Degree In Mechanical Engineering
ECD6323
CAD / CAM
Chapter 4: Applications
(Application of CAM in NC programming. CAM and CNC interface. CNC machining.)
(8 Hours)
By Dr. Umar Nirmal
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – What you need before you start?
Design Planning Manufacturing Assembly
Discrete manufacturing is an industry term for the manufacturing of finished products that are
distinct items capable of being easily counted, touched or seen. Discrete manufacturing involves
parts and systems like nuts and bolts, brackets, wires, assemblies and individual products.
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Discrete vs. Process
Q4.1. In the making of automotive tires, identify which manufacturing process it undergoes and support your answer with evidence /
sketch with explanation.
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Conventical vs. Concurrent
Q4.2. In your own words,
explain what happens when
there is a significance savings
in lead time between the
conventional vs. concurrent
manufacturing in a typical
manufacturing process.
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Lead Time
A lead time is the latency between the initiation and execution of a
process. For example, the lead time between the placement of an order
and delivery of a new car from a manufacturer may be anywhere from
2 weeks to 6 months.
Q 4.3: What happen if the lead time is not fulfilled as agreed
Waiting time for Proton e-mas?
between the supplier and customer?
Spot the difference? Any? Why? 6
PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Business Plan
Q4.4. Why Business Plan and Bill
of Materials (BOM) is the CORE
essence of a manufacturing
organization?
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Manufacturing Strategies and their Effect on Lead Time
Q4.5. What are the elements in a
typical manufacturing factor that
effects the lead time?
Level of Detail
Planning Horizon 8
PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Manufacturing Strategies and their Effect on Lead Time (cont’d)
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PART 1: INFORMATION REQUIREMENTS OF MANUFACTURING – Typical Flow of Manufacturing in an Organization
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PART 2:
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PART 2: Communication
Q4.6. In a typical manufacturing plant,
what type of communication is used to
control the machines?
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PART 3: MATERIALS HANDLING SYSTEMS
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PART 3: MATERIALS HANDLING SYSTEMS – What is used
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PART 3: MATERIALS HANDLING SYSTEMS – Automatic Guided Vehicles (AGV)
Q4.7. State FOUR disadvantages of
implementing AGV in the manufacturing
sector.
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PART 3: MATERIALS HANDLING SYSTEMS – Types of AGV
Infrared / Laser
AGV ROBOT
Wire Guided
On Board Cam
AGV ROBOT
Watch the video: Automated Guided Vehicle Weasel®, E-Commerce, Supply Chain, Hermes Fulfilment GmbH at:
[Link]
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Q4.8. From you understanding on Automated Guided Vehicles (AGV), setup an AGV operation floor plan with the
following criteria below:
a) AGV is to carry different automotive components / parts where the total load exerted by the AGV should not
be more than 100kg.
b) The AGV is operated fully by Lithium-Ion batteries where the AGV automatically goes back to the charging
station for charging during low battery. During this charging process, the AGV passes the task if any to the next
available AGV to complete the task; i.e. send item A to location B.
c) The AGV uses artificial Intelligence (AI) where it can detect possible hazards (i.e. obstacles along its pathway)
and avoid it during operation.
d) All the AGV’s in the manufacturing plant is monitored real time in a special room by a skilled operator.
e) In case of emergency AGV collision or system faulty, the operator will be notified.
Besides the above requirements, you are highly encouraged to assume with proper justifications where necessary
when you build your entire system. Present your answer in the form of a neat sketch with detail labelling where
necessary. Answers with poor and unclear labelling will not be marked.
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PART 3: MATERIALS HANDLING SYSTEMS – Rail Guided AGV
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PART 3: MATERIALS HANDLING SYSTEMS – Robots
Bearing sorting Robot: [Link] 19
PART 3: MATERIALS HANDLING SYSTEMS – Basic Components of a Robot
Manipulator
End Effector
Power Supply
Controller
Base
- Base: Provides the main base of the robot’s stability.
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PART 3: MATERIALS HANDLING SYSTEMS – Automated Storage and Retrieval System (AS/RS)
Key Highlights and Functions of AS/RS in the Manufacturing Sector:
a) Versatile Deployment – widely used in warehouse
b) Enhanced Efficiency – fast and possible zero error
c) Labor Cost Reduction – less manual labour needed
d) Workplace Safety – low human error
e) Integration and Control – can be integrated with conveyors,
AGV’s and etc.
f) Global Adoption – LINFOX Logistics, Tiong Nam Logistics, etc.
Automated Storage / Retrieval System: [Link] 21
PART 3: MATERIALS HANDLING SYSTEMS – Major Components of an AS/RS
Stacker Crane
Shutters (in yellow)
Occupied
Rack
Support Rail
Back
Empty Racks
Operation
Carrier
Control System (store / retrieve)
Robots AI Sensors and
Steel Rollers 360 Cam
Front
Conveyor Belts
Operation Drive System
Inspection Center
Battery Pack
Steel Wheels
Cargo Service
Guided Rail
Flow of Materials
Back Operation
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PART 3: MATERIALS HANDLING SYSTEMS – Major Components of a Stacker Crane
Q4.10. State the main parts of a
stacker crane which is used in an AS/RS
system.
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ASRS in operation: [Link]
In A Typical Warehouse – where are you?
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Can you have an AS/RS combined with an AGV in a logistics warehouse?
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PART 3: MATERIALS HANDLING SYSTEMS – AS/RS linked with AGV
AS/RS
AGV
Q4.11. Illustrate the main
objective in integrating
AGV with AS/RS in a
typical manufacturing
system.
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PART 4: FLEXIBLE MANUFACTURING SYSTEM (FMS)
&
COMPUTER INTEGRATED MANUFACTURING (CIM)
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PART 4: FMS and CIM - Definition
Pros and Cons:
5. Flexible manufacturing control offers numerous benefits, including increased adaptability, reduced
production times, and resource efficiency.
6. It also relies heavily on automation, which may reduce reliance on human labor, leading to potential job
implications.
7. ???
Q4.12. Illustrate FOUR pro’s and con’s in FMS.
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PART 4: FMS and CIM - Equipment
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PART 4: FMS - Requirements
Q4.13. State the FOUR main requirements in a FMS.
Flexible manufacturing system for American aerospace customer:
[Link] 30
PART 4: FMS - Setup
Workstation
Debris generated during machining is collected by the
automatic recycling system for proper disposal
*Tool Supply
to the
Machine Workpiece
Handling
Q4.14. Draw a typical FMS setup with neat sketches and correct labelling.
It’s a Tool Management System (TMS) that periodically update the tool inventory and the status of the tool, ex: tool life span, tool availability, etc.)
FMS: [Link] 31
PART 4: FMS and CIM in Industry 5.0?
*ERP – Enterprise Resources Planning
2024
onwards?
• Industry 5.0 focus on integrating technology with human capabilities to create a harmonious collaboration between machines and people in the workplace.
• Industry 5.0 aims beyond mere efficiency and productivity, prioritizing the well-being of workers and the contribution of industry to society.
• Industry 5.0 emphasis on societal value and well-being, shifting the focus from profits and growth to a human-centric and sustainable approach.
• Industry 5.0 is characterized by three key pillars: human-centric, resilient, and sustainable.
• Industry 5.0 calls for a shift in business strategy to prioritize talent, diversity, and empowerment, placing people at the core of organizational objectives.
[1] [Link]
[2] [Link] 32
PART 4: Tool Monitoring System / Life System
Tool Wear
HIGH COST Tool Failure
Machine downtime Test Run of new tool
Solution???
Penalty due to past Lead Time Tool setup time
Calibration Etc.
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PART 4: Tool Monitoring System / Life System
Acoustics Emissions during a typical machining process is the sound generated by the whole system; i.e. machine motor,
cutting tool, machine vibration and etc. However, specific sensors pick up the sound from the cutting tool and send them to
the processor which than filter out unwanted sound resulting only the sound from the cutting tool to be analysed. Hence, the
Life System to this machine will map the sound of the cutting tool with the virgin cutting tool and be able to predict the time
where the cutting tool need to be replaced before it fail completely. 34
PART 4: Summary of Computer Integrated Manufacturing (CIM)
FMS AS/RS
AGV Robots
What is Computer Integrated Manufacturing (CIM)? - [Link] 35
Q4.15. Illustrate how a ‘Tool Monitoring System’ works during a typical machining operation.
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