’s are classified in engineering/manufacturing environment?

Data encountered in a manufacturing environment can be classified into 4 basic types

a) Resource data, which describes the resources involved in production, such as machines
and tools.

b) Product data, which consists of graphic, text and numeric data.

c) Operational data, which describes the events of production, such as schedules and lot
sizes.
d) Production data, which describes how the parts are to be manufactured.

20. What is database?

A database is a collection of files as an organized assembly of information that users

can access for various purposes; that is, adding, deleting, or modifying data.

21. What is data model?

A data model is a logical representation of a collection of data elements. Data models

are the basic building blocks for designing all databases.

22 What is DBMS?

DBMS stands for Database management system. A program which lets you manage
information in databases. The program we use to organize our data and the actual data
structure we create with that program.

23. What is Primary key?

A key is used to represent unique value in a table. For example, in student table every
student has unique identification such as ID.

24. What is foreign key?

A key used in one table to represent the value of a primary key in a related table.
While primary keys must contain unique values, foreign keys may have duplicates. For
instance, if we use student ID as the primary key in a Students table (each student has a
unique ID), we could use student ID as a foreign key.

25. What is normalization?

The process of structuring data to minimize duplication and inconsistencies. The

process usually involves breaking down a single table into two or more tables and defining
relationships between those tables. Normalization is usually done in stages, with each stage
applying more rigorous rules to the types of information which can be stored in a table.
27. Mention the different levels of data modelling.

The Data structures are created within a database. The extent of the relationships
among them, plays an important role in determining the effectiveness of DBMS. Therefore
the database design becomes a crucial activity in the database environment. The task of
Database design is made simpler when data models are used. Models are ''Simplified
abstractions of real-world events or conditions". For example, such abstractions will enable
us to explore the characteristics of entities and the relationships that can be created among
such entities. If the models are not logically sound, the database designs derived from them
will not deliver the database system's promise of effective information drawn from an
efficient database.

28. What is Network Data Model?

A network data model is simply a graph wherein nodes represent unique records, and
links between nodes represent association between the corresponding records.

29. What is Hierarchical Data Model?

The hierarchical data model is similar to the network data model except that the
relationships among the records are represented in the form of tree structure.

30. What is Data Associations?

A link describes an association between two records. The following are the different
types of data associations used in DBMS in manufacturing scenario.

1. One-to-one association

2. One-to-many association

3. Many-to-many association

31. List out the Database operators.

To manipulate data in a relational database, three basic operations can be applied to the
tables. These are:

• Selection,

• Projection
• Join.

PART-B (16 MARKS)

1. Explain about MAP/TOP.

2. Explain manufacturing Automation Protocol.

3. Explain Technical Office protocol.

4. Explain the features of a database management system and database model

5. Describe about the following

a) Database operators.

b) Relational databases

6. What are the three levels of architecture of a database system? Describe them.
 B.E/B.TECH DEGREE EXAMINATION NOVEMBER/DECEMBER 2011

Seventh Semester

Mechanical Engineering

ME 2402- COMPUTER INTEGRATED MNUFACTURING

(Regulation 2008)

PART-A

1. List any two reasons for using a CAD system.

I. To increase the productivity of the designer.

II. To improve the quality of design.
III. To improve communication
IV. To create a database for engineering

2. What are the components of a CAD system?

1. Geometric modeling.
2. Design analysis and optimization
3. Design review and evaluation and
4. Documentation and drafting.

3. List any two benefits of CIM.

Tangible benefits Intangible benefits

 Higher profits  Improved customer service.

 Improved quality  Greater flexibility
 Shorter flow times  Greater responsiveness
 Reduced inventory levels  Improved competitiveness
 Shorter vendor lead time.  Safer working environment

4. What are the various network topologies?

1. Star
 2. Tree
3. Bus
4. Ring
5. Hybrid

5. State the role of GT in CAD/CAM integration.

GT applications provide a common database for effective integration of CAD and

CAM, which leads to successful implementation of CIM.

For the effective integration of CAD and CAM one needs to integrate the
information used by all the departments in a shop such as
design,manufacturing,quality,etc.GT provide the much needed common language for the
users. It gives a means to structure and save information about parts, such as design and
manufacturing attributes ,processes ,and manufacturing capabilities.

6.List any two benefits of CAPP.

The benefits of implementing CAPP includes the following

1. Process rationalization and standardization

2. Productivity improvements
3. Product cost reduction
4. Elimination of human error
5. Reduction in time

7.Mention any two methods used to collect data from the shop floor.

1.Manual/clerical data input techniques

I. Job traveller
II. Employee time sheet
III. Operation tear strips
IV. Prepunched cards

2. Data collection terminals

I. Push button keyboards

II. Keyboards based terminals
 3.Automated input techniques

I. Optical bar code readers

II. Magnetic card readers
III. Magnetised or bar-code cards

8.Write any two applications of FMS?

1. Machining
2. Assembly
3. Sheet metal press working
4. Forging
5. Plastic injection moulding.

9. Define lean manufacturing.

Lean manufacturing may be defined as an adaption of mass production in which

workers and work cells are made more flexible and efficient by adapting methods that
reduces waste in all forms.

10. What are the components of DDC?

1. Transducers, sensors, and associated instrumentation

2. Actuators
3. Digital computers
4. Analog-to-digital converter
5. Digital-to-analog converter
6. Input and output multiplexers.

Part-B

11. (a) Describe the application of computers for design.

Applications

1. Design
 Assembly layout
 New part design
 Standard part library
  Tolerance specification
 Interface and clearance specification
 Part relations in an assembly
2. Analysis
 Interference checking
 Fit analysis
 Weight and balance
 Volume and area properties
 Structural analysis
 Kinematics analysis
 Tolerance stacking
3. Documentation
 Drawing generation
 Technical illustration
 Bill of materials
 Image rending
4. Manufacturing
 Process planning
 NC part program generation
 NC part program verification
 NC machine simulation
 Inspection programming
 Robot programming and verification
 Factory layout
5. Management
 Review and release
 Engineering changes
 Project control and monitoring
 Selection of standard parts and assemblies
 Design standards
 11. (b) (1) Explain any two drawing features in CAD.

Some of important drawing features in CAD are

 Scaling
 Rotation
 Translation
 Editing
 Dimensioning
 Labeling
 Zoom
 Redraw

1. SCALING;

 Scaling features is used to change, increase or decrease, the

size of an object.
 Scaling can be achieved by multiplying the orginal
coordinates of an object by the scaling factor.
 Scaling transformation are 2D and 3D transformation.
 IN AutoCAD package, the SCALE command is used to
shrink or enlarge the already existing drawing objects by
specifying a scale factor.

2. ROTATION:

 Rotation refers to the movement of an object in such a way

that the distance between a certain fixed point and any
given point of that body remains constant.
 In AutoCAD package, the ROTATE command is used to
rotate the selected objects through a specified angle about a
phase point.
(b) (2), Name the types of modeling in CAD? Explain about any one of them.

The types of modeling in CAD are

 Geometric modeling
 Wireframe modeling
 Surface modeling
 Solid modeling.

GEOMETRIC MODELLING:

 The geometric modeling is the computer compatible mathematical

description of the geometry of the object.
 This mathematical description allows the image of the object to be
displayed and manipulated on the computer screen and also it can be
stored in the memory and retrieved back and displayed on the computer
screen whenever required.

12. (a) (1) Explain the model of CIM.

 CIM is a broad term describing the computerised integration of all aspects

of design, planning, manufacturing, distribution, and management.
 CIM includes all the engineering functions of CAD/CAM but also
includes the business functions of the firm as well.
 CIM is a methodology and a goal, rarther than an assemblage of
component and computers.
 The purpose of CIM is to be enable the company to transform ideas into a
high quality products in the minimum time and at minimum cost and the
CIM goes beyond the scope of FMS or CAD/CAM system. The concept
is to integrate information from marketing, entry maintenance,
accounting, shipping, and so on.
 All the CIM technologies are tied together using a network and integrated
database. The data integration allows CAD systems to be linked to
computer aided manufacturing, numerical control part programmes , and
 manufacturing planning and control systems can be linked to be
automated material handling systems to facilitate material handling.
 CIM consists of subsystems that are integrated into a whole. These
subsystems consists of following:
I. Product design
II. Manufacturing planning
III. Manufacturing control
IV. Business planning and support.
 These subsystems are designed, developed, and applied in such a manner
that the output of one system serves as the input of another system.
Organizationally, these subsystems are usually divided into two functions.

1. Business planning functions: they include activites such as

forecasting, scheduling, material-requirements planning, invoicing, and accounting.

2. Business execution function: They include production and

process, control, material handling, testing, and inspection.

(2) List the CIM data transmission methods. Explain about any two of them.

 The transmission of binary data across a link can be accomplished either in

parallel mode or serial mode.
 In parallel mode, multiple data are sent with each clock pulse. While, in
serial mode, one bit is sent with each clock pulse.
1. PARALLEL TRANSMISSION:
 The mechanism for parallel transmission is conceptually very simple.’n’
wires are used to send ‘n’ bits at one time.As each bit has its own
wire,all ‘n’ bits of one grop can be transmitted with each clock pulse
from one device to another.
 Parallel transmission works for n=8.Typically all the wires are bundled
in a cable with a connector at each end.
 The advantage of parallel transmission is speed. Parallel transmission is
faster than serial transmission but the cost is higher than serial
transmission.As it is expensive, it is usually limited to short distance.
2. SERIAL TRANSMISSION;
  In serial transmission, one bit follows another, so only one
communication channel is required.
 The advantage of serial order parallel transmission is that with only one
communication channel, serial transmission reduces the cost of
transmission over parallel by a factor ‘n’.
 Since communication within devices is parallel, conversion devices are
required at the server end and receiver end.
 Serial transmission occurs in two ways
I. Asynchronous transmission.
II. Synchronous transmission.

[OR]

(b) (1), Describe point -to-point type of communication in CIM.

Star Topology;

 In a star topology, each devices has a dedicated point –to-point link

only to a central controller, usually called a hub.
 The star topology, also known as point-to- point connection, links each
device directly with the others.
 This topology does not allow direct traffic between devices. if one
device wants to send data to another,it sends the data to the hub, which
then relay to the other connected devices.

ADVANTAGES;

1. In a star,each device needs only one link and one I/O port to connect it to any number
of others.
2. It is very robust. Because each device has an independent connection to the central
hub, the network can continue to function if any of the individual nodes fails.
3. This topology has minimum data traffic along the cables for optimum performance.

DISADVANTAGES:

1. If the hub goes down, then the entire network will fail.
2. More cabling is required in a star than tree, ring, or bus topology, this is because
each device in star directly connected to the center.
 3. The addition of a new device to a star network involves a connection all the way to
the central hub.

(2), Explain LAN model network in CIM.

LOCAL AREA NETWORK;

 A local area network is a privately owned communications network that

serves users within a confined geographical area.
 The range is usually within a mile-perhaps one office, one building, or a
group of buildings close together,as a college campus.
 The LAN is usually privately owned and links the devices in a single
office, building, or campus. Depending on the needs of an organization
and the type of technology uses, a LAN can be as simple as two PCs and a
printer in someone’s home office, or it can extend throughout a company.
 LAN s are designed to allow resources to be shared between personal
computers or workstations. The resources to be shared can include
hardware,software or data.
 In many business environments, a LAN links a work group of task-related
computers, for example, engineering workstations or accountingPCs.
 Traditionally, LANs have data rates in the 4 to16 Mbps range.Today,
however, speeds are increasing and reached 100 Mbps with gigabit
systems.
 The main advantage of LAN is to enable organizations to realize large
productivity
gainsand cost savings through the inherent efficiencies of resource sharing

13. (a) (1) Explain the various DCCLASS coding systems.

 DCCLASS stands for Design and Classification Information Systems.It

was developed at Brigham Young University.
 The DCLASS pare family code is comprised of eight digits partitioned
into five code segments.
 As could be,
 The first segment(three digits) is used to denote the basic
shape
  The second segment(4th digit) is used to specify the
complexity of the parts
 The third segment (5th digit) is used to specify the overall size
of the coded part.
 The fourth segment (6th digit) represents precision.
 The final segment (two digits) is used to denote the material
type.
 The advantage of this system is that it can be easily computerized and
hence can be used as commercial coding system.

(2) How a facility is designed using GT?

 Once parts have been grouped into part families by parts classification and
coding or production flow analysis, the next problem would be
determining how to arrange the machines in the shop.
 Facility layout, also known as plant layout, refers to the physical
arrangements of production facilities. It is the configuration of
departments, work centres, and equipment in the conversion process.
 The objective of facility layout is to design a physical arrangements that
most economically meets the required output quantity and quality.
 There are three basic ways to arrange machines in a shop.They are
1. Line (or product) layout,
2. Functional (or process) layout,and
3. Group (or combination) layout.

[OR]

(b)What are the various approaches to CAPP? Explain them.

The two general approaches to process planning are;

1.Manual process planning and

2. Computer Aided Process Planning(CAPP).

I. Retrieval CAPP system, and

II. Generative CAPP system.
MANUAL PROCESS PLANNING

In traditional process planning systems the process plan is prepared manually.

The task involves examining and interpreting engineering drawings, making decisions on
machining processes selection, equipment selection, operations sequence, and shop practices.
Therefore, the manual process plan is very much dependent on the skill, judgement and
experience of the process planner.That’s why if different planners were asked to develop a
process plan for the same part, they would probably come up with different plans.

ADVANTAGES;

 Manual process planning is very much suitable for small scale companies with
few process plan to generate.
 This method is highly flexible.
 This requires low investment costs.

DISADVANTAGES;

 Manual process planning is a very complex and time consuming job requiring
a large amount of data.
 This method requires the skilled process planner.
 More possibilities for human error because tis method depends on the
planner’s skill, judgement and experience.
 It increases paper work.
 Inconsistent process plan result in reduced productivity.

COMPUTER AIDED PROCESS PLANNING(CAPP);

In order to overcome the drawbacks of manual process planning, the

computer aided process planning is used. With the use ofcomputers in the process planning,
one can reduce the routine clerical work of manufacturing enginners. Also it provides the
opportunity to generate rational, consistent and optimal plans. In addition, CAPP provides the
interface between CAD and CAM.

Benefits of CAPP;

The benefits of implementing CAPP include the following;

 1. Process rationalization and standardization: CAPP leads to more logical and
consistent process plans than manual process planning.
2. Productivity improvements: As a result of standard process plan, the productivity is
improved (due to more efficient utilization of resources such as machines, tooling and
labour).
3. Product cost reduction: Standard plans tend to result in lower manufacturing costs
and higher product quality.
4. Elimination of human error
5. Reduction in time: As a result of computerizing the work, a job that used to take
several days, is now done in a few minutes.
6. Reduced clerical effort and paper work
7. Improved legibility: Computer- prepared route sheets are neater and easier to read
than manually prepared route sheets.
8. Faster response to engineering change: Since the logic is stored in the memory of the
computer, CAPP becomes more responsive to any changes in the production
parameters than the manual method of process planning.

14. (a) What are the phases of shop floor control system? Explain them.

The three important phases of SFC are;

1. Order release,
2. Order scheduling, and
3. Order progress.
1. Order Release
 This order release phase provides the documentation needed to process
a production order through the factory.
 The collection of documents is sometimes referred as the shop packet.
 The shop packet for an order consists of;
i. Route sheet – used to list the sequence of operations and
tools required.
ii. Material requisitions- used to get necessary raw materials
from inventory.
iii. Job cards- used to report the labour for each operation on the
route sheet.
 iv. Move tickets – used to move the parts between the work
centres.
v. Part lists – required for assembly jobs.
 In a typical factory which works on manual processing of data the above
documents move with the production order and are used to track the
progress through the shop. In a CIM factory, more automated methods
are used to track the progress of the production orders.

2. Order Scheduling
 The second phase of shop floor control is the order schedulingmodule,
which follows directly from the order release module.
 In this phase, the order scheduling module assigns the production orders
to the various work centres in that plant. In other words, order
scheduling executes the dispatching function in production planning and
control.
 The order scheduling module prepares a dispatch list that indicates
which production order should be accomplished at the various work
centres. It also provides the information about relative priorities of the
different jobs by showing the due dates for each job. By following the
dispatch list in making work assignments and allocating resources in
different jobs, the master schedule can be best achieved.
 The two inputs required to the order scheduling are
I. The order release, and
II. The priority control information
 Two elements of order scheduling: The order scheduling module is used
to solve the following two problems in production controls;

1. Machine loading: Allocating orders to work centres is

known as machine loading. The term shop loading is used when loading of all machines in
the plant are done.

2. Job sequencing: Determining the priority in which the jobs

should be processed is termed as job sequencing. In most cases, each work centre will have a
queue of orders waiting to be processed. This queue problem can be solved by job
sequencing.

 To determine the sequence, priorities are given to the jobs in the queue,
and the jobs are processed in the order of their relative priorities.
 Priority sequencing rues, also known as dispatching rules, have been
develop to establish priorities for production orders in the plant. Some of
the commonly used priority sequencing rules .

3. Order progress:

 The third and final phase of SFC is order progress phase.

 The order progress phase monitors the status of the various orders in the
plant. Work-in-progress, and other characteristics that indicate the
progress and performance of production.

 Order progress collects data from shop floor and generates reports to
assist production management. In other words, the function of order
progress module is to provide information that is useful in managing the
factory based on data collected from the factory.

(b) (1) What are the components of an FMS? Explain.

Four basic components of a FMS are:

1. Workstations,
2. Material handling and storage system,
3. Computer control system, and
4. Human resources

1. WORK STATIONS;
 The workstations used in FMS depends upon the type of product manufactured
by the system. In metal cutting/machining systems, the principle processing stations are
usually CNC machines tools. In addition, a FMS requires other several machines for
completing the manufacturing. Yhe types of workstations that are usually found in FMS are;

i. Load/unload stations,
ii. Machining stations,
iii. Assembly workstations,
iv. Inspection stations, and
v. Other processing stations.

2. MATERIAL HANDLING AND STORAGE SYSTEM:

 Material handling and storage system is the second main component of

an FMS.
 Generally, requirements set against the FMS material handling and
storage systems include part transportation, raw material and final
product transportation, and storage of workpieces, empty pallets,
auxiliary materials, wastes, fixtures and tools.
 They are
i. Functions of the material handilingsysyem,
ii. Types of FMS layout, and
iii. Types of handiling equipment used in FMS.

3. COMPUTER CONTROL SYSTEM:

 The third major component of FMS is the computer control system.
 In flexible manufacturing systems, computers are required to control
the automated and semi-automated equipment and to participate in the
overall coordination and management of the manufacturing system.
 A typical FMS computer control system consists of a central
computer and micro-computers controlling the individual machines
and other components. The central computer coordinates the activities
of the components to achieve smooth overall operation of the system.
4. HUMAN RESOURCES;
  The fourth and final component in the FMS is human labour.Like in any
other manufacturing approaches, the operation of the FMS are also
managed by human labours.
 In FMS human labours are needed to perform the following functions:
i. To load raw workparts into the system.
ii. To unload finished workparts from the system.
iii. For tool changing and tool setting.
iv. For equipment maintenance and repair.
v. To furnish NC part programming in a machining system.

(2) List the functions performed by the FMS computer control system.

1. Workstation/processing station control. Computer control system controls

the operations of the individual processing or assembly stations in the factory.
For controlling the machine centres, CNC is used.
2. Distribution of control instructions to workstations. A direct numerical
control (DNC) Is used in a machining FMS to download the part programs to
the machines. The DNC computer control system also stores the programs,
allows entering and editing of programs.
3. Production control. Computer control system, based on data entered into the
computer, helps to take decision on part mix and rate of input of the various
parts onto the system.
4. Material handling system control. Computer control system controls the
material handling system and coordinates its activities with those of thee
workstations.
5. Work piece monitoring. The computer control system also monitors the
status of each cart and/or pallet in the primary and secondary handling
systems.
6. Quality control. This function of computer sontrol system ids to detect and
possibly reject defective work units produced by the system.
7. Safety Monitoring. This function of computer control system is to protect
both human workers in operating the system and the equipment comprising
the system.
 8. Failure diagnosis. This function of computer control system involves
diagnosing equipment malfunction, preparing preventive maintenance
schedules, and maintain spare parts inventory.

15. (a) (1) List out the inventory types. Explain them.

There are two general types of inventory systems. They are:

1. Fixed- order quantity models, and

2. Fixed- time period models

1.Fixed Order Quantity Models:

 This model is also known as the economic order quantity model, Q

model, re-order point inventory system, and perpetual inventory
system.
 This is the oldest and most common re-ordering system. Under this
system, the size of the order ( order quantity) is predetermined and
fixed, but the time of its placement (ordering time) is allowed to vary
depending upon the fluctuation in demand.
 To use the fixed-order model, the inventory remaining must be
continually monitored, thus the fixed- order quantity is a perpetual
system.
 This model requires that every time a withdrawal from inventory or
an addition to inventory is made, records must be updated to ensure
that the reorder point has or has not been reached.

2. Fixed- Time Period Models;

 The fixed-time period models are also referred to as the periodic

system, periodic review system, fixed- order interval system, and p-
model.
 In a fixed – time period system, periodic review of inventories are
made and an order is invariably placed in that period.
 In other words, p-model has a fixed ordering interval, but he size of the
order quantity may vary with the fluctuation in demand.
  The ordering procedure consists of reviewing the inventory position
after a fixed period of time, known as review period. At each review
period, an order is placed for an amount equal to the difference
between a fixed replacement level and the actual inventory level.
 This model generally require a higher level of safety stock than a
fixed-order quantity system.

(2) What are the inputs to MRP? Explain them.

The three important inputs to MRP are:

1. Master production schedule,

2. Bill of materials file, and
3. Inventory record file.

Master Production Schedule (MPS):

Master production schedule (MPS) is a detailed plan that states how many end
items will be available for sale or distribution during specific periods.

The MPS is used:

I. To set due dates for the availability of end items.

II. To provide information regarding resources and materials required to
support the aggregate plan.
III. As an input to MRP, which will set specific production schedules for parts
and components used in end items.

Bill of Materials File:

 The bill of materials designates what items and how many of each are used to
make up a specified final product.
 The bill of materials file is used to compute the raw material and component
requirements for end products listed in the master schedule.
 It provides information on the product structure by listing the component parts
and subassemblies that make up each product.
Inventory Record File:

 All the data related to the inventory are recorded in the inventory record file.
 The inventory record file contains the following three segments;
1. Item master data segment: It provides the items identification by part
number and other data, such as lead time, cost, and quantity.
2. Inventory status data; It provides a time-phased record of inventory
status.
3. Subsidiary data segment: it provides subsidiary data such as purchase
orders, scrap or rejects, and engineering changes.

[OR]

(b) (1) Describe the process control methods in manufacturing.

 Process control is a process of controlling the controllable input

variables
So as to achieve the desired performance evaluation variables.
 Process control can be achieved by employing various strategies. The
important process control strategies are:
1. Feedback control strategy,
2. Regulatory control strategy,
3. Feedback forward control strategy,
4. Preplanned control strategy,
5. Steady- state optimal control strategy, and
6. Adaptive control strategy.
 The selection of a particular strategy depends on the type of process
and the performance objectives to be achieved.

(2) Compare lean and agile manufacturing.

LEAN MANUFACTURING AGILE MANUFACTURING

 Standardized products  Customized products
 Longer market life  Shorter market life
 Produce-to-forecast  Produce-to- order
 Low information content  High information content
 Single time sales  Continuing relationship
 Pricing by production cost  Pricing by customer value
 B.E/B.TECH DEGREE EXAMINATION MAY/JUNE 2012

Seventh Semester

Mechanical Engineering

ME 2402- COMPUTER INTEGRATED MNUFACTURING

(Regulation 2008)

PART-A

1. What are the drawing features of CAD package?

 Geometric modeling features
 Editing or manipulation features
 Display the control features
 Drafting features

2. What are the advantages of solid modeling?

 Mass properties (such as area, volume, weight, centre of gravity) of physical models
can be calculated quickly.
 Solid models are unambiguous models.
 Cross-sectional views of models can be obtained easily.
 It can be used for interference/clearance checking of moving parts.

3. What is the difference between automation and CIM?

 Automation may be defined as the process of having mechanisms follow a
predetermined sequence of operations with little or no human labor, using specialized
equipment and devices that perform and control manufacturing process.
 CIM is the automated version of the manufacturing process where the three major
manufacturing functions-product and process design, production planning and control,
and production process-are replaced by the automated technologies.
 In fact, CIM represents the logical evolution of the automation concept.
4. What is meant by asynchronous data transfer?
In asynchronous data transfer, data is sent one byte (or character) at a time. Each string of
bits making up the byte is bracketed, or marked off, with special control bits.

5. Mention the benefits of GT?

 GT results in product design cost and time savings.
 GT results in reduced materials handling cost because of the group layout of the shop.
 GT simplifies production and inventory control activities.
 GT leads to an automated process planning systems.
6. What is CAPP?
CAPP refers to computer-aided process planning. CAPP is used to overcome the
drawbacks of manual process planning. With the use of the computers in the process
planning, one can reduce the routine electrical work of manufacturing engineers. Also it
provides the opportunity to generate rational, consistent and optimal plans.

7. List the different stages of shop floor control?

 Order release,
 Order scheduling and
 Order progress.

8. State the functions of computer control systems of FMS?

The functions that are performed by the FMS computer control system include:
 Workstation/processing station control
 Distribution of control instructions of workstations
 Production control
 Material handling systems control.

9. Define agile manufacturing.

Agile manufacturing is and enterprise level manufacturing strategy of introducing new
products into rapidly changing markets, and organizational ability to thrive in a competitive
environment characterized by continuous and sometimes unforeseen change.
10. What are the inputs to MRP system?
 Master production schedule,
 Bill of materials file, and
 Inventory record file.

PART B

11. (a) Describe about operator input devices used at the graphics workstation.

CAD HARDWARE:
The cad hardware generally includes the computer, one or more graphical display
terminals, keyboard and the other peripheral equipment.
In cad, the drawing boards are replaced by electronic input and output devices, printer,
card reader, and hard copy unit, as shown in fig1.1

CAD SOFTWARE:
Cad software consists of (i) system software, and (ii) application software.
(i) System software:
System software are used to perform/control the operation of the computer .These
software are responsible for making the hardware components to work and interact with each
other and the end user.
Examples of system software are the operating systems, all kinds of hardware drivers,
compilers, and interpreters.
(ii) Application software:
Application software, are also known as application programs, are used for general or
customized/specialized problems.
Examples of application software are AutoCAD, Solid works, Pro-E, ANSYS,
ADAMS,etc.
(b) (i) What are the functions of graphics passage?

Computer-Aided Drafting:
 The process of preparing drawings with the aid of computer is known as computer-
aided drafting or computer-assisted drafting or computer graphics.
  The computer graphics includes the methods of makings plane and geometrical
drawings. Thus, plotting of points, drawing of lines, squares, circles, etc., and building
up of single blocks, form the computer activities in the dimensions.
 Pictorial views of a machine components, as viewed from different direction can be
obtained by using computer graphics.
 In present days, the availability of sophisticated computer hardwasre and components
programmes have enabled solid modeling, which is a 3D representation of product.
 Display of all the surfaces in colour and thus on obtaining realistic imagses of objects
is also possible in computer graphics. It forms an integral part of computer-aided
design(CAD) and computer-aided manufacturing(CAM).

Advantages Of Computer-Aided Drafting Are:

 It is a fast and convenient method.
 Drawing can be stored in database.
 Changes in drawings can be done easily and quickly.
 Neat and clean drawings of good quality can be prepared.
 Accuracy can be maintained.

Functions Performed Bye Computer-Aided Drafting:

 Basic set-up of a drawing.
 Drawing the objects.
 Changing the object properties.
 Translating the objects.
 Scaling the objects.
 Clipping the object to fit the image to the screen.
 Creating symbol libraries for frequently used objects.
 Text insertion.
 Dimensioning.

FEATURES OF CAD SYSTEMS:

 Modelling and drafting: the majority of systems provide 2D and 3D modeling
capabilities. Some low cost CAD systems are dedicated to 2D drafting only.
 Ease of use: the users find CAD systems very easy to learn and use.
  Flexibility: Popular CAD systems provide greater flexibility when configuring the
available hardware. Hundreds of computers, display devices, expansion boards, input
and output devices are compatible and configurable with popular software’s.
 Modularity: Standard input and output devices are attached to standard connectors
thereby making the system modular in nature.
 Low maintenance cost: Little maintenance is needed to keep the system functional.

(ii) Explain about 2-dimensional transformations.

Some of the important 2D transformations include:

 Translation
 Scaling
 Rotation
 Shear
 Twist
2D TRANSLATION:
 Translation is nothing but moving an object across the screen from one position to
another.
 The translation transformation positions the object to a new location.
 The translation is accomplished by adding the coordinates of each corner point the
distance through which the object is to be moved.
 Translation of a point: Consider a 2D point P, having coordinates x, y. To translate
point P by a distance x in x-direction, a translation matrix is added to the original
matrix. Now the point has new coordinates.
 The translation of point P about original position to its new position.
2D SCALING:
 Scaling is the transformation and used to change, increase or decrease, the size of an
object.
 Scaling can be achieved by multiplying and the original coordinates of an object by
the scaling factor, along x direction and y along the y-direction.
 Scaling factors are always positive. If the scaling factor is less than 1, the object is the
compresses of the scaling factor is more than 1, the object is stretched.
  If scale factors are different, the object changes in both size and shape. This
differentiating scaling is known as non-uniform scaling.
 The different cases of scaling transformation are illustrated.
2D ROTATION:
 Rotation refers to the movement of an object in such a way that the distance between
a certain fixed point and any given point of that body remains constant.
 In mathematics, the rotations a transformation technique is commonly used in
rendering and animation techniques.
2D REFLECTION:
 Reflection is a transformation in which the direction of one axis is reversed.
 Reflection is transformation produces mirror images of an object.
 The mirror image for 2d object is generated relative to an axis of the reflection by
rotating the object 180degree about the reflection axis
 The reflection transformation is useful in the construction of symmetric objects. if the
object is symmetric with respect to plane, only half of the geometry is created and
then the half model is copied by reflection to develop the full model
2D SHEAR:
 Shearing is a deformation of an object in which parallel plane remain parallel but are
shifted in a direction parallel to them
 A transformation that distorts the shape of an object such that the transformed shape
appears as if the object were composed of internal layers that had been caused to slide
over each other is called a shear.
 A shearing in the x-direction relative to the x-axis unalters the y-coordinate while
shifts the x-coordinate by a value directly proportional to the y-coordinate.
12. (a) (i) what are the benefits of CIM?
 Faster responses to data changes for manufacturing flexibility
 Increased flexibility towards introduction of new products.
 Improved accuracy and quality in the manufacturing process
 Improved quality of the products
 Reduction of lead times which generates a competitive advantage
 Streamlined manufacturing flow from order to delivery
 Easier training and re-training facilities
 Control of data flow among various units and maintenance of user library for
system wide data.
 Creation of a truly interactive system that enables manufacturing function to
communicate easily with other relevant functional units.

(ii) Explain about the following data transmission methods: (1) Simplex and (2) duplex

The term transmission mode refers to the direction of information flow between two devices.
There are three types of transmission modes. they are
 simplex
 half duplex
 full duplex
Simplex
In simplex transmission, data can travel in only one direction.
half duplex
in half duplex transmission data travels in both directions but only in one
direction at a time
full duplex
in full duplex transmission data is transmitted back and forth at the same time.
(b)(i) Describe about seven layer OSI model
 physical layer: it is the lowest layer of the OSI model. it concerned with
transmitting raw bits over a communication channel. it also defines the procedures
and functions that physical devices and interfaces have to perform.
 data link layer: the main task of the data link layer is to transform a raw
transmission facility into a reliable link and is responsible for node to node
delivery.
 network layer: the network layer layer specifies the intra-network operations and
different types of addressing and routing services. logical and service addressing
are provided from network layer.
 transport layer: the transport layer is responsible for source to destination delivery
of the entire data. it performs the service of sending and receiving segments of
data to session layer.
 session layer: it allows users on different machines to establish sessions between
them. it is the network dialog controller. it establish, maintaines, synchronizes and
manages the interaction between communicating systems
 presentation layer: it is concerned with the syntax and semantics of the
information exchanged between two systems.
 application layer: it enables the user, whether human or software, to access the
network. it prvides user interface and support for services such as electronic mail,
remote file access and transfer, shared database management, and other types of
distributed information services.

(ii) Explain about network topologies.

Topology is a term used to describe the way in which
computers are connected in a network. The physical topology describes the actual layout of
the network hardware. the logical topology describes the behaviour of the computer on the
network from the perspective of its human operators.
Network Topology – Definition:
The specific physical, i.e., real, or logical, i.e., virtual, arrangement of the elements of a
network.
Two networks have the same topology if the connection configuration is the same, although
the networks may differ in physical interconnections, distances between nodes, transmission
rates, and/or signal types.
Vertical Topology
Hierarchical
Mesh
Horizontal Topology
Star
Bus
Tree
Ring

Vertical Topology
Hierarchical (tree) topology: existence of a central node (root) and of various sets of
level organized nodes (intermediary nodes); the leaves of the tree are the workstations. The
data flow between any two nodes goes up-down using the upper levels nodes. Mesh
topology: there are at least two nodes with two or more paths between them.
Bus topology: all nodes, i.e., stations, are connected together by a single bus (the main trunk).
Stations are connected using interfaces, named transceivers or attachment units (AUI).

Ex: pure Ethernet LAN, Token Bus.

Multipoint medium Transmission propagates throughout medium Heard by all

stations Need to identify target station Each station has unique address Full duplex
connection between station and AUI Allows for transmission and reception Need to regulate
transmission To avoid collisions and hogging Data in small blocks – frames Terminator
absorbs frames at end of medium.

Ring topology: every node has exactly two branches connected to it (a succession of point-to-
point links). Stations are connected using interfaces (repeaters).

Ex: Token Ring LAN.

Repeaters joined by point to point links in closed loop Receive data on one link and
retransmit on another Links unidirectional Data in frames Circulate past all stations
Destination recognizes address and copies frame Frame circulates back to source where it is
removed Media access control determines when station can insert frame

Dual Ring – allows for a second (reserve) ring; data flow has here an opposite direction; not
all stations linked to both rings

Star topology: there is a central node (switch) and peripheral nodes. The peripheral nodes are
connected to the central node, which rebroadcasts all transmissions received from any
peripheral nodes to all peripheral nodes on the network, including the originating node. Ex:
switched Ethernet LAN.

Extended star: links individual stars together, by linking the centers (hubs/switches); also
known as snowflake topology.

13. (a) (i) Expain about the parts classification and coding.

Coding is a systematic process of establishing an alphanumeric value for parts based

on selected part features. Classification is the grouping of parts based on code values.
 It is the most sophisticated most difficult most time consuming and widely used of the
three methods.

Design and manufacturing attributes

1. Systems based on part design attributes

2. Systems based on part manufacturing attributes
3. Systems based on both design and manufacturing attributes.

Coding system

1. Hierarchical codes
2. Attribute codes
3. Decision tree codes

Reasons for using a coding scheme

1. Design retrieval
2. Automated process planning
3. Machine cell design

Selection of a coding system

1. Objective of the classification system

2. Robustness
3. Expandability
4. Differentiation
5. Automation
6. Efficiency
7. Cost
8. Simplicity

(ii) Describe about OPTIZ coding systems.

Coding systems

1. Optiz classification system

2. DCLASS system
3. CODE system
 4. RNC system
5. Brisch system
6. MICLASS system
7. KK-3 system
8. CUTPLAN system
9. Part analog system
10. COFORM.

Optiz classification system

 It was developed by H Optiz of the University of Aachen in Germany.

 It is the most popular methods. This system uses alpha numeric symbols to represent
the various attributes of a part.
 The optiz coding scheme are as follows: 12345 6789 ABCD
 The first five digits code the major design attributes of a part and are called the form
code
 The next four digits are for coding manufacturing related attributes and are called
supplementary code
 The letters code the production operation and sequence and are referred to as the
secondary code. The secondary code can be designated by the firm to serve its own
particular needs.

(b) Explain about CAPP

CAPP provides the interface between CAD and CAM. With the use of computers in
the process planning one can reduce the routine clerical work of manufacturing engineers.
The cycle from concept to design, planning, production, quality control and feedback to
design goes on in which one can easily understand the crucial role of planning. In job/batch
manufacture, as an enormous amount of data is needed for planning as well as other
activities, data bases are required and the flow of information
should be fast for a high performance of the total manufacturing system

Benefits of CAPP
1. Process rationalization and standardization
 2. Productivity improvement
3. Product cost reduction
4. Elimination of human error
5. Reduction in time
6. Reduced clerical effort and paper work
7. Improved legibility
8. Faster response to engineering changes
9. Incorporation of other application programs

Approaches of Capp

1. Retrieval CAPP system

2. Generative CAPP system

Retrieval CAPP system: Variant process planning approach is sometimes referred as

a data retrieval method. In this approach, process plan for a new part is generated by
recalling, identifying and retrieving an existing plan for a similar part and making necessary
modifications for new part. As name suggests a set of standard plans is established and
maintained for each part family in a preparatory stage. Such parts are called master part. The
similarity in design attributes and manufacturing methods are exploited for the purpose of
formation of part families. Using coding and classification schemes of group technology
(GT), a number of methods such as coefficient based algorithm and mathematical
programming models
have been developed for part family formation and plan retrieval.

Generative CAPP system: In generative process planning, process plans are generated
by means of decision logic, formulas, technology algorithms, and geometry based data to
perform uniquely processing decisions. Main aim is to convert a part form raw material to
finished state. Hence, generative process plan may be defined as a system that synthesizes
process information in order to create a process plan for a new component automatically.
Generative process plan mainly consists of two major components:
(i) Geometry based coding scheme.
(ii) Proportional knowledge in the form of decision logic and data.
14. (a) Explain about factory data collection system.

Shop floor control depends on analysing of regularly generated data, which forms the
basis of control decisions. Fatory data collection and analysis are important tasks within shop
floor control.

Types of data collected by FDC

I. Number of pieces completed at a certain work centre
II. Direct labour time spent on each other
III. List and number of parts that are scrapped
IV. List and number of parts that requiring rework
V. Equipment downtime and
VI. Time clocks used by employees to punch in and out of work

Types of data collection system

1. On-line data collection systems
2. Off-line data collection systems

In online system the data are entered directly into the plant computer system and are
immediately available to the order progress module.
Advantage: The data file representing the status of the shop is always kept at the current state.

In an offline data collection system the data are collected temporarily in a storage
device or in a standalone computer system to be entered and processed by computer in a
batch mode.
Advantage: It is easier to install and implement when compared to other data system.

Different Data input techniques:

1. Manual/clerical input techniques
i. Job traveler
ii. Employee time sheets
iii. Operation tear sheets
iv. Prepunched cards
2. Data collection terminals
 i. Push button keypads
ii. Keyboard based terminals
a) One centralized terminals
b) Satellite terminals
c) Work station
3. Automated input techniques
i. Optical bar code readers
ii. Magnetic card readers
iii. Magnetized or bar-coded cards

b) (i) Explain about FMS workstation.

The work stations/processing stations used in FMS depends upon the type of product
manufactured by the system. The types of work stations that are usually found in FMS are,
1. Load/unload stations
2. Machining stations
3. Assembly work stations
4. Inspection stations and
5. Other processing stations

Load/unload stations
 This is the physical interface between the FMS and the rest of the factory.
 At loading stations, raw work parts enter the system.
 At unloading stations, finished parts exit the system.
 Both accomplished either by manually or by automated handling systems.
Machining Stations
 It is a multipurpose CNC machine tool that has an automatic tool changing capability
 CNC machining centers possess the features such as
i. Automatic tool changing and storage
ii. Use of palletized work parts
iii. Use of CNC and
iv. Capability for distributed numerical control (DNC)
 Different modules including
 a) Turning modules
b) Milling modules
c) Head changers
d) Head indexes

Assembly Workstations

 Assembly operations are performed by some FMSs.

 Flexible automated assembly workstations are used in FMS for products made in
batches.
 For this purpose industrial robots are considered as the most appropriate automated
assembly workstations.

Inspection stations:

 The inspection operations can be done either at machining work stations itself or at
specific inspection stations.
 The following inspection methods/equipments are used
i. Coordinate measuring machine
ii. Special inspection probes and
iii. Machine vision

Other processing stations

In additions to machining centers, a FMS often has

 Sheet metal processing workstations
 The forging processing stations

In addition to above work stations other stations include

 Stations for cleaning part/pallet fixtures,
 Central coolant delivery systems for entire FMS and
 Centralized chip removal systems
(ii) List the applications of FMS

1. Machining
2. Assembly
3. Sheet metal press working
4. Forging
5. Plastic injection moulding
6. Welding
7. Textile machinery manufacture and
8. Semiconductor component manufacturing

15. a) (i) How MRP works

MRP is effectively a large calculator, so what information does MRP use in its
calculations? MRP needs the following information (and for it to be accurate) in order to
suggest sensible parts ordering dates & amounts and achievable work plans:
 A bill of material (BOM) for each project / job / order (an example of a BOM is given
below)
 A build / work time for each part of each job (i.e. design, assembly, painting, testing
etc.)
 A complete on-hand inventory of all parts i.e. an accurate record of the number of
stocked parts.
 Delivery lead times of parts i.e. the elapsed time from order placement to parts being
received at your company.
 The due date (expected delivery) of the job / order to the customer.
A bill of material, or BOM, is basically a structured list of all the parts (including
quantities) that are needed for a job / project.
The BOM defines the structure of the job and all the parts that are required.
In addition to this information MRP will also be told information such as: the amount of time
it takes your suppliers to deliver the parts that need ordering; the build time of the sub-
assemblies; the time taken to test the job, and so on.
Using this information in conjunction with the BOM means that MRP can plan
backwards from the planned delivery date of the job and will suggest dates that parts need to
be ordered by and work needs to have started by if the job is to be completed on time. MRP
will also flag tasks that are slipping and parts shortages.

(ii)Explain about cost planning and control

The cost planning and control system consists of the database to determine the
expected costs of manufacture each products of the company
It also consists of cost collection and analysis software to determine the expected costs
and actual costs of manufacturing.
 Cost estimating: is the process of determining the probable cost of the product before
the start of the product and its manufacture.
 Cost accounting: is the determination of an actual cost of a component after adding
different expenses in various departments.

Objectives
1. To determine the expected costs to manufacture and sell each of the company’s
products.
2. To determine the actual costs to manufacture and sell each of the company’s products.
3. To find the difference between the actual costs and expected costs and reasons for
these difference.

Cost planning
This is also called as cost estimating, is concerned with the determination of standard
cost of the product
Data requirements of cost estimating
1. General design specifications
2. Rate of production
3. Layout drawings
4. Lists of proposed subassemblies
5. BOM of product
6. Test/ inspection procedures/equipments.
7. Machine tool and equipment requirements.
8. Packaging and/or transportation requirements
 9. Manufacturing routings
10. Operation analysis
11. Workspace studies
12. Standard time data

b) (i) what are the components of DDC explain its figure

1. Transducers, sensors and associated instrumentations

2. Actuators
3. Digital computer
4. Analog to digital converter
5. Digital to analog converter
6. Input and output multiplexers

(ii) Explain about lean manufacturing;

In its most basic form, lean manufacturing is the systematic elimination of waste from all
aspects of an organization’s operations, where waste is viewed as any use or loss of resources
that does not lead directly to creating the product or service a customer wants when they want
it. In many industrial processes, such non-value added activity can comprise more than 90
percent of a factory’s total activity.

When companies implement several or all of these lean methods, several outcomes
consistently
result:
 Reduced inventory levels (raw material, work-in-progress, finished product) along
with associated carrying costs and loss due to damage, spoilage, off-specification, etc;
 Decreased material usage (product inputs, including energy, water, metals, chemicals,
etc.) by reducing material requirements and creating less material waste during
manufacturing;
 Optimized equipment (capital equipment utilized for direct production and support
purposes) using lower capital and resource-intensive machines to drive down costs;
  Reduced need for factory facilities (physical infrastructure primarily in the form of
buildings and associated material demands) by driving down the space required for
product production;
 Increased production velocity (the time required to process a product from initial raw
material to delivery to a consumer) by eliminating process steps, movement, wait
times, and downtime;
 Enhanced production flexibility (the ability to alter or reconfigure products and
processes rapidly to adjust to customer needs and changing market circumstances)
enabling the implementation of a pull production, just-in-time oriented system which
lowers inventory and capital requirements;
 Reduced complexity (complicated products and processes that increase opportunities
for variation and error) by reducing the number of parts and material types in
products, and by eliminating unnecessary process steps and equipment with unneeded
features.

At the same time, lean implementation consistently fosters changes in organizational

culture that exhibit the following characteristics:
 A continual improvement culture focused on identifying and eliminating waste
throughout the production process;
 Employee involvement in continual improvement and problem-solving;
 Operations-based focus of activity and involvement;
 A metrics-driven operational setting that emphasizes rapid performance feedback and
leading indicators;
 Supply chain investment to improve enterprise-wide performance; and
 A whole systems view and thinking for optimizing performance.

There are numerous methods and tools that organizations use to implement lean
production systems. Eight core lean methods are described briefly below. The methods
include:
1. Kaizen Rapid Improvement Process
2. 5S
3. Total Productive Maintenance (TPM)
4. Cellular Manufacturing / One-piece Flow Production Systems
5. Just-in-time Production / Kanban
6. Six Sigma
7. Pre-Production Planning (3P)
8. Lean Enterprise Supplier Networks
 B.E. / B. TECH. DEGREE EXAMINATIONS,
NOVEMBER/DECEMBER 2012.
SEVENTH SEMESTER
MECHANICAL ENGINEERING
ME 2402-COMPUTER INTEGRATED MANUFACTURING
(REGULATION 2008)
PART A-(10 X 2 = 20 MARKS)

1. What is meant by geometry and topology?

Ans: Pictorial representation of a machine component is known as geometry. The topology of
network is the geometric representation of relationship of all links and linking devices to each
other.

2. List any four rules of dimensioning?

Ans:
1. Provide the size and location of each feature.
2. Dimensions features in the view that shows true size and shape.
3. Use diameter dimensions for circles' and radial dimensions.
4. Omit unnecessary dimensions.

3. Mention the benefits of CIM.

Ans:
i) Make the total process more productive, efficient.
ii) Increase product reliability.
iii) Decrease the cost of production.
iv) Greater flexibility.

4. Differentiate between LAN model and MAP model.

Ans: A Local Area Network is a privately owned communication network that serves users
within a confined geographical area. Manufacturing Automation Protocol (MAP) standard is
essentially. On application - specific subset of the ISO protocols designed to meet the needs
of factory automation.
5. What is meant by mono code and poly code structures?
Ans:In Mono code structure the interpretation of each successive symbol depends on the
value of the preceding symbols. In Poly code structure, the interpretation of each symbol in
the same sequence does not depend on the value of pro ceding symbols.

6. List out the techniques available. for the formation of cell in GT?
Ans: Variant CAPP is based on Group Technology (GT) classification and coding approach
used to identify a large number of part attribute (or) parameters.

7. Differentiate between dedicated FMS and random order FMS

Ans: A dedicated FMS is designed to produce a limited variety of configurations. A random
ordered FMS is designed to produce large part family of considerable variation in part
configuration.

8. State the purpose of primary and secondary material handling systems.

Ans: The general purpose of material handling is to move the raw materials, work-in process,
finished parts, tools, and supplies from one location to another location and facilitate the
overall operations manufacturing.

9. Write down the three phases of shop floor control?

Ans:
i) Order release
ii) Order scheduling
iii) Order progress.

10. What is meant by procurement lead time?

Ans: It is the basic feature. We use it to create solid models of 2 1/2D objects with uniform
thickness. It requires a profile and an extrusionvector.
 PART B- (5 x 16 = 80 marks)

11. (a) Explain the following transformation with examplei) Translation ii) Scaling iii)
Rotation.

Ans:
Translation:
The translation transformation positions the object to a new location. The translation
accomplished by adding the coordinates of each corner point the distance through which the
object to be moved.
Translation of Point: Consider a 2D point P, having the coordinates x,y. to translate point P,
by a distance ∆x in x direction and ∆yin y direction. A translation matrix T is to be added to
original matrix. The translationdistance (∆x, ∆y) is called translation vector.
Let,
P- Original position
P’- New position
T - Translation matrix.
Mathematically
x' =X+∆x
y' = y+∆y

Therefore,
x x′ ∆x
P=[y] P`=[ ] &T=[ ]
y′ ∆y
Thus the equation is expressed as,
P'=P+T

Scaling:

Scaling is the transformation used to change, increase indecrease, the size of an object.
Scaling is achieved by multiplying theoriginal coordinates of an object by the scaling factor
Sxalong x-directionit and Sy along y-direction.

Scaling of a Point: Mathematically after scaling, (P'(x',y'))

x' =x.Sx
y' = y.Sy
Matrix form,

x′ x Sx 0
[ ]=[y] [ ]
y′ 0 Sy
P’= P.S
Sx 0
S= [ ]
0 Sy
Rotation:

Rotating refers to the movement of an object in such a way that the distance between a
certain fixed point and any given point of that body remains constant.

11. (b) Discuss the concept of B-Repand CSG techniques of solid modelling. Also mention
the properties of solid model.

Ans:
Boundary Representation (B-rep):This approach is widely used in most of solid modellers.
This solid model created by using B-rep technique may be stored in graph based on data
structure system.

The tetrahedron is composed of our vertices namely A, B, C and D. The coordinate of these
vertices is stored in the database. These connectives to form the solid are popularly known as
"topology." In Brep modeller, in addition to store the topology of solid, topological
consistency of the models is also carried out in order to create geometrically valid solid
models.
Advantages:
1. Computational efiort and time required to display the models are less compared with CSG.
2. Combining wireframe and surface models and possible.
3. Complex engineering objects can be modelled very easily compared with CSG.

Disadvantages:
1. The data to be stored is more and hence it requires more memory.
2. Sometimes geometrically valid solids are not possible.

Constructive Solid Geometry (CSG): A solid modeller has a library of set of basic elements
shapes known as primitives like, cuboid, cylinder, sphere, cone, wedge, tones, etc.
Object = (A - B) U(C - D)
In this approach, the physical objects are modelled by combing these primitives bya set of
Boo lean operations. The type of Boo lean operations is used in CSG are Union (U),
Difference (-) and Intersection (∩).
Here, directed graph is used to store model data in structure. The tree type data structure is
shown.
Advantages of CSG:
1. Since the data to be stored are less, memory is less.
2. Create fully valid geometrical solid model.
3. Complex slopes may be developed relatively quickly with available set of primitives.
4. Less skill is enough.
Disadvantages:
1. More computational effort and time required whenever the modelis to be 'displayed in
screen.
2. Getting fillet, chamfer, and taper in the model is difficult.

12. (a) Explain and compare the different types of network topologies.

Ans:
Topology: Topology is the term used to describe the way in which computers (or)
workstations are connected in a network. The physical topology describes the actual layout of
the network hardware, the logical topology describes the behaviour of the computer-on the
network, from the perspective of its human operations. The topology of a network is the
geometric representation of the relationship of all links and linking devices to each other.
These are five basic topologies possible:
i) Star Topology
ii) Tree Topology
iii) Bus Topology
iv) Ring Topology
v) Hybrid Topology

Star topology:
In a star topology, each device has a dedicated point to point link to a control controller,
usually called a hub. This topology does not allow direct traffic between devices. If one
device wants to send data to another, it sends data to hub which then relay to the other
connected devices.

Advantages:
Ease of service: In a star topology, each device needs only one link and one I/O port to
connect it to any number of others. This factor makes it easy to install and reconfigure.
Robustness: It is very robust, because each device has an independent connection to control
hub, the network can continue to function of any of the individual nodes fails.

Disadvantages:
Central hub depending: If the hub goes down, then entire network will fall.
Long cable length: More cabling is required in a star than tree ring; or bus topology.

Tree Topology:
A tree topology is a variation of star. As in a star nodes in a tree arelinked to a centre hub that
controls traffic to a network.However, notevery device plugs directly into hub.

Advantages:
i) Easy to extend: Because of the nature of the tree topology. It is ,easier to add new nodes or
branches to it.
ii) . Fault isolation: It is possible to disconnect whole branches of the network from the main
structure.

Disadvantages:
Dependent on the root; If the herb device fails to operate, the entire network fails. In this
respect, the tree suffers from the same reliability problem as the star.

Bus Topology:
The bus network works like a bus system at rush hour, with various buses pausing in different
bus zones to pick up the passengers. Nodes are connected to the bus cable by drop lines and
taps. A drop line is connected between device and main cable. This is known as "multi-drop
line".

Advantages:
i) Short cable length and simple wiring layout.
ii) Resilient architecture.
iii) Easy to expand.

Disadvantages:
i) Fault diagnosis.
ii) Slow performance.

Ring Topology:
In a ring topology, each device is connected to twoand only two neighbouring devices. Each
node passes information alongto the next, until it arrives at its intended destination.Thus, in a
ring topology information travels in one direction only.

Advantages:
i) Short cable length.
ii) Faster performance.
iii) Suitable for optical fibres.
iv) No wiring closet space required.
Disadvantages:
i) Node failure causes network failure.
ii) Difficult to diagnose fault.
lii) Network reconfiguration is difficult.

Hybrid Topology:
By modifying (or) combining some of thecharacteristics of the pure network topologies a
more useful networkmay be obtained. These combinations are called hybrid topologies.
a) Star bus: In this two (or) more star topologies are linked togetherusing a bus trunk (called a
back born).

b) Star ring: In this two or more star topologies are linked together using a central hub.

12. (b) Discuss the various data transmission methods adopted in ClM
Ans:
System Modelling:
ClM is an ideal state in which computer based manufacturing applications communicate
information to coordinate design, planning and manufacturing processes. Thus the ClM needs
on integration architecture which supports each applications local data requirements. To
understand each systems data requirement, it is required to model them using system
modelling tools. The preparatory phase of analysing a company problem and its solution is
called system analysis. System analysis usually generates by uses some form of flow
diagrams.
Flow diagram, a type of graphical model, users various graphical symbols to represent
activities and relationships within the systems. Though modelling of ClM systems or similar
or other systems requiring to be computerized, they are significantly different in their
implementation. The specific characteristics to be incorporated in the ClM systems model
include:

i) Complexity of operation.
ii) The large amount of their operation.
iii) Their cyclic operations.
iv) Uncertain or variable behaviour of certain part their changing nature of accommodate new
markets involvements of human as part of the system.

System Modelling Tools: There are-several system modelling tools available.' SADT for
analysing and specifying software systems is considered as the landmark system modelling
tool. The further development of family ICAM definition languages/modelling techniques.
This development is known by the acronym IDEF.
IDEFO: It provides a formalized modelling notations for representing the type offunctional
analysis.
The building block ofIDEFO as it consists ofa rectangle specifying the activity and four
arrows (input, output and mechanism), are also representing the resources. The sources can
be any aspect of companies operation, expect its activities.it may be machines, material data,
information, people product, method, etc.
It may be noted that the activities in an IDEFO model or usually specified using their
imperative of a verb to find emphasise that an actionis taking place.
13. (a) (i) Explain the 'concept of OPTIZ coding system with example.
Ans:
Optiz Classification System: The optiz system was developed by H. Optic of Aachen
University, Germany. In fact it was the most popular and one of the first published
classification and coding systems schemes for mechanical parts.
This system uses alpha numeric symbols to represent the, various attributes of the part.
The optiz coding system uses the following digit sequence.
Example: 12345 6789 ABCD.
The first five (12345) digits code the majordesign of the part andare called the "Form Code".
The next for digits (6789) are for coding manufacturing related attributes and are called
"Supplementary Code".
13. (a) (ii) Apply rank order clustering technique to the part machine incidence matrix (Table
-1) to arrange parts and machine into groups.

13. (b) (i) Differentiate between generative and variant approach in CAPP. Also write the
benefits of CAPP.
Ans:
Generative CAPP Systems: In generative approach, an automatic computerized system is
used to synthesize or generate each individual process plan automatically and without
reference to any prior plan. The automatic computerized system consists of decision logic,
formulas, technology algorithms and geometry based data to uniquely determine the many
processing decisions required for generating process plans. Thus, the generative CAPP
system automatically generates the process plans based on decision logics and pre-coded
algorithms.

Advantages:
i) It can generate consistent plans rapidly.
ii) Few components can be planned as early as existing.
iii) It has potential for integrating with an automated manufacturingfacility to provide
detailed control information.

Drawbacks:
i) The generative approach is complex and difficult to develop.

Retrieval (or) Variant CAPP System:

A retrieval CAPP system, also called a variant CAPP system, hasbeen widely used in
machining applications.In this system, a process plan for a new part is created by recalling,
Identifying and retrieving an existing plan for a similar part, and marketingthe necessary
modifications for the new part.The variant CAPP approach by manually. The computer is
assistedby providing an efficient system for data management, retrieval, editingand high
speed printing of process plan.

Advantages:
i). Once a standard plan has been written, a variety or parts can beplanned.
ii) Simple and easy installation program.
iii) Efficiency processing.
iv) Easy to learn and use.

13. (b) (ii) Briefly explain the steps involved in generation route sheet using variant approach
CAPP.
Ans:
The process plan is generally documented as a job routing or operation sheet. The operation
sheet is also called as "route sheet", "instruction sheet", "traveller" or "Planner". The route
sheet lists the production operations and associated machine tools for each component and
subassembly of the product.
A route sheet usually provides the following information:
i) Part identification.
ii) Description of processing steps in each position.
iii) Operation sequence and machines.
iv) Standard setup and cycle times.
v)Tooling requirements for each operation.
vi) Production control information.

14. (a) Explain the three phases in shop floor control with block diagram. Also discuss the
techniques available for data collection in shop floor.
Ans:
Phase of SFC: The three important phases of SFC are:
i) Order release.
ii) Order scheduling.
iii) Order progress.

1) Order Release: This order release phase provides the documentation needed to process a
production order through the factory.The collection of document is sometimes referred as
shop packet
i) Route sheet: used to list the sequence of operations and tools required.
ii) Material requisitions: used to get necessary raw materials from inventory.
iii) Job cards: used to report the labour for (each operations on the route sheet.
iv) Move tickets: used to move the parts between the work centres.
v) Parts lists: required for assembly jobs.

2) Order Scheduling:
The second phase of shop floor control is the order scheduling module,which follows directly
from the order release module.In this phase, the order scheduling module assigns the
production ordersto the various work centres in that plant.Order scheduling executes the
dispatching function in production planningand control. The two elements of order
scheduling,
1. Machine loading.
2. Job sequencing.

3) Order Progress
The order progress phase monitors the status of the various orders inthe plant, work in
progress (WIP), and other characteristics thatindicates the progress and performance of
production.Order process collects data from shop floor and generatesreports toassist
production management. In other words, the function of orderprogress module is to provide
information that is useful in managingthe factory based on data collected from the factory.

14. (b) (i) Explain the types of FMS layout configurations. Also write its primary material
handling systems.
Ans:
Types of FMS Layout:
The material handling system establishes ~MS layout. These types of layout configurations
commonly used are:
1. In-line layout
2. Loop layout
3. Ladder layout
4. Open-field layout
5. Robot-centred cell.

1) In-Line Layout: The materials and handling systems are arranged in a straight line in the
in-line layout.
2) Loop Layout: In Loop layout, the workstations are arranged in loop.
3) Ladder Layout: The Ladder layout, an adaptation of the loop layout, consists of a loop with
rungs on which workstations are located.
4) Open Field Layout: The open field layout, also an adaptation of loop configuration
consists of multiple loops, ladders, ad sliding, organized to achieve the desired processing
requirements.
5) Robot-Centred Cell: In the robot centred cell, one or more cells (or) robots are used as the
material handling systems.
Primary Material Handling Systems: The primary material handling system establishes the
basic layout of the FMS and is responsible for moving work parts between workstations in
the system.
14.(b)(ii) Write short notes on classifications of FMS layout according to number of
machines.
Ans:
The classification of FMS based on the number of machines in the system:
1. Flexible Manufacturing Cell (FMC), and
2. Flexible Manufacturing System (FMS).

Flexible Manufacturing Cell: It consists of two or three processing workstations (usually

CNC machining' centres or turning centres), a load/unload station, and a part handling
systems. The part handling system that is used in a FMC shall have a limited parts storage
capacity.

Flexible Manufacturing System: It consists of four or more processing workstations

connected mechanically by a common part handling system and electronically, by a
distributed computer system.

According to Groover, there are three differences between the FMC and FMS, they are:
1. An FMC has two or three machines, while an FMS has four or moremachines.
2. FMS generally includes non-processing workstations such as part cleaning and deburring
stations. Coordinate measuring machines and so on. But FMC does not include any non-
processing workstations.
3. The computer control systems of an FMS is generally larger and more sophisticated than
that of a FMC. For example, computer functions such as diagnostics and tool life monitoring
cannot be performed in FMC.
15. (a) List the inputs required for material requirements planning. Also explain the concept
of MRP with neat sketch.
Ans:
Inputs of MRP:
The three important inputs of MRP are:
1. Master Production Schedule.
2. Bill of Materials.
3. Inventory Record File.

Master Production Schedule: Master Production Schedule (MPS) is a detailed plan that states
how many end items (i.e., the final product to be sold customer) will be available for sale or
distribution during specific periods.
Purpose of MPS:
The MPS is used:
i) To set due dates for the availability of ends items.
ii) To provide information regarding resources and materials required to support the
aggregate plan.
iii) As the input to MRP, this will set specific production schedules for parts and components
used in end items

Bill of Materials: The bill of material designates the what items and how many of each are
used to make up a specified final product. The bill of materials file is used to compute raw
materials and components required for end products lists in the master schedule.

Inventory Record File:AIl the data related to the inventory are recorded in the inventory
record.
The inventory record file contains the following three segments:
1. Item master data segment: It provides the items identifications by part number and other
data, such as lead time, cost and quantity.
2. Inventory status data: It provides a time phased record ofinventory status.
3.Subsidiary data segment: It provides subsidiary data such aspurchase orders scrip or rejects
and engineering changes.

15. (b) (i) State the principles of lean manufacturing and list down major kinds of wastages.
Ans:
Key Principles of Lean Manufacturing:
1. Recognition of wastes.
2. Standard processes.
3. Continuous flow.
4. Pull-production.
5. Quality at the source.
6. Continuous improvement.
Main Kinds of Wastes:
1. over production.
2. Defects.
3. Inventory.
4. Transportation.
5. Waiting.
6. Motion.
7. Correction.
8. Over processing.
9. Knowledge disconnection.

15. (b) (ii) Discuss the types of production monitoring systems.

Ans:
Production Monitoring System: Computer process monitoring,also known as production
monitoring, is a data collection system in whichcomputer is connected directly to workstation
and association equipment for the purpose of observing the operations.Computer process
monitoring involves the use of computer to observe the process and associated equipment and
to collect and recorddata from the operation.
Three important topics related to the technology and applications of automated data
collection system for computer process monitoring are:

1. Data acquisition systems

2. Data logging systems.
3. Multilevel scanning.

Data Acquisition Systems: A data, acquisition system (ADAS) is a computer system used to
automatically collect data from a process or piece of equipment. These perform an analysis of
data or transmit the data to another computer for processing and analysis. A
microprocessor/minicomputer is used as the controller (or) processor in DAS.
Data Logging Systems: A data logger (DL) 'is a device that automatically collects and stores
data for offline (batch) analysis. The data logger can be interfaced with tape punches,
magnetic tape units, printers, plotters and so on.
Multilevel Scanning: In a multi-level scanning, there are two levels of process scanning
performed by the computer system, a high level scanned a low level scan. High level
scanning is used to scan key variables and status data, during normal operation of the
process.Low level scanning involves a more complete data logging and analysis procedure to
a certain source of malfunctions.
 B.E /B. Tech. DEGREE EXAMINATIONS, MAY/JUNE 2013
Seventh Semester
Mechanical Engineering
ME 2402/ME 72-COMPUTER INTEGRATED
MANUFACTURING
(Regulation 2008)

PART A

1) Distinguish between reflection and scaling transformations

Ans: Reflection is also called as mirror or mirror image. It can be either in x axis or y axis
A Scaling transformation alters the size of an object. This can be carried out in any axis.

2) What is sculptured surface?

Ans: A sculptured surface is defined as a collection or sum of interconnected and bounded

parametric patched together with bending and interpolation formulas.

3) What is a communication network? List its types.

Ans: A communication network is a collection of equipment and physical media that

interconnects two or more computers.

 Local Area Networks (LANs)

 Metropolitan Area Networks (MANs)
 Wide Area Networks (WANs)

4) What is MAP model?

Ans: MAP (Manufacturing Automation Protocol) is an implementation of the OSI model. It

is hardware cum software implementable set of rules that facilitate information transfer
among network computer.

5) What is the main difference between hierarchical codes and attribute code structure?
Ans: In hierarchical structure, the interpretation of each successive symbol depends on the
value of preceding symbols. In attribute structure, the interpretation of each symbol in the
sequence does not depend on the value of preceding symbol.

6) What is CMPP system?

Ans: CMPP refers to Computer Managed Process Planning. It is a commercial generative

process planning system capable of automatic process decisions

7) Distinguish between On-Line and Off-Line data collection systems

Ans:In On-Line system, the data are entered directly into the plant computer system and are
immediately available to order progress module.
In Off-Line system, the data are collected
immediately in a temporary storage device or a standalone computer system to be entered and
processed by plant computer in batch mode.

8) List some important advantages of implementing FMS.

 Increased machine utilisation
 Reduced inventory
 Reduced manufacturing lead time
 Shorter response time

9) What do you mean by fixed-order quantity model?

Ans: Fixed order quantity model in the assemblage if the fixed quantities of units are used to
denote the fixed dimensions

10) What is direct digital control?

Ans: DDC is the automated control of a condition or process by a digital device.

 PartB

11) (a)(i) Write short notes on 3D scaling and 3D shearing geometric transformation.

Ans: Three Dimensional transformations: 3D scaling of an element is used to enlarge it to

reduce its size. The scaling need not necessarily be equally in the x, y and z axis. The scaling
transformation is given by,

S= m 0 0

0 n 0

0 0 p

For equal value of m, n and p scaling is linear. It also has the effect of repositioning
the element with respect the Cartesian system origin. In scaling factors less than 1, the size
factors are less than is reduced and it is moved closer to the origin. If the factors larger than 1,
the element is enlarged and removed farther from origin. This would produce alternation in
the size of element by the factor m in the x axis, n in y axis and p in z-axis respectively.

(b)(ii)Consider a point P(3,2) in a coordinate plane. Perform reflection of the point P (1)
through y axis and (2) through x axis
 11)(b) Explain with suitable example, how a solid model is generated using boundary
representation and write the advantages of solid modelling.

Ans: Boundary representation is one of the two most popular and widely used schemes to
create solid models of physical objects. A B-rep model (or) boundary model is based on the
topological notion that a physical object is boundedby a set of faces. A closed surface is one
that is continuous without break. An orient able surface is one in which it is possible to
distinguish twosides by using direction of surface normal to point inside and outside of the
solid model under construction. The database of boundary model contains both its topology
and geometry.

At first let usdevelop the boundary model of solid S. For simplification, we assume that an
approximate B-rep scheme is used.
Based on the figure, the model has 16 faces, 28 vertices, 42 ed 2 loops, I body and I geners.
They all satisfy the Eulers law. A suggested sequence to create model in shown. The
sequence matches the planning strategy reflected, in which the cylindrical face of the hole has
approximated by the eight faces. The figure is an isometric view although it onlyreflects
topology construction and not geometry. It is presented in this way for clarity and learning
purposes. Each step in the fig, shows the operators used and its results and whatever needed
in previousstep.
An intermediate topology that is created for construction purposes has to be killed. Noise that
the face is created, arid operator is chosen arbitrarily. Similarly, the body created by this
command is part of the topology and in fact is the body of solid S. The reader can perhaps
find totally different set of steps to construct the solid model.
Advantages of Solid Modelling:
1)The main advantages of solid modelling is very appropriate to construct solid models of
unusual shapes that are difficult to buildusing primitives.
2)It is very simple to convert. B-rep into wire frame.

12) (a)(i) Explain the importance of CIM. Also write the reasons for implementing CIM.
Ans: Importance of CIM

• Development ofNC, CNC and ONC.

• The advert and cost-effectiveness of computers.
• Manufacturing challenges, such as global competition, highlabour cost, demand for quality
products, lower product cost.
• The capability-to-cost attractiveness of microcomputers.
• Evaluating and developing different products strategies.
• Analysingmarkets and generating forecasts.

Reasons for Implementing ClM

1. To Meet Competitive Pressures
i. Reduced read time.
ii. Reduced production material and labour costs.
iii. Reduced inventory, increased quality.
2. To Co-ordinatesand Organise Data: CIM helps firms respondto the competitive pressure by
the better use of data.
3. To eliminate paper and the costs associated with its use CIMenables Information to be
stored electronicallyand displacedon terminals.
4.To Automatic Communication with is a factory and increasethe speed: The networks of a
CIM .Implementation permit thesending of messages,Memoranda and documents by
electronicmail over long distance.
5. To Facilitate Simultaneous Engineering: Concurrent engineering is a methodology of
restructuring the product development activity in an organisation using a cross functional
team and is a technique adopted to improve the efficiency.

12.(a)(ii) Explain in detail the communication matrix in CIM

Ans:What are the communication in ClM?

• Person-to-Person Communication
• Computer-to-Computer Communication
• Machine-to-Machine Communication
• Person-to-Computer Communication
• Computer-to-Person Communication
• Person-to-Machine Communication
• Machine-to-Person Communication
• Computer-to-Machine Communication
• Machine-to-Computer Communication.

12)(b)(i) Explain briefly the seven layers of ISO/OSI reference model

Ans:

Physical Layer: The physical layer is concerned with transmittingraw bits Over a
communication channel. The design issue ofphysical layer consider: electrical, mechanical,
functional andprocedural attributes.
Data Link Layer:The main task of the data link layer is totransfer a raw transmission facility
into a reliable link and isresponsible for node-ta-node delivery.
Network Layer:The network layer specifies the inter-networkoperations and different type of
addressing and routing services.Logical and service addressing are provided from network
layer.
Transport Layer: The transport layer is responsible for source-to-destination delivery of the
entire data.
Session Layer: It is the network dialog controller. If establishes,maintains, synchronizes, and
manages the interaction betweencommunicating system.
Presentation Layer:There is concerned with the syntax andsemantics of the information
exchanged between two systems.
Application Layer: The application layer enables the user, whether human or software, to
access the network.

12)(b)(ii) What is CSMA/CD? And also write the rules for CSMA/CO.

Ans:

CSMA/CD:
The carrier sense Multiple Access with collisionDetection, is a network control technique that
describes the rules for managing/controlling access to networks.
The rules for CSMA/CD:

Rule 1: If the medium is idle, transmit; otherwise go to Rule 2.

Rule 2: If the medium is busy, continue to listen until the channel is idle,then transmit
immediately.
Rule 3: If the collision is detected during transmission.
Rule 4: After transmitting the jamming signal, wait random amountsof time, referred to as the
backoff. (Repeat rule 1).

13) (a)Explain the methods for part family formation with a suitable illustration and
discuss with examples: "coding system structure"

Ans:
 13)(b)(ii) Discuss the benefits of computed aided processplanning (CAPP) and explain
CAPP approaches in detail

Ans: Process Rationalization and Standardization: CAPP loads to more logical and consistent
process plants than manual process, planning.

Producing Improvement: As a result of standard process plan, the productivity is improved.

Product Cost Reduction:Standard plans tend to result in lowermanufacturing costs and higher
product quality.
ELIMINATION OF HUMAN ERROR
Reduction in Time:As a result of computerising the work a job thatused to take several day is
now done in a few minutes.Reduce clerical effort and paper work.
Improved legibility:Faster response to engineering changesIncorporations of process
planning.
CAPP approaches:
• Retrieval CAPP system
• Generative CAPP system.

Generative CAPP Systems:

Thus the generative CAPP system automatically generates tileprocess plan based on decision
logics and pre-coded algorithms.
Retrieval CAPP System:
It is also called a variant CAPP system.
It is based on the principles of group technology and partsclassification and coding.
In this system, for each partfamily standard process plan is preparedand stored in computer
files.
Through classification and coding a code number is generated. The standard plan is retrieved
and edited for the new part.

14) (a)(i) What are the functions of shop floor control' (SFC)?

Ans: The major functions of shop float control are:

1. Assigning priority of each shop order (scheduling).

2. Maintaining work-in-process quantity information CD's patching. .
3. Conveying shop-orders status information to the office (follow up).
4. Providing actual output data for capacity control purpose.
5. Providing quantity by location by shop wider far work-in process inventory and accounting
purposes.
6. Providing measurement of efficiency, utilisation, andproductivity of manpower and
machines.

14) (a)(ii) Explain briefly the technologies used in Automatic Identification systems.
Ans:

1. Encoded Data: A code is nothing but a set of symbols orsignals, usuallyrepresenting

alphanumeric characters. Whendata are encoded, the characters are translated into amachine
readable code.
2. Machine Reader or Scanner: As the name suggests,machine reader is a device that reads
the encoded data. Forthis purpose, usually encoded data are converted into anelectrical analog
signal.
3. Decoder: Decoder transforms the electrical signal into digitaldata and finally back into the
original alphanumericcharacters.
Types of Automatic Identification Technologies:
1. Bar codes.
2. Radio frequency systems.
3. Magnetic stripe.
4. Optical character recognition.
5. Machine vision.

Bar Code Technology: Bar Code Technology is rapidlyreplacing the keyboard and other data-
entry devices forrecording manufacturing information and data.
Radio Frequency Identification (RFID):The item beingtracked has a transponder that
transmits a specific radiofrequency representing a unique signature or data streamthat the
transmitter or reader can interrogate.
Magnetic Identification: Magnetic identification systemsare based on magnetic strips similar
to those on the back ofmost credit/debit cards.
Optical Character Recognition: Another form, ofautomatic identification is optical character
recognition (OCR). OCR refers to the use of specially designed alphanumeric characters that
are machine readable by an optical rending device.

14) (b)(i) Explain the functions of a FMS computer control system. (8)
Ans:

1. Workstation/processing station control.

2. Distribution of control instructions to workstations.
3. Prodution control.
4. Material handling system control:
(i) Traffic control.
(ii) Shuttle control.
5. Workpiece monitoring.
6. Tool control:
(i) Tool location.
(ii) Tool-life monitoring.
7. Quality control.
8. Failure diagnosis.
9. Safety monitoring.
10. Performance monitoring and reporting.

14) (b)(ii) Discuss the application, advantages and disadvantages of a FMS

Ans:
EMS Applications:

1. Mac timing
2. Assembly
3. Sheet-metal press working
4. Forging
5. Plastic injection modulating
6. Welding
7. Textile machinery manufacture.

Advantages of FMS:

1. Increased machine utilization

2. Reduction inventory
3. Reduced manufacturing lead time
4. Greater flexibility in production scheduling
5. Reduce direct labour
6. Increased labour productivity
7. Shorter response time
8. Consistent quality
9. Improved product quality.

Disadvantages of FMS:

1. Very high capital investment is required to implement a FMS.

2. Acquiring, training and maintaining the knowledgeable labourpool requires heavy
investment.
3. Fixtures can sometimes cost much more with FMS, andsoftware development across costs
could be as much as12.20% of the total expense.
4. Since tool variety could undermine efficiency.
5. Complex design estimating method.

15) (a)(ii) Write short notes on material requirements planning (MRP)

Ans:
MRP is a computational technique that converts the master schedule far final products into a
detailed schedule for the raw materials and parts used in the final products.
Basic Characteristics of MRP: MRP drives demand for components, sub-assemblies,
materials, etc., from demand far and production schedules of parent items.
MRP offsets replenishment orders purchase orders or production schedules, relative to the
date when replenishment is needed.

Information, needed for MRP:

1. Demand for all products.

2. Let sizing policies for all parts.
3. Opening inventory levels,
4. Safety stock requirements.

Inputs to MRP:

1. Master production schedule.

2. Bills of materials file.
3. Inventory record file
.
Inputs to MPS:

1. Market requirements.
2. Production plan from aggregate planning.
3. Resources available.

15)(b)(ii) Describe the components and their arrangement of a direct digital control

Ans:
Each remote or satellite intelligence unit CSIU ran 2280 microprocessors whilst the front end
ran 11 in a parallel processingconfiguration with paged common memory.

Elements of a Direct Digital Control System:

Pointer:
The word pointerin used to describe data storage locations within aDDC system. Data can
come from sensors or from software calculationand logic. Data can also be sent to controlled
devices or softwarecalculations and logic. Each data storage location has a unique meansof
identification at addressing.
Direct digital source CDDCJ data can be classified three differentways by data type, data
flow and data source.

Data Type:
Data type is classified as digital, analog or accumulating. Digitaldata may also be called
directed data or binary data. The value of thedata is either 0 or I.

Data Flow:
Data flow refers to the data as a going into or out of the DDCcomponent/logic. Inputs points
describe data used on input informationand output points describe data that are output
information.

Controller:

A controller is defined as a device that has inputs (sensors), outputs(controllable devices) and
the ability to execute control logic (software).

LAN Communication:
Communication between devices on a network can be characterizedas peer-for-peer or
polling, on a peer-to-peer LAN, each devices canshare information LAN communication.
 15) (b) Explain about lean manufacturing.

Ans:
Lean manufacturing lean enterprises, or lean production, oftensimply, "lean", is a production
practice that considers the expenditure ofresources for any good other they’re the creation or'
values for the endcustomers to be tasteful, and thus a target for elimination.Lean is centred on
preserving valve with less work.Lean manufacturing is a management philosophy derived
mostlyfromthe Toyota production system (TPS) and identified as "Lean onlyin the 1990s".
TI,s is renowned for its focus on reduction of the original Toyotaseven wastes to improve
overall customers valve.The steady growth ofToyota, from a small company to the
world’slargest automates has focused attention on how it has achieved this.Since Taylor or
find and learning from their mistakes.
 B.E /B. Tech. DEGREE EXAMINATIONS, NOV-DEC 2013
Seventh Semester
Mechanical Engineering
ME 2402/ME 72-COMPUTER INTEGRATED
MANUFACTURING
(Regulation 2008/2010)

Part A

1) What are the advantages to be gained by the adoption of cad ?

Ans :
 Increased design productivity
 Shorter lead time
 Flexibility in design
 Improved design analysis
 Greater accuracy in design calculation

2) Specify the range of application for which the geometric modelling information is
used ?
Solid modelling, constructive solid geometry, boundary representation and wireframe
modelling.

3)Differentiate IGES and GKS Graphic standards?

Ans:

The Initial Graphics Exchange Specification (IGES) is a file format which defines a
vendor neutral data format that allows the digital exchange of information among Computer-
aided design (CAD) systems.

The Graphical Kernel System (GKS) was the first ISO standard for low-level computer
graphics, introduced in 1977. GKS provides a set of drawing features for two-dimensional
vector graphics suitable for charting and similar duties. The calls are designed to be portable
across different programming languages, graphics devices and hardware, so that applications
written to use GKS will be readily portable to many platforms and devices.
4) Differntiate modulation and Demodulation?
Ans: MAP (Manufacturing Automation Protocol) is an implementation of the OSI model. It
is hardware cum software implementable set of rules that facilitate information transfer
among network computer.

5) Explain opitz coding system ?

Ans: The opitz coding scheme uses three different codes
 The first five digits (12345) code the major design attributes of a part and are
called “form code “
 The next four digits (6789) are for coding manufacturing – related attributes
and are called “supplementary codes “.
 The letters (ABCD) code the production operation and sequence and are
referred to as “secondary code”
6) Define Group Technology?

Ans: Group Technology or GT is a manufacturing technique in which the parts having

similarities in Geometry, manufacturing process and/or functions are assembled together.

7)Mention the importance of shop floor control system (SFC)?

Ans: 1. Assigning priority of each shop order (scheduling).

2. Maintaining work-in-process quantity information CD'spatching. .

3.Conveying shop-orders status information to the office (followup).

4.Providing actual output data for capacity control purpose.

8) What are the inputs and outputs of MRP.

Input :
 Master Production Schedule
 Bill of material file
 Inventory record file
Output :
The output of MRP is the list of end items available every period that is feasible with
respect to demand and capacity.

9)Describe CIM data transmission methods?

 Ans:
 Analog Transmission
 Digital transmission

10) List Different types of production monitoring system?

Ans :
 Data acquisition system
 Data logging systems
 Multilevel Scanning

PARTB

12)(a)(i) Explain the open system interconnection architecture (OSI) formulated by ISO?
Ans:

Physical Layer: The physical layer is concerned with transmittingraw bits Over a
communication channel. The design issue ofphysical layer consider: electrical, mechanical,
functional andprocedural attributes.
Data Link Layer:The main task of the data link layer is totransfer a raw transmission facility
into a reliable link and isresponsible for node-ta-node delivery.
Network Layer:The network layer specifies the inter-networkoperations and different type of
addressing and routing services.Logical and service addressing are provided from network
layer.
Transport Layer: The transport layer is responsible for source-to-destination delivery of the
entire data.
Session Layer: It is the network dialog controller. If establishes,maintains, synchronizes, and
manages the interaction betweencommunicating system.
Presentation Layer:There is concerned with the syntax andsemantics of the information
exchanged between two systems.
Application Layer: The application layer enables the user, whether human or software, to
access the network.
12 a) (ii) Illustrate the communication matrix used in CIM ?

ANS:
• Person-to-Person Communication
• Computer-to-Computer Communication
• Machine-to-Machine Communication
• Person-to-Computer Communication
• Computer-to-Person Communication
• Person-to-Machine Communication
• Machine-to-Person Communication
• Computer-to-Machine Communication
• Machine-to-Computer Communication
1. Person-to-Person Communications (P-P)
./ The person-to-person communication is required to carry out all the manufacturing
activities of an enterprise.
./ From CIM perspective, the employees can to be communicated more via keyboards and
'soft' copies (video display units) rather than direct communication or through hard copies
(i.e., information on paper).
2. Computer-to-Computer Communications (C-C)
v' Since computer-to-computer communications forms the basis of all communications in
CIM, the rest of this chapter focuses on computer-to-computer communications.
v' In fact, the tremendous growth In computer technologies, communications, data
transmission methods, transmission medium, architectures and protocols, and databases have
made CIM a reality.
3. Machine-to-Machine Communications (M-M)
v' In this context, the term machine refers to any device or equipment other than computers.
v' In a manufacturing enterprise, manufacturing machines have to communicate with each
other through automation to achieve the set productivity.
v' Machine-to-machine communication is achieved using mechanisms such as gears, cams,
servo motors, hydraulic drives, pneumatic drives, PLCs, actuators, electromechanical
devices, etc.
4. Person-to-Computer (P-C) (or Computer-to-Person (C-M)) Communications
v' The development of high-level computer languages have increased the need for person-to-
computer communications in a manufacturing plant.
v' P-C communications call for the trend for user friendliness of equipment and software,
ergonomic designs of computer devices so that human comfort is ensured.
5. Person-to-Machine (P-M) (or Machine-to-Person (M-P)) Communications requires
minimal direct communication between machines and their operators.
v' The operators are assisted by database management system of CIM for any data retrieval
and storage, so that to effectively direct/control the machine operations.
v' However, CIM demands critical communication between machines and maintenance team
to maximize the machine utilization.

Computer-to-Machine (C-M) (or Machine-to-Computer (M-C})

Communications
../ It is found that the lack of computer-to-machine communication has been considered a
bottleneck in the development of CIM .
../ Machines used in a CIM environment have computers or built-in microprocessors.
This facilitates direct communication between computer and machine, With minimal
interfacing.

12 b) i) What are the network topologies available ? discuss them in detail ?

ANS :

Topology is a term used to describe the way in which computers/workstations are onnected in
a network. The physical topology describes the actual layout of the network hardware; the
logical topology describes the behaviour of the computer on the network, from the
perspective of its human operators.
The topology of a network is the geometric representation of the relationship of all the links
and linking devices (usually called nodes) to each other.
Thus the logical layout, or shape, of a network is called a topology. Topology defines the
physical or logical arrangement of links in a network.

15a) i) Discuss the benefits of direct digital control (DDC) ?

Some important advantages of the direct digital control system over the traditional analog
control system are given below.
1. DDC performs more-efficient control actions (than those by the analog control system).

2. DDC provides more control options (such as performing more-complex control algorithms,
and implementing on/off control and non-linearties in the control functions) than traditional
analog control system.

3. DDC has the ability to integrate feedback measurements from multiple loops and to
implement optimizing strategies to improve overall process performance.

4. A digital computer in DDC makes editing the control programs (such as programming and
reprogramming of control algorithms) much easier and less costlier.

15a) ii) Discuss the activities under computer aided manufacturing planning and
manufacturing control ?
 Activities of manufacturing planning include :
 Aggregate production planning
 Mater production planning
 Material requirements planning (MRP)
 Capacity Planning

Activities under manufacturing control :

 Shop floor control (SFC)
 Inventory control
 Manufacturing resource planning (MRP II)
 Just-in-time (JIT) production systems.

15 b i)Describe the features of MRP I and MRP II ?

ANS:
MRP I:
Material requirements planning (MRP) is a computational technique that converts the master
schedule for final products into a detailed schedule for the raw materials and parts used in the
final products.
Basic Characteristics of MRP
Two basic characteristics of MRP are:
1. MRP drives demand for components, subassemblies, materials, etc. demand for and
production schedules of parent items.
2. MRP offsets replenishment orders (purchase orders or production schedule relative to the
date when replenishment is needed.
. Information Needed for MRP
The following informations are needed for MRP:
-/' Demand for all products.
-/' Lead times for all finished goods, components, parts and raw materials.
-/' Lot sizing policies for all parts.
-/' Opening inventory levels.
-/' Safety stock requirements.
-/Any orders previously placed but which haven't arrived yet.
The three important inputs to MRP are:
1. Master production schedule,
 2. Bill of materials file, and
3. Inventory record file.
MRP Output:
The output of MRP is the list of end items available every period that is feasible with respect to
demand and capacity.

MRP II:
An expansion of the material requirements planning systems to include other portions of the
productive system was natural and to be expected. Manufacturing resource planning (MRP II)
represents the natural evolution of closed-loop MRP (materials requirements planning).
MRP II is an integrated information system that synchronize all aspects of the business.
system coordinates sales, purchasing, manufacturing, finance and engineering by adopting a
focal production plan and by using one unified database to plan and update the activities in all
the systems.
Important MRP II system functions include:
1. Management planning-business strategy, aggregate production planning master production
scheduling, rough-cut capacity planning, and budge planning.
2. Customer services-sales forecasting, order entry, sales analysis, and finish goods inventory.
3. Operations planning-purchase order and work order release.
4. Operations execution-purchasing, product scheduling and control, work-inprocess
inventory control, shop floor control, and labour hour tracking.
5. Financial functions cost accounting, accounts receivable, accounts payable general ledger,
and payroll.

15 b) ii) Brief Lean and Agile Manufacturing ?

Ans :
Lean production also known as lean manufacturing, is a set of tools and
methodologies that aims for the continuous elimination of all wastes in the production process.
./ Lean production is also called as the Toyota Production System (TPS), because the
concept was originated at Toyota motors, in Japan after World War H.
./ The term 'lean production' was coined by researchers at the Massachusetts Institute
of Technology (MIT) to describe the successful activities and programs o
Toyota motors.
 : Lean production can be defined as an adaption of mass production in which workers
and work cells are made more flexible and efficient by adopting methods that reduce waste in all
forms.

Lean manufacturing lean enterprises, or lean production, often simply, "lean", is a production
practice that considers the expenditure of resources for any good other they’re the creation or'
values for the end customers to be tasteful, and thus a target for elimination. Lean is centered
on preserving valve with less work. Lean manufacturing is a management philosophy derived
mostly from the Toyota production system (TPS) and identified as "Lean only in the 1990s".
TI,s is renowned for its focus on reduction of the original Toyota seven wastes to improve
overall customers valve. The steady growth of Toyota, from a small company to the world’s
largest automates has focused attention on how it has achieved this. Since Taylor or find and
learning from their mistakes.

Agile Manufacturing:
Agile manufacturing is a term applied to an organization that has created the
processes, tools and training to enable it to respond quickly to customer needs and market
changes while still controlling costs and quality .
Agile manufacturing can be defined as (i) an enterprise level manufacturing strategy of
introducing new products into rapidly changing markets, and (ii) an organizational ability to
thrive in a competitive environment characterized by continuous and sometimes unforeseen
change.
An enabling factor in becoming an agile manufacturer has been the development of
manufacturing support technology that allows the marketers, the designers and the production
personnel to share a common database of parts and products, to share data on production
capacities and problems--particularly where small initial problems may have larger
downstream, so that it is cheaper to correct quality problems at the earliest possible point in
the process.
Agile manufacturing is seen as the next step after LEAN is the evolution of
production methodology. The key difference between the two is like between a thin and an
athletic person, agile being the latter. One can be neither, one or both. In manufacturing
theory being both is often referred to as agile.
 B.E/B.TECH DEGREE EXAMINATION NOVEMBER/DECEMBER 2014

Seventh Semester

Mechanical Engineering

ME 2402- COMPUTER INTEGRATED MNUFACTURING

(Regulation 2008)

PART-A

1. Difference between 2D and 3D wire frame modeling ?

2D Wireframe:
Displays the objects using lines and curves to represent the boundaries. Raster and
OLE objects, linetypes, and lineweights are visible. Even if the value for the
COMPASS system variable is set to 1, it does not appear in the 2D Wireframe view.

3d Wireframe:
Displays the objects using lines and curves to represent the boundaries. Displays a
shaded 3D UCS icon. You can set the COMPASS system variable to 1 to view the
compass. Material colors that you have applied to the objects are shown.

2. What is sculptured surface?

Sculptured surfaces are used in geometric modelling to describe all sorts of bendy
things like aeroplane wings, car bodies, gas-turbine blades, ship's hulls and so on that
can't be described by simple curved surfaces such as cylinders and cones.

3. What are the specific characteristics that are to be incorporated in the CIM
system model?
1. The complexity of their operation
2. The large amount of data involved
3. Their cyclic operation
4. Uncertain or variant behaviour of certain behaviour
5. Their changing nature to accommodate new markets
6. Involvement of humans as part of the system

4. What does the term transmission mode refer to ? And also list the various types
of transmission mode?

There are three transmission modes available. They arc

iv) Simplex
v) Half-duplex
vi) Duplex.
 5. List any four design considerations guiding the cell formation?

1. Parts/products to be fully completed in the cell.

2. Higher operator utilisation
3. Fewer operations than equipment
4. Balanced equipment utilisation in the cell.

6. What are the various components of a CAPP system?

CAPP system contains of two main components.

1. Manufacturing data base (part description, machine tool library etc.)
2. Decision logic (to represent the process planner)

7. What are objectives of FDC system?

The purpose of the Factory Data Collection (FDC) system in shop floor control is to provide
basic data for monitoring order progress. In a computerized SFC system these data are
submitted to the order progress module for analysis and generation of work order status reports
and exception reports.

8. Differentiate the primary and secondary material handling system.

The primary handling system establishes the FMS lay-out and is responsible
for moving parts between stations in the system.

The secondary handling system consists of transfer devices, automatic pallet

changers, and other mechanisms to transfer parts from the primary material handling
system to the workhead of the processing station, or to a supporting station.

9. What is Direct digital control?

Direct digital control (DDC) is the automated control of a condition or

process by a digital device (computer). DDC is considered by many to be a more
modern, granular and responsive update to older HVAC controlsystems based upon
PLC technologies.

10. What is master production schedule?

MPS is a detailed plan that states how many end items (i.e the final product to be sold to
thecustomer) will be available for sale or distribution during specific periods.

Part B (5 X 16 = 80 Marks)

11) a) i) Explain briefly the surface modeling facilities available in an advanced modeler

An advanced surface modeler helps to design complex sculptured surfaces easily. They
provide a number of tools for model creation, shape control and visualization.

i. Model creation features for curves and surfaces:

• Accurate fitting of unevenly spaced points
• Control over tangency, curvature and inflection
• Capability of one surface on to another
• Projection of one surface on to another
• Offset curves
• Planar and ruled surfaces
• Surfaces of revolution
• Lofting
• Sweeping
• Blending
• Surface created from 3-D digitized points
• Interpolation of surfaces
• Offset surfaces
• Split and merging of surfaces

ii. Shape control of surfaces:

Advanced surface modeling softwares make it easy to effect changes in design
and shape. They provide what is called variational constraint based shape control.
Shape control can be effected through dimensional or geometric constraints and
can have tangent associativity. Surface can also be controlled by equations.
Advanced energy based shape control helps to:
• fair curves
• achieve higher order edge/tangency control
• introduce local bulges or inflections
• shape curves locally to fit a specific point

iii. Visualization:
Surface models have visualization tools for shading, hidden line elimination,
creation of perspective views and evaluated surface displays.

ii) Write a shorts on generative NC machining based on solid modeling.

The geometry of solid models can serve as the basis for generating CNC codes for
manufacturing the component. Solid modeling based generative machining software helps to:
(i) evolve stock model
(ii) capture manufacturing planning
(iii) design the tooling
(iv) develop feature driven machining programs

Solid modeling based machining software encompasses the complete machining

environment. The tool paths generated by it avoid grouping of parts, avoid collision with
clamps and optimize motion. Thus solid modeling technique helps in
(i) conceptualize the design
(ii) provide interface to analysis
(iii) generate NC tool paths

A number of software packages are available now for modeling. Important among
them are:

 AUTOCAD
 IDEAS
 PRO/ENGINEER
 UNIGRAPHICS
 CADDS V
 CATIA
 CADAM
 IEMS
 SOLID WORKS
 SOLID EDGE
 IRON CAD

Or

b) i) Explain the characteristics of solid modeling packages

Several important characteristics of solid modeler make them capable of creating

designs faster. These include parametric design, the ability to establish relations and the
ability to build assemblies.
Parametric Design
When a feature is created in a solid modeler dimensions are created. These
dimensions do more than show the size of the feature. They define parameters that control
part geometry. Since parameters control geometry, the geometry is said to be dimension
driven. Parameters can be driven by dimensional values, or they can be driven by other
parameters using a relation.

For instance, the length parameter of a feature is set up so that it is always twice the
width parameter. If the width changes, the length will change too.

There are other kinds of values that can be used as parameters. A formula that relates
specific feature geometry to volume, temperature, stress, weight, and other properties can
also be used in parametric designs. When parameters change, other parameters driven by the
modification also change. This is the essence of parametric design.

Relations and Relationships

 Solid models provide two fundamental ways to relate elements of geometry to one
another within a design. One is as already mentioned i.e. setting up relations between
parameters. The length to width example just described shows a simple application of
parametric relations. Another example that gives a better idea of the power of relations.

Within an assembly, the designer can define a relation such that the diameter of a bore
in one component part always equals the diameter of a shaft, plus a clearance value,
on another part. This relation ensures that the parts always fit in an assembly, even if the
diameter of the shaft changes. If the design engineer modifies the diameter of the shaft, the
diameter of the bore automatically changes to accommodate it.

Behaviour Modeling
Behavior modeling is the latest development in mechanical CAD. It gives the
designers more efficient and adaptable ways of creating designs. It helps to synthesize
required functional behavior, design context and geometry. Through an intelligent process of
knowledge capture and iterative solving behavior modeling allows engineers to pursue highly
innovative and robust designs. The process of behavior modeling involves:

Smart models: These encapsulate engineering intelligence. Designs are created using
feature based techniques, which capture geometry, specifications, design intent, and process
knowledge-all at the design level. Engineering objective based design:
Design tools use feature based design specifications within the smart model to drive and
adapt product design. Using objective driven functions, engineers can arrive at an optimum
design, even in designs with several
variables and constraints and multiple objective criteria.

ii) Explain briefly the basic 3D transformation for scaling, translation and
rotation

2D TRANSLATION:
 Translation is nothing but moving an object across the screen from one position to
another.
 The translation transformation positions the object to a new location.
 The translation is accomplished by adding the coordinates of each corner point the
distance through which the object is to be moved.
 Translation of a point: Consider a 2D point P, having coordinates x, y. To translate
point P by a distance x in x-direction, a translation matrix is added to the original
matrix. Now the point has new coordinates.
 The translation of point P about original position to its new position.
2D SCALING:
 Scaling is the transformation and used to change, increase or decrease, the size of an
object.
 Scaling can be achieved by multiplying and the original coordinates of an object by
the scaling factor, along x direction and y along the y-direction.
  Scaling factors are always positive. If the scaling factor is less than 1, the object is the
compresses of the scaling factor is more than 1, the object is stretched.
 If scale factors are different, the object changes in both size and shape. This
differentiating scaling is known as non-uniform scaling.
 The different cases of scaling transformation are illustrated.
2D ROTATION:
 Rotation refers to the movement of an object in such a way that the distance between
a certain fixed point and any given point of that body remains constant.
 In mathematics, the rotations a transformation technique is commonly used in
rendering and animation techniques.

12) a) i) Discuss how CIM can act as an enabling technology for concurrent engineering

Concurrent engineering or Simultaneous Engineering is a methodology of

restructuring the product development activity in a manufacturing organization using a cross
functional team approach and is a technique adopted to improve the efficiency of product
design and reduce the product development cycle time. This is also sometimes referred to as
Parallel Engineering. Concurrent Engineering brings together a wide spectrum of people from
several functional areas in the design and manufacture of a product.
Representatives from R & D, engineering, manufacturing, materials management,
quality assurance, marketing etc. develop the product as a team. Everyone interacts with each
other from the start, and they perform their tasks in parallel. The team reviews the design
from the point of view of marketing, process, tool design and procurement, operation, facility
and capacity planning, design for manufacturability, assembly, testing and maintenance,
standardization, procurement of components and sub-assemblies, quality assurance etc as the
design is evolved.
Even the vendor development department is associated with the prototype
development. Any possible bottleneck in the development process is thoroughly studied and
rectified. All the departments get a chance to review the design and identify delays and
difficulties. The departments can start their own processes simultaneously. For example, the
tool design, procurement of material and machinery and recruitment and training of
manpower which contributes to considerable delay can be taken up simultaneously as the
design development is in progress. Issues are debated thoroughly and conflicts are resolved
amicably.

Concurrent Engineering (CE) gives marketing and other groups the opportunity to
review the design during the modeling, prototyping and soft tooling phases of development.
CAD systems especially 3D modelers can play an important role in early product
development phases. In fact, they can become the core of the CE. They offer a visual check
when design changes cost the least. Intensive teamwork between product development,
production planning and manufacturing is essential for satisfactory implementation of
concurrent engineering.
 The teamwork also brings additional advantages ; the co-operation between various
specialists and systematic application of special methods such as QFD (Quality Function
Deployment), DFMA (Design for Manufacture and Assembly) and FMEA (Failure Mode and
Effect Analysis) ensures quick optimization of design and early detection of possible faults in
product and production planning. This additionally leads to reduction in lead time which
reduces cost of production and guarantees better quality.

ii) Discuss the hierarchical structure of computer control of manufacturing

system.

With the hierarchical structure, the interpretation of each succeeding symbol depends
on the value of the preceding symbols. In the chain type structure, the interpretation of each
symbol in the sequence is fixed and does not depend on the value of preceding digits. Most of
the commercial parts coding systems are used in industry are a combination of the two pure
structures.

When selecting a coding system for a component’s representation, there are several
factors to be considered. They include:

i. The geometry of components (i.e., rotational, prismatic, deep drawn, sheet metal etc.)
ii. The code structure
iii. The digital representation (i.e., binary, octal, hexadecimal etc.)
iv. Material of manufacture - ferrous, non ferrous, plastics, composites etc.
When using a code to represent an engineering design, it is important to represent the basic
features of the design. For process planning, it is desirable to have codes that can distinguish
unique production families. Some of the coding systems that have been successfully
implemented in process planning are given below:

i. OPITZ system
ii. The CODE system
iii. The KK-3 system
iv. The MICLASS system
v. DCLASS system
vi. COFORM (coding for machining)
Or

b) Explain the two modes of transmitting the binary data across a link.

Network technology can be broadly classified into two categories. They are Local
area network (LAN) or Wide area networks (WAN). LANs are intended to serve a number of
users who are physically located close together. WANs are more akin to telephone network,
tying different people in different buildings, cities or even countries.

LAN
 A network is a linking of a group of computers to communicate with each other and
share software and hardware resources via the cables and interfaces that connect the
computers and peripherals. Application softwares used in a network allow several users
access the same program and data at the same time. As the name implies, a Local Area
Network or LAN is a system that covers short distances. Usually LAN is limited to a single
department or a single building or a single campus. Typical data transmission speeds are one
to 100 megabits per second.

Local area networks (LANs) fall into different sizes. Their topology, access method,
medium, and market are different throughout. It is a private data communications system
covering a limited geographical area, which is typically about a kilometre long. A LAN lets a
factory network communicate with computers vertically and horizontally. It allows sharing of
input and output devices and databases. The LAN allows access to remote mainframes. Many
LAN topologies are available today.

WAN
A message is routed through several interim points before reaching its final
destination; a WAN may also incorporate the ability to automatically change to an alternate
message routing path if the computer at one location fails. A LAN (local area network) has 2
to 10 times more traffic on it than a wide area network (WAN). Each individual point within
a network that can communicate through the network is called a node. Each node is assigned
a unique address. This way, a destination address can be put into each message and it can be
sent to correct recipient.

13) a) i) Discuss the following with examples : Mono code, poly code and mixed code.

Mono code or Hierarchical code

The structure of these codes is like a tree in which each symbol is qualified by the
preceding characters. Figure 7.1 depicts the monocode generation scheme. The first digit
(from 0 to 9) divides the set of parts into major groups such as sheet metal parts, machined
parts, purchased parts, and raw materials, and so forth. The second subsequent digits further
partition the set into subgroups for each of these groups. For example, the second digit
partitions the machined parts into rotational (0) and nonrotational (1) parts. Consider a code
100 in figure 7.1. It represents a machined rotational part with a length to diameter ratio of
less than 0.5. The digit 1 in the first place of code has different meaning and different
information. Therefore, the digits in a monocode cannot be interpreted
independently; the interpretation depends on the information contained in the preceding
symbol.

Advantage:
 It can represent a large amount of information with very few code positions.
  The hierarchical nature of the code makes it useful for storage and retrieval of design
related information such as geometry, material, and size as depicts in figure7.1.

Disadvantage:
 A drawback is related to the complexity of the coding system.
 The applicability of these codes in manufacturing is limited, as it is difficult to cover
information on manufacturing sequences in hierarchical manner.

Chain code or Poly code

In polycode the code symbols are independent of each other. Each digit in specific location
the code represents a distinct bit of information. Numeral 3 in the third position always means
axial and cross hole no matter what numbers are given to position 1 and 2.

Advantages:
Chain codes are compact and are much easier to construct and use.

Disadvantage:
They cannot be as detailed as hierarchical structures with the same number of coding
digits.

Mixed code is mixture of the hierarchical code and chain code (Figure 7.2). It retains the
advantage of both mono and chain code. Therefore, most existing code system uses a mixed
structure. One good example is widely used optiz code

ii) Discuss the various benefits of implementing the GT in a firm and also discuss
about the advantageous and limitations of using GT.

Implementation of group technology results in more focused factories.

When group technology is applied, a manufacturing company will typically realize the
following benefits:
Product engineering -
 Reduce part proliferation
 Help design standardization
 Provide manufacturing feed back
Manufacturing engineering -
 Process selection
 Tool selection
 Machine purchases
 Material handling
Production engineering -
 Reduce lead time
 Reduce delays
 Reduce set-up time
 Improve product quality
Production planning and control -
 Group scheduling
 Stock accountability
 Reduce expediting
 Improved product design
 Reduced materials handling
 Better employee satisfaction

Other benefits:
• Increased productivity
• Improved accuracy in estimation of costs
• Greater standardization and variety reduction
• Reduced set up times
• Better product delivery (Helps to implement just-in-time (JIT) manufacturing)
• Reduced cost of purchasing
 • Improved plant efficiency

Or

b) Explain briefly on CAPP. In what ways CAPP is considered very significant. What
factors should be considered while selecting the best CAPP system.

In conventional production system, a process plan is created by a process planner. It

requires a significant amount of time and expertise to determine an optimal routing for each
new part design. However, individual engineers will have their own opinions about what
constitutes the best routing. Accordingly there are differences among the operation sequences
developed by various planners. Efficient process planning requires the service of experienced
process planners. Because of the problems encountered with manual process planning,
attempts have been made in recent years to capture the logic, judgment and experience
required for this important function and incorporates them into computer programmes. Based
on the features of a given part, the program automatically generates the sequence of
manufacturing operations. The process planning software provides the opportunity to
generate production routings which are rational, consistent and perhaps even optimal.

It has the following advantages:

i. Reduces the skill required of a planner.
ii. Reduces the process planning time.
iii. Reduces the process planning and manufacturing cost.
iv. Creates more consistent plans.
v. Produces more accurate plans.
vi. Increases productivity.

The current approaches for computer aided process planning can be classified into two
groups:
i. Variant
ii. Generative
 Structure of a typical CAPP

CAPP BASED ON CAD MODELS

Using a CAD model as input to a process planning system can eliminate the human
effort of translating a design into code and other descriptive form. A CAD model contains all
the details about a design. However, an algorithm is necessary to identify a general machined
surface in a CAD model. Additional code is needed to convert the machined surface shape
from raw material shape. CAD/CAM system uses a CAD model as its input. Several other
systems such as GENPLAN, AUTOPLAN, etc., also use a CAD database interactively for
tool and fixture selection.

CAPP BASED ON DECISION LOGIC

The decision logic determines how a process or processes are selected. The major
function of the decision logic is to match the process capabilities with the design
specification. The different techniques in decision logic are:
i. Decision trees
ii. Decision tables
These two techniques are methods of describing or specifying the various actions associated
with the combination of input conditions.

CAPP BASED ON ARTIFICIAL INTELLIGENCE (AI)

 AI can be defined as the ability of a device to perform functions that are normally
associated with the human intelligence. These functions include reasoning, planning, and
problem solving. Applications for AI have been in natural language processing, intelligent
data base retrieval, expert consulting systems, theorem proving, robotics, scheduling, and
perception problems. Process planning applications have been considered as part of an expert
consulting system.

14) a) i) List and briefly explain the various priority sequencing rules used for job
sequencing

The order schedule module addresses to two important activities in shop floor
production control.
(i) Machine loading
(ii) Job sequencing.
Allocating the orders to the work centres is termed as machine loading or shop loading,
which refers to the loading of all machines in the plant. In most cases each work centre will
have a queue of orders waiting to be processed. This queue problem can be solved by job
sequencing. This involves determining the order in which the jobs will be processed through
a given work centre. To determine this sequence, priorities are given to jobs in the queue and
the jobs are processed according to the priorities. Several queuing models are available in
operations management to solve this problem. This control of priorities is an important input
to the order scheduling module.

Rules to establish the priorities are:

(i) Earliest due date: These are given high priority
(ii) Shortest processing time: Shorter processing time orders are given high priority.
(iii) Least slack time: Orders with least slack time are given high priority.

Fluctuations in market demand, equipment breakdown, cancellation of the order by

customer and defective raw material or delay in the receipt of materials affect the priority.
The priority control plan reviews the relative priorities of the orders and adjusts the dispatch
list accordingly.

ii) Explain briefly the technology used in Automatic identification system for
computer process monitoring.

i) BAR CODE TECHNOLOGY

Bar code technology is primarily an automatic identification technique. The data is simply
reduced to a printed form, which consists of a symbol made of successive line segments. A
bar code reader is used to illuminate the bar code symbol and examine successive segments
of the symbol. The detected area may be a highly reflected area (space) or a non-reflective
(bar). As the reader moves reader over the bar code symbol, due to reflectivity and
nonreflectivity,
alternate transitions from light to dark and dark to light occur. These are detected
and the time it will take will be converted to digital representations of ones and zeros of
the bar code messages. Most commonly used bar codes are:

(i) Universal Product Code (UPC)

(ii) Interleaved 2 of 5 (ITF)
(iii) Code 39
There are two types of bar code readers. They are classified as:
(i) Fixed Beam Reader
(ii) Moving Beam Reader

ii) OPTICAL CHARACTER RECOGNITION

The optical character recognition (OCR) employs special fonts which can be read by man and
machine. This is more reliable than key entry but less reliable compared to bar code
technology. OCR fonts or characters are ‘read’ by software template techniques or feature
extraction or combination of both. So each character is to be unique compared to other
characters in the set.

When a number of pages of data are to be input to a computer system, optical page readers
are very useful. Optical page readers are similar to the office copiers. In OCR, entire page is
to be scanned before next page is presented to the reader. The characters in a page are
identified by the reader by the specific font styles and sizes.

In OCR, the reading device is to be passed over the OCR character a number of times. Here,
the reader must be precisely positioned over the string which is to be read. The poses a
problem when long strings of information are to be read. OCR is very sensitive to the motion
of the operator’s hand during reading. OCR can not read the symbols on the moving objects.
To read the information on the moving objects a strobe light is to be synchronized with
object.

Or

b) i) List and explain the functions of the material handling system in a FMS

The work stations/processing stations used in FMS depends upon the type of product
manufactured by the system. The types of work stations that are usually found in FMS are,
1. Load/unload stations
2. Machining stations
3. Assembly work stations
4. Inspection stations and
5. Other processing stations

Load/unload stations
 This is the physical interface between the FMS and the rest of the factory.
 At loading stations, raw work parts enter the system.
  At unloading stations, finished parts exit the system.
 Both accomplished either by manually or by automated handling systems.
Machining Stations
 It is a multipurpose CNC machine tool that has an automatic tool changing capability
 CNC machining centers possess the features such as
i. Automatic tool changing and storage
ii. Use of palletized work parts
iii. Use of CNC and
iv. Capability for distributed numerical control (DNC)
 Different modules including
a) Turning modules
b) Milling modules
c) Head changers
d) Head indexes

Assembly Workstations

 Assembly operations are performed by some FMSs.

 Flexible automated assembly workstations are used in FMS for products made in
batches.
 For this purpose industrial robots are considered as the most appropriate automated
assembly workstations.

Inspection stations:

 The inspection operations can be done either at machining work stations itself or at
specific inspection stations.
 The following inspection methods/equipments are used
i. Coordinate measuring machine
ii. Special inspection probes and
iii. Machine vision

Other processing stations

In additions to machining centers, a FMS often has

 Sheet metal processing workstations
 The forging processing stations

In addition to above work stations other stations include

 Stations for cleaning part/pallet fixtures,
 Central coolant delivery systems for entire FMS and
 Centralized chip removal systems
(ii) List the applications of FMS

1. Machining
2. Assembly
3. Sheet metal press working
4. Forging
5. Plastic injection moulding
6. Welding
7. Textile machinery manufacture and
8. Semiconductor component manufacturing

ii) Write short notes on automated guided vehicle system.

Automatic Guided Vehicles (AGV)

AGV is one of the widely used types of material handling device in an FMS. These
are battery-powered vehicles that can move and transfer materials by following prescribed
paths around the shop floor. They are neither physically tied to the production line nor driven
by an operator like forklift. Such vehicles have on-board controllers that can be programmed
for complicated and varying routes as well as load and unload operations.

The computer for the materials handling system or the central computer provides
overall control functions, such as dispatching, routing and traffic control and collision
avoidance. AGV’s usually complement an automated production line consisting of conveyor
or transfer systems by providing the flexibility of complex and programmable movement
around the manufacturing shop.

15) a) (i) State the principles of lean manufacturing and list down major kinds of
wastages.
Key Principles of Lean Manufacturing:
1. Recognition of wastes.
2. Standard processes.
3. Continuous flow.
4. Pull-production.
5. Quality at the source.
6. Continuous improvement.
Main Kinds of Wastes:
1. over production.
2. Defects.
3. Inventory.
4. Transportation.
5. Waiting.
6. Motion.
7. Correction.
8. Over processing.
9. Knowledge disconnection.

15. (a) (ii) Discuss the types of production monitoring systems.

Production Monitoring System: Computer process monitoring,also known as production
monitoring, is a data collection system in whichcomputer is connected directly to workstation
and association equipment for the purpose of observing the operations.Computer process
monitoring involves the use of computer to observe the process and associated equipment and
to collect and recorddata from the operation.
Three important topics related to the technology and applications of automated data
collection system for computer process monitoring are:

1. Data acquisition systems

2. Data logging systems.
3. Multilevel scanning.

Data Acquisition Systems: A data, acquisition system (ADAS) is a computer system used to
automatically collect data from a process or piece of equipment. These perform an analysis of
data or transmit the data to another computer for processing and analysis. A
microprocessor/minicomputer is used as the controller (or) processor in DAS.
Data Logging Systems: A data logger (DL) 'is a device that automatically collects and stores
data for offline (batch) analysis. The data logger can be interfaced with tape punches,
magnetic tape units, printers, plotters and so on.
Multilevel Scanning: In a multi-level scanning, there are two levels of process scanning
performed by the computer system, a high level scanned a low level scan. High level
scanning is used to scan key variables and status data, during normal operation of the
process.Low level scanning involves a more complete data logging and analysis procedure to
a certain source of malfunctions.
Or
 b) What is MRP? Explain the inputs to MRP and various MRP outputs. Also list
the various benefits of MRP.

MRP is effectively a large calculator, so what information does MRP use in its
calculations? MRP needs the following information (and for it to be accurate) in order to
suggest sensible parts ordering dates & amounts and achievable work plans:
 A bill of material (BOM) for each project / job / order (an example of a BOM is given
below)
 A build / work time for each part of each job (i.e. design, assembly, painting, testing
etc.)
 A complete on-hand inventory of all parts i.e. an accurate record of the number of
stocked parts.
 Delivery lead times of parts i.e. the elapsed time from order placement to parts being
received at your company.
 The due date (expected delivery) of the job / order to the customer.
A bill of material, or BOM, is basically a structured list of all the parts (including
quantities) that are needed for a job / project.
The BOM defines the structure of the job and all the parts that are required.
In addition to this information MRP will also be told information such as: the amount of time
it takes your suppliers to deliver the parts that need ordering; the build time of the sub-
assemblies; the time taken to test the job, and so on.
Using this information in conjunction with the BOM means that MRP can plan
backwards from the planned delivery date of the job and will suggest dates that parts need to
be ordered by and work needs to have started by if the job is to be completed on time. MRP
will also flag tasks that are slipping and parts shortages.

Inputs of MRP:
The three important inputs of MRP are:
1. Master Production Schedule.
2. Bill of Materials.
3. Inventory Record File.

Master Production Schedule: Master Production Schedule (MPS) is a detailed plan that states
how many end items (i.e., the final product to be sold customer) will be available for sale or
distribution during specific periods.
Purpose of MPS:
The MPS is used:
i) To set due dates for the availability of ends items.
ii) To provide information regarding resources and materials required to support the
aggregate plan.
iii) As the input to MRP, this will set specific production schedules for parts and components
used in end items
Bill of Materials: The bill of material designates the what items and how many of each are
used to make up a specified final product. The bill of materials file is used to compute raw
materials and components required for end products lists in the master schedule.

Inventory Record File:AIl the data related to the inventory are recorded in the inventory
record.

The inventory record file contains the following three segments:

1. Item master data segment: It provides the items identifications by part number and other
data, such as lead time, cost and quantity.
2. Inventory status data: It provides a time phased record ofinventory status.
3.Subsidiary data segment: It provides subsidiary data such aspurchase orders scrip or rejects
and engineering changes.
Output :
The output of MRP is the list of end items available every period that is feasible with
respect to demand and capacity.
 B.E/B.TECH DEGREE EXAMINATION APRIL/MAY 2015

Seventh Semester

Mechanical Engineering

ME 2402- COMPUTER INTEGRATED MNUFACTURING

(Regulation 2008)

PART-A (10 * 2 = 20)

1) Write the various methods for representing the solids in CAD.

The solid representation of an object is based on the idea that a physical object
divides an n-dimensional space En into two regions: interior and exterior separated by
the object boundaries (two-manifold objects)

2) Mention the reasons for implementing CAD.

 Increase the productivity of the designer.
 Improve the quality of a design
 Improve the communication
 Minimize the errors

3) What is meant by topology?

Topologies are the ways of routing the interconnections. Eg: Star network, bus
network etc.

4) Write the types of guided media.

Twisted pair, Co-axial cable, Optical fibre

5) List the factors to be considered in selection of coding system.

i. Systems based on design attributes
ii. Systems based on part manufacturing attributes
iii. Systems based on both design and manufacturing attributes

6) List any two advantages of CAPP.

 Reduces the skill required of a planner.
 Reduces the process planning time.
 Reduces the process planning and manufacturing cost.
 Creates more consistent plans.
 Produces more accurate plans.
 Increases productivity.

7) Define Master production schedule.

The master schedule is a macro level document which sets top-level priorities
for what
 will be manufactured and when, looking at the material that will be required over the
production cycle.

8) Write the main elements of FMS

 Production equipment,
 Support systems,
 Materials handling system,
 Automated storage and retrieval systems.

9) List the types of Inventory

Raw materials, Work-in-process, finished good, Transit inventories, Buffer inventory.

10) Define the term direct digital control.

Direct digital control (DDC) is the automated control of a condition or process
by a digital device (computer). DDC is considered by many to be a more modern,
granular and responsive update to older HVAC controlsystems based upon PLC
technologies.

PART-B (5 * 16 = 80)

11 a) i) What are the homogenous co-ordinates? How can the composition of 2D

Transformation be carried out?

Each transformations with the exception of translation can be represented as a row vector X,
Y and a 2 X 2 matrix. However, all the four transformations discussed above can be
represented as a product of a 1 X 3 row vector and an appropriate 3 X 3 matrix. The
conversion of a two-dimensional co-ordinate pair (X, Y) into a 3-dimensional vector can be
achieved by representing the point as [X Y 1]. After multiplying this vector by a 3 X 3 matrix,
another homogeneous row vector is obtained [X1 Y1 1]. The first two terms in this vector are the co-
ordinate pair which is the transform of (X, Y). This three dimensional representation of a two
dimensional plane is called homogeneous coordinates and the transformation using the homogeneous
co-ordinates is called
homogeneous transformation. The matrix representations of the four basic transformations are given
below.
 ii) What is CAD ? Discuss the various design related tasks performed by CAD.

Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing.

The various design related tasks performed by CAD are as follow as:

i) Interactive computer graphics and modeling

Interactive Computer Graphics features a top-down, programming-oriented approach to

computer graphics. Capitalizing upon this top-down and hands-on approach, the text quickly
gets students writing interesting 3D graphics programs. Angel uses OpenGL, a graphics
library supported by most workstations, and the C++ programming language, allowing
students to be aware of what is happening at the lowest levels of computer-graphics
programming.

ii) Computer aided engineering

Computer-aided engineering (CAE) is the use of computer software to simulate

performance in order to improve product designs or assist in the resolution of engineering
problems for a wide range of industries. This includes simulation, validation, and
optimization of products, processes, and manufacturing tools.

iii) Computer aided drafting

Computer-aided drafting (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing. CAD output is often in the form
of electronic files for print, machining, or other manufacturing operations.

iv) Computer Integrated manufacturing

Computer-integrated manufacturing (CIM) is the manufacturing approach of using

computers to control the entire production process. This integration allows individual
processes to exchange information with each other and initiate actions. Through the
integration of computers, manufacturing can be faster and less error-prone, although the main
advantage is the ability to create automated manufacturing processes. Typically CIM relies
on closed-loop control processes, based on real-time input from sensors. It is also known as
flexible design and manufacturing

Or

b) i) Discuss the computer graphics display devices.

Modern computer graphics displays are simple in construction. They consist of

basically three components.

i. Monitor

ii. Digital Memory or Frame Buffer

iii. Display Controller

Most of the computer graphics displays use raster CRT which is a matrix of discrete
cells each of which can be made bright. A graphic entity like line or circle is represented as a
series of “points or dots” on the screen. Therefore, it is called as a point plotting device. The
video display screen is divided into very small rectangular elements called a picture element
or pixel. This happens to be the smallest addressable screen element.

Graphic images are formed by setting suitable intensity and color to the pixels which
compose the image. Depending upon the resolution screens may have varying number of
pixels. For example, an SVGA monitor with a resolution of 1024 x 768 will have 1024 pixels
in every row (X - direction) and 768 pixels in every column (Y-direction). Monitors of larger
size will have resolution of 1024 x 1024 or more. A raster scan system displays the image on
a CRT in a certain fixed sequence. The refresh rate is the number of complete images or
frames scanned per second.

In the case of interlaced refresh cycle odd numbered raster lines are refreshed during
th
1/60 of a second. Even numbered raster lines are refreshed during the next 1/60th of a
second. In non-interlaced displays, all lines are refreshed in 1/60th of a second. The quality of
noninterlaced display is hence, superior. These systems, however, require expensive frame
buffer memory and display controller.

ii) List the benefits and applications of CAD.

Applications and benefits of CAD

 Two Dimensional Drafting: This is the most common use of a CAD package. 2-D
drawings are used for manufacturing a product.

 Report Generating: To generate reports and bill of materials. Spreadsheets and word-
processors can be linked to provide a report writing facility.

 3-D Modeling: To create the wireframe, surface and solid models. The 3-D models are
for concept verification, manufacturing, FEA, etc.

 Finite Element Analysis: FEA package is used for pre-processing, analysis, and post-
analysis of structures. For this application, a CAD package contains both the modeling
and analysis modules.

 Manufacturing: manufacturing software is usually called CAM, and contains CAD

software as one of the components. CAM software provides capabilities of carrying out 2
and 3-axes machining.

12. a) i) State the special features of LAN. Also describe the various elements of LAN.

Features of LAN
1. Networking limited to a small geographical area (less than 1km radius)

2. High speed data transfer.

3. Data error rate is very less since data is transffered to limited distance.

4. Managing local area networks is easy as only a single technology and symmetrical topology is
used.

5. Only limited number of computers connected in a LAN network.

6. Types of data supported is tailored to the application.

A LAN in a CIM setup is a system comprising the following basic elements:

(i) Computers: (PC’s, Design Workstations, CNC Systems, robots, PLC’s etc.)

(ii) Network Cable: A transmission cable is attached to each device (computer/ peripheral) to enable
the transmission of messages from one device to another.

The two major means of electrically carrying data on a LAN are as follows:
BASE BAND allows devices to send digital data at a set speed. All nodes in the LAN are
exposed to data, but a node will ignore a message if it is intended for another node. BROAD BAND is
similar to cable television. A number of very high frequency signals are placed in line and data is sent
using these signals as “carriers,” in the same way as television uses several channels. Several
“networks” can, in essence, share the same cable, because it is possible to filter out all but desired
“carriers”.
(iii) Network Interface Card (NIC): This is communication hardware in the form of an add-on card for
sending and receiving messages. This is also called network adapter. NIC is plugged into one of the
slots of the PC expansion slots and the transmission cable is attached to the connector provided on the
card.

(iv) Network Server: Network Server is the computer used to manage shared resources. Server is a
combination of hardware and software. The file server performs the following tasks:
• Manages the shared hard disc
• Makes sure that multiple requests do not conflict each other
• Protects data
• Prevents unauthorized access to databases and application programs
• Maintains a list of privileges and authorizations

(v) Central Mass Storage: The hard disc of the file server should have sufficient capacity (usually in
term of several Gigabytes) to meet the storage requirements of the users of the network.

ii) What is meant by product data management ? Explain why it is important in

CAD/CAM integration.

Databases are one component needed to deliver instant, accurate data. Engineering
information systems are the other. An engineering data management system should automatically
notify members of the design team with updates and circulate latest change orders. In order to derive
maximum benefit from CAD it must be possible to deliver CAD data efficiently and seamlessly to all
downstream applications related to engineering planning. Product data management is a technology
developed to meet this need. PDM systems work on network layouts called client-server architectures.
The server is also called a vault, even though the information may be distributed over several
workstations. The vault acts as the heart of an engineering network. The vault or the server has the
capabilities to handle efficiently large amounts of complex information. Product development
engineers access the vault through their desktop computers called clients.
This client-server idea works efficiently because it runs on two separate, synchronized
databases. One database stores product information such as CAD drawings, part specifications,
analysis data, and manufacturing product information. The other database, called a meta database is a
relational database that stores information about the data. For example given a drawing number this
gives information about the attributes of the drawing i.e. where a drawing is stored and when it was
last updated etc. The client software lets the clients talk to the server, allowing design engineers,
manufacturing engineers, and
manager’s access to the information stored.

The features of a PDM system include:

 Electronically track, access, sort and retrieve design data enabling the engineers to work on the
most recently updated designs.
 Integrating the design environment by providing facilities for viewing drawings created in
different CAD systems like AutoCAD, PRO/E, Unigraphics, CADDS 5, I-DEAS, Solid Edge,
Solid Works etc.
 Providing a CAD view-and-mark up package to view complete designs on the screens of the
clients so that planning engineers can satisfy themselves that designs are complete before they
are released to manufacturing planning.
 Retrieving drawings and designs based on limited information so that design engineers can
retrieve already available designs, thereby saving valuable time in product development.
Capturing design revision information from a variety of documents like drawings, part lists,
bill-of-materials (BOM).
 Providing data security through multi-tier access control.
 Creating comprehensive back-up and recovery procedures.
  Automatic disk clean-up of old drawing versions and batch back-up.
 Generating audit trails such as who designed the part, who modified the part, who approved the
design etc.
 Providing graphical user interface tool kits so as to enable the design team to create new
applications.

PDM offers several benefits for the speedy execution of product development projects:

 PDM helps engineers to access design drawings in minutes.

 Managers know how many drawings were released for fabrication.
 Manufacturing engineers know exactly when to start fabrication.
 Two designers cannot simultaneously edit the same drawing.
 Two drawings cannot have the same drawing numbers.
 All information from drawing-release statistics to revision details pass to the primary project
management system that tracks overall project status for all the company activities.
 The PDM system keeps a complete history of the modifications, when the modifications
took place and keeps all previous versions of data for a period defined by the company.
 Subcontractors can be given direct access to PDM database. Controls ensure that no
subcontractor can access data associated with the sub-sets of projects he is not involved
with.

Or

b) i) What is meant by serial transmission and explain the types in detail?

When extremely high data rates are not required, the number of wires required for data
communication can be reduced substantially by converting the bytes to be transmitted into a serial bit
stream. This requires only two wires for bi-directional transmission and a ground line. In a serial bit
stream the bits are represented by codes having specific time intervals. The standard asynchronous
serial formats used in data communications allocate a time interval known as baud period to each bit.

The bits are transmitted in separate groups, usually 8 bits long, called characters. The name
“character” is used because each group of bits represents one letter of the alphabet when text is being
sent. In the standard asynchronous format, the time between characters when no data is being
transmitted is indicated by a steady high voltage called a mark. The transmitter tells the receiver that a
character is about to start by sending a low-bit known as start bit Each character is preceded by a low-
level start bit, which synchronizes the receiver and transmitter clocks. The character (5, 6, 7 or 8) bits
follow, least significant bit first.

The asterisk (*) indicates optional bits. An optional parity bit and one or more stop (high-
level) bits terminate the character. Each bit lasts one baud rate period. Serial receivers and transmitters
can be instructed to send or receive as few as 5 or as many as 8 bits per character. After the desired
number is sent out an optional parity bit may follow. The parity bit P is useful if the data line is
suspected to be noisy for accurate transmission. For even parity P=1 if the number of 1’s in the
character is odd and P=0, if the number of 1’s is even. At the end of the bits the transmitter inserts one
or more high stop bits into the data stream.

Because any amount of time can elapse between characters the serial data transmission
method is called asynchronous method. The standard baud rates are 110, 150, 300, 600, and 1200.
2400, 4800, 9600 and 19200. Printers and other hard copy devices are usually restricted to low baud
rates. Using an 8-bit character with one parity and one stop bit, there is a total of 10 bits. A
transmission rate of 300 baud yields 30 characters/sec. A UART or Universal Asynchronous Receiver
Transmitter is a special chip used to simultaneously transmit and receive serial data performing the
appropriate parallel/serial conversions and inserting or checking extra bits used to keep serial data
synchronized. Bytes sent as 8 bit parallel data to the output data port are converted into a standard
format serial bit stream for transmission inside UART. Similarly an incoming serial bit stream is
detected by the receiver inside the UART and converted to parallel data.

ii) Describe the seven layer OSI model in computer networking.

The International Standardization Organization (ISO) developed a model for data communications.
This is known as ISO-Open System interconnection (OSI) model. This standard defines a series of
seven layers in which communication processing takes place.

These protocol layers are:

 Physical layer Data link layer
 Network layer Transport layer
 Session layer Presentation layer
 Application layer
Each layer contains a specific set of functions. It is organized such that any given layer may be
implemented in a number of ways and remains compatible with layers above and below it. There have
been also standard protocols and techniques established for implementing individual layers. An
example of these is the Institute of Electrical and Electronics Engineers (IEEE) 802 LAN standards,
which define certain ways of implementing Layers 1 and 2.

Seven layer OSI model in computer networking

13 a) i) Discuss the production flow analysis in detail.

Production flow analysis (PFA) was established by J. Burbidge to solve the family-
formation problem for manufacturing cell design. This analysis uses the information contained on
production route sheets. Work parts with identical or similar routing are classified into part
families which can be used to form logical machine cells in a group technology layout. Since
PFA uses manufacturing data rather than design data to identify part families, it can overcome
two possible abnormalities that can occur in part classification and coding. First, parts whose
basic geometries are quite different may nevertheless require similar or identical process routing.
Second, parts whose geometries are quite similar may nevertheless require process routing that
are quite different.
The procedure in PFA consists of the following steps.

1. Machine classification. Classification of machines is based on the operation that can be

performed on them. A machine type is assigned to machines capable of performing similar
operations.
2. Checking part list and production route information. For each parts, information on the
operations to be taken and the machines required to perform each of these operations is checked
carefully
3. Factory flow analysis. This comprise a micro level examination of flow of components through
machines. Thus, it allows the problem to be decomposed into a number of machine-component
groups.
4. Machine-component group analysis. This analysis recommended manipulating the matrix to
form cells.

Many researchers have been subsequently developed algorithm to solve the family-formation
problem for manufacturing cell design. In PFA, a large matrix generally termed as incidence is
constructed. Each row represents an OP code, and each column represents a component. We can
define the matrix as Mij, where i indicates the optiz code and j indicates components for example
Mij = 1 if component j has OP code i; otherwise Mij = 0. The objective of PFA is to bring
together those components that need the similar set of OP codes in clusters.

ii) Explain the criteria for selecting a CAPP system.

CAPP BASED ON CAD MODELS

Using a CAD model as input to a process planning system can eliminate the human
effort of translating a design into code and other descriptive form. A CAD model contains all
the details about a design. However, an algorithm is necessary to identify a general machined
surface in a CAD model. Additional code is needed to convert the machined surface shape
from raw material shape. CAD/CAM system uses a CAD model as its input. Several other
systems such as GENPLAN, AUTOPLAN, etc., also use a CAD database interactively for
tool and fixture selection.

CAPP BASED ON DECISION LOGIC

The decision logic determines how a process or processes are selected. The major function of
the decision logic is to match the process capabilities with the design specification. The
different techniques in decision logic are:
i. Decision trees
ii. Decision tables
These two techniques are methods of describing or specifying the various actions associated
with the combination of input conditions.

CAPP BASED ON ARTIFICIAL INTELLIGENCE (AI)

AI can be defined as the ability of a device to perform functions that are normally
associated with the human intelligence. These functions include reasoning, planning, and
problem solving. Applications for AI have been in natural language processing, intelligent
data base retrieval, expert consulting systems, theorem proving, robotics, scheduling, and
perception problems. Process planning applications have been considered as part of an expert
consulting system.

There are two types of knowledge involved in process planning systems: Component
knowledge, and process knowledge. The component knowledge defines the current state of
the problem to be solved (declarative knowledge). On the other hand, the knowledge of
processes defines how the component can be changed by processes (procedural knowledge).

Or

b) i) List the benefits and applications of group technology.

When group technology is applied, a manufacturing company will typically realize the following
benefits:

Product engineering -
 Reduce part proliferation
 Help design standardization
 Provide manufacturing feed back

Manufacturing engineering -
 Process selection
 Tool selection
 Machine purchases
 Material handling

Production engineering -
 Reduce lead time
 Reduce delays
 Reduce set-up time
 Improve product quality

Production planning and control -

 Group scheduling
 Stock accountability
 Reduce expediting
 Improved product design
 Reduced materials handling
 Better employee satisfaction

Other benefits:
 Increased productivity
 Improved accuracy in estimation of costs
 Greater standardization and variety reduction
 Reduced set up times
 Better product delivery (Helps to implement just-in-time (JIT) manufacturing)
 Reduced cost of purchasing
 Improved plant efficiency

ii) Explain briefly about the variant CAPP system.

 A variant process planning system uses the similarity among components to retrieve the
existing process plans. A process plan that can be used by a family of components is called a standard
plan. A standard plan is stored permanently with a family number as its key. A family is represented
by a family matrix which includes all possible members. The variant process planning system has two
operational stages:
• A preparatory stage and
• A production stage.

During the preparatory stage, existing components are coded, classified, and subsequently grouped
into families. The process begins by summarizing process plans already prepared for components in
the family. Standard plans are then stored in a data base and indexed by family matrices.

Process family matrix

The operation stage occurs when the system is ready for production. An incoming part is first coded.
The code is then input to a part family search routine to find the family to which the component
belongs. The family number is then used to retrieve a standard plan. Some other functions, such as
parameter selection and standard time calculations, can also be added to make the system more
complete . This system is used in a machine shop that produces a variety of small components.
14) a) Explain in detail the phases of shop floor control system.

A typical shop floor control system consists of three phases. In a computer integrated
manufacturing system these phases are managed by computer software. In today’s
implementation of shop floor control, these are executed by a combination of computers and
human resources. The following sections describe the important activities connected with this
task.

ORDER RELEASE

The order release in shop floor control provides the documentation needed to process
a production order. The documents in the shop floor order may consists of the following
documents

(i) Route Sheet

(ii) Material requisition to draw necessary materials from the stores
(iii) Job cards or other means to report direct labour time given to the order.
(iv) Instructions to material handling personnel to transport parts between the work
centres in the factory
(v) Parts list for assembly, in the case of assembly operations.

In a typical factory which works on manual processing of data these documents move
with the production order and are used to track the progress through the shop. In a CIM
factory, more automated methods are used to track the progress of the production orders.

The order release is connected with two inputs. Authorization proceeds through the
various planning functions (MRP, capacity planning). These provide timing and scheduling
information. The engineering and manufacturing database provides the product structure and
process planning information needed to prepare the various documents that accompany the
order through the shop.

ORDER SCHEDULING
This module assigns the production orders to various work centres, machine tools, welding
stations, moulding machines etc., in the plant. It follows directly from the order release
module. Order scheduling executes the dispatch function in production planning and control.
The order scheduling module prepares a dispatch list that indicates which production order
should be accomplished at the various work centres. It provides the information on the
relative priorities of the various jobs by showing the due dates for each
job.
By following the dispatch list in making work assignments and allocating resources to
different jobs the master schedule can be best achieved. The order schedule module addresses
to two important activities in shop floor production control.
(i) Machine loading
(ii) Job sequencing.
Allocating the orders to the work centres is termed as machine loading or shop loading,
which refers to the loading of all machines in the plant. In most cases each work centre will
have a queue of orders waiting to be processed. This queue problem can be solved by job
sequencing. This involves determining the order in which the jobs will be processed through
a given work centre. To determine this sequence, priorities are given to jobs in the queue and
the jobs are processed according to the priorities. Several queuing models are available in
operations management to solve this problem. This control of priorities is an important input
to the order scheduling module. Rules to establish the priorities are:

(i) Earliest due date: These are given high priority

(ii) Shortest processing time: Shorter processing time orders are given high priority.
(iii) Least slack time: Orders with least slack time are given high priority.

Fluctuations in market demand, equipment breakdown, cancellation of the order by

customer and defective raw material or delay in the receipt of materials affect the priority.
The priority control plan reviews the relative priorities of the orders and adjusts the dispatch
list accordingly.

Order Progress
The order progress module in the shop floor control system monitors the status of the various
orders in the plant work-in-process and other characteristics that indicate the progress and
performance of production. The function of the order progress module is to provide the
information that is useful in managing the factory based on the data collected from the
factory.

The order progress report includes:

(i) Work order status reports: These reports indicate the status of the production orders.
Typical information in the report includes the current work centre where each order is
located, processing hours remaining before completion of each order, whether the job is on-
time or behind schedule, and priority level.

(ii) Progress report: A progress report records the performance of the shop during the period
of master schedule and reports the number of operations completed and not completed during
the time period.

(iii) Exception reports: These reports bring out the deviations from the production schedule
(ex. overdue jobs).

The above reports are useful to production management in making the decisions about
allocation of resources, authorization of the overtime hours, and other capacity issues, and in
identifying areas of problems in the plant that adversely affect the implementation of the
master production schedule.
Or

b) i) List and explain the various functions that are performed by the FMS
computer control systems.

ii) Discuss the benefits of FMS.

 Reduced cycle times

 Lower work-in-process (WIP) inventory
 Low direct labour costs
 Ability to change over to different parts quickly
 Improved quality of product (due to consistency)
 Higher utilization of equipment and resources (Utilization better than standalone CNC
machines)
 Quicker response to market changes
 Reduced space requirements
 Ability to optimize loading and throughput of machines
 Expandability for additional processes or added capacity
 Reduced number of tools and machines required

15 a) i) Explain the problems associated with the traditional production planning and
control.

Production planning and control address a fundamental problem of

 low productivity
 inventory management
 resource utilization.

Production planning is required for scheduling, dispatch, inspection, quality

management, inventory management, supply management and equipment management.
Production control ensures that production team can achieve required production target,
optimum utilization of resources, quality management and cost savings.

ii) Explain the four classes of users and four steps of evolution in MRP.

MRP is a time-phased planning system that detects when the due date of an order is out of
phase with it’s “need date”, and ultimately keeps the priorities valid in a changing
manufacturing environment. The original MRP programs linked material requirements with
inventory levels and replenishment purchase orders and work orders over a time frame. MRP
brought out discrepancies and helped to restore a balance between the inventory requirements
and replenishments. The program determined net requirements
for every manufactured and purchased component and created planned purchase orders or
work orders for these items.

The managers were then required to either confirm the orders or change the quantities
or due dates. MRP was a very good management planning tool, if the indicated
manufacturing lead time and the inventory levels were correct. Despite this method, which
improved inventory control and material planning, many manufacturers realized there were
several segments in the manufacturing chain that were missing. They constantly felt that there
was more to their job than monitoring material availability.
This led to the development of manufacturing resource planning or MRP II. MRP-II systems
go for beyond the planning tools of MRP. They are in effect manufacturing control systems.
These systems can plan, track, and control almost any aspect of manufacturing, from
inventory levels to job costing, to the placement of finished goods on the proper truck to get
to the right distributor.

However, as the compulsions of the global competition and complexities of economic

manufacturing grew the manufacturers had to go for more efficient planning tools. This led to
the development of enterprise resource planning (ERP). ERP attempts a dynamic enterprise
modeling which can respond to any exigencies of a manufacturing and marketing demand.
Further, manufacturers are implementing efficient supply chain management systems to keep
customers happy and maintain their profit levels. Information Technology (IT) has thus
become the back bone of manufacturing activity.

A word of caution may not be out of place here. Any manufacturing system will not
give the desired results unless the focus is on continuous improvement. Traditionally, systems
have been designed “top down.” In simple terms, the approach has been one of imitating the
“push system”. This is in contrast with the Toyota Production System (TPS) where the
emphasis is on making people involved think. The reason why a mention ismade here of TPS
is that proper understanding and follow up can improve production efficiency and cut down
lead time and cost.

ROLE OF MRP IN A CIM SYSTEM

i. Computer Aided Engineering

ii. Operations Management
iii. Computer Aided Manufacturing
iv. Intelligent Warehouse System
 It can be seen that the systems are linked to a central data storage system to enable
different departments to share the manufacturing data. The manufacturing information system
ties the activities of several departments together in a closed loop for effective manufacturing
control to achieve high productivity. It is necessary to understand the functioning of various
segments of a manufacturing system to appreciate the complexities of working of an
enterprise. The efficiency in manufacturing is dependant on timely access to data and
availability of materials. A CIM system serves exactly the same purpose.

Or

b) i) Explain briefly about Master production schedule with neat sketch.

MASTER PRODUCTION SCHEDULE (MPS)

The production plan is in turn translated into the master production schedule (MPS).
The master schedule is a macro level document which sets top-level priorities for what will
be manufactured and when, looking at the material that will be required over the production
cycle. The MPS planning period, or horizon, can be of any length, but should be at least as
long as a company’s longest cumulative lead time (the time it takes to complete a product
from raw material to finished goods.).

Many systems include a rough cut capacity planning (RCCP) capability, which
compares certain MPS items of the master schedule to specified key resources of the plant (or
multiple plants) to determine if the master schedule is workable, given current the plant
capacity. If the master schedule is not achievable, the system modifies the MPS or the
production plan (For example, reduce the amount of products to be produced or commit to
increasing the capacity of the plant) until the master schedule is achievable.

Master production schedule provides great flexibility in reflecting the overall production plans of
management, allowing planned production to be based on predicted demand.
The master production schedule software is useful in many ways.

• Enables the user to scan through the file starting at any point to easily locate data.
• Accesses items by number or partial description.
• Eases forecasting.
• Allows interactive entry of requirement and replenishment orders on the master schedule
including creation of firm planned orders.
• Merges existing shop orders, purchase orders, and MRP planned orders into the master
schedule for easy comparison with customer orders and sales forecast orders.
• Maintains orders by exact date, allowing reports to be detailed or summarizes into a variety
of user-defined periods.
• Supports “what if” analysis by projecting into the future with adjustments to quantities.
• Displays or prints how much of each inventory item is available to promise for delivery in
current and future periods.
• Identifies under or over-scheduled key work centres though rough cut capacity planning.
• Pinpoints desired information responding to user-specified parameters.