ME 445 Integrated Manufacturing Systems

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1 ME 445 Integrated Manufacturing Systems

2 Staff COURSE INSTRUCTOR Prof. Dr. M. A. Sahir ARIKAN COURSE ASSISTANT Fulya EROL (Office: B-175) ME 445 Integrated Manufacturing Systems 2

3 Schedule COURSE SCHEDULE All lectures are at ME G203. Section 01 Tuesday 13:40-14:30 Thursday 13:40-15:30 ME 445 Integrated Manufacturing Systems 3

4 Teach basic elements of flexible automation, Teach/practice CNC machines and programming, and robotics, Introduce the concepts of modern technologies used in today s manufacturing enterprises, like, group technology (GT), integrative manufacturing planning and control, etc., Give a broad view of Computer Integrated Manufacturing (CIM) and its basic features. Objectives-I ME 445 Integrated Manufacturing Systems 4

5 Objectives-II During the CIM Laboratory practice hours, perform process planning and programming, manufacture some parts personally by using CNC machine tools, thus: Experience the CIM environment and some related activities, Learn and practice process planning, CNC machining, PLC programming by writing programs for handling and manufacturing of parts. ME 445 Integrated Manufacturing Systems 5

6 Two Midterm Examinations (MT I 20 % - MT II 20 %) Multiple-choice, problem solving Closed book and notes. Final Examination (40 %) Multiple-choice, problem solving Closed book and notes. CIM Laboratory (20 %) If attendance is over 70 % Bonus up to 5% Grading maximum (70% gets 0, 100% gets 5% bonus) TOTAL 105 % ME 445 Integrated Manufacturing Systems 6

7 REGULAR EXAMINATIONS Examination dates, hours, and places will be announced by the Mechanical Engineering Department. MAKE-UP EXAMINATIONS Examinations Make-up examinations may be given to those with valid excuses (i.e. medical report,...) approved by the Mechanical Engineering Department. If you are eligible to take any of the make-up examinations, you must contact the course instructor or the course assistant. Make-up examinations may not be of multiple-choice type. All make-up examinations will be given after the final. ME 445 Integrated Manufacturing Systems 7

8 Examinations EXAMINATION RULES During the examinations you are only allowed to use pencil and eraser; when allowed calculators. Your mobile phones should be in your handbag, backpack, etc. or in your pocket. During the examinations, you will be given a question booklet and an answer sheet. Return both of them to the assistants before you leave the classroom. If you do not return both of them, your examination will not be evaluated (will be invalid) and a disciplinary investigation will be started according to the Disciplinary Regulations of Middle East Technical University. ME 445 Integrated Manufacturing Systems 8

9 Quality characteristic CIM Laboratory (20 %) Sensors Process Planning and Programming for Turning and Milling (Will be determined later.) CIM Laboratory Practice Statistical Process Control PLC Ladder Diagram Programming UC CL LCL Order of sampling ME 445 Integrated Manufacturing Systems 9

10 CIM Laboratory Practice Duration: about 7-8 weeks; Needs to allocate extra hour(s) per week ; (excluding lunch break : 12:30-13:30) A student is only allowed to miss only one week of the CIM Laboratory work, without a valid excuse (10 points will be deducted from overall CIM Laboratory grade), If missed weeks are more than one, letter grade from the course will be NA. assistant(s) will evaluate the CIM Laboratory work. ME 445 Integrated Manufacturing Systems 10

11 CIM Laboratory Practice CIM Laboratory hours will be arranged until the end of the 2 nd or 3 rd week by considering the course schedules of the students. For the arrangement, individual course schedules will be collected during lecture hours in the 2 nd or 3 rd week. CIM Laboratory practice will start in the 3 rd or 4 th week of the semester. ME 445 Integrated Manufacturing Systems 11

12 CIM Laboratory Practice If missed CIM Laboratory weeks -without a valid excuse- are more than one, regardless of your other grades, NA will be given as your COURSE GRADE at the end of the semester. If your course grade is NA, you will not be able to take the FINAL (and RESIT) examination. ME 445 Integrated Manufacturing Systems 12

13 CIM Laboratory Practice Besides attending the CIM Laboratory, you are expected to finish the assigned practice and write a report with an acceptable quality (i.e. get an acceptable grade) Acceptable grade is 60/100 from each practice. ME 445 Integrated Manufacturing Systems 13

14 CIM Laboratory Practice For a practice, if your grade is less than 60/100, you will be requested to improve it until your grade becomes 60/100 or above. If you don t improve, you will get NA from the course. ME 445 Integrated Manufacturing Systems 14

15 Class attendance will be taken starting from the first lecture. Even if you are planning to add the course afterwards, attend the classes starting from the first lecture. For some reason, if you are planning to register to the course afterwards by directly applying to the Mechanical Engineering Department, again attend the classes starting from the first lecture. Otherwise you will not be accepted. Attendance ME 445 Integrated Manufacturing Systems 15

16 Attendance If your class attendance is less than 70.0 %, regardless of your other grades, NA will be given as your COURSE GRADE at the end of the semester. If your course grade is NA, you will not be able to take the FINAL (and RESIT) examination. ME 445 Integrated Manufacturing Systems 16

17 Your class attendance will be determined by considering the number of lecture hours you have attended and total number of attendances taken during the semester. Class attendance will be taken for every lecture hour. Why 70 %, but not 100 %? The remaining 30 % is for the lecture days in which you are: officially participating in a university activity, for something personal,..., etc % Attendance ME 445 Integrated Manufacturing Systems 17

18 70.0 % Attendance Your attendance will be determined by considering the number of lecture hours you have attended and total number of attendances taken during the semester. Class attendance will be taken for every lecture hour. You should attend at least 70 % of the lectures, regardless of whatever your excuse is; except medical reports. The remaining 30 % is for your excuses. ME 445 Integrated Manufacturing Systems 18

19 Rules and Regulations - Attendance Middle East Technical University Rules and Regulations Governing Undergraduate Studies Attendance and Examinations ARTICLE 23 (1) Students must attend the theoretical and practical class hours, examinations and other academic studies as required by the instructors. ME 445 Integrated Manufacturing Systems 19

20 Attendance (2) The attendance records of students are kept by the instructors. (3) The effect of student attendance on the right to take mid-term and final examinations and on the letter grades for a semester; mid-term examinations, homework assignments, practical applications and other similar studies for which the students are responsible and the effect of these on the letter grades for a semester; the requirements to take the final examination, if any, are determined by the instructors and announced to the students at the beginning of the semester. ME 445 Integrated Manufacturing Systems 20

21 Assessment and Grades ARTICLE 24 Assessment and Grades (1) Students are given a letter grade for each course at the end of the semester they are registered. (2) This letter grade is at the discretion of the instructor offering the course. (3) In determining the letter grade, the students mid-term and final examination grades, their success in their studies within the semester and their attendance during course and practical work are taken into consideration. ME 445 Integrated Manufacturing Systems 21

22 Assessment and Grades - NA ARTICLE 24 b) The grade NA is designated by the course instructor to students who have been deemed unsuccessful due to one of the conditions below. The grade NA is processed as FF in the calculation of Grade Point Average. 1) Not qualifying to take the final exam due to failure in fulfilling the attendance requirements. 2) Not qualifying to take the final exam due to failure in fulfilling the provisions regarding course practices. 3) Having taken none of the mid-term and final examinations. ME 445 Integrated Manufacturing Systems 22

23 Text Book 4/E will be published in 2015 Automation, Production Systems, and Computer-Integrated Manufacturing Mikell P. Groover 3/E ISBN-10: ISBN10: ISBN-13: ISBN13: PEARSON - Prentice Hall, 2008 PEARSON NEW INTERNATIONAL EDITION, 2013 ME 445 Integrated Manufacturing Systems 23

24 Reference Books Nanua Singh, "System Approach to Computer-Integrated Design and Manufacturing", Wiley, Paul Kenneth Wright, "21st Century Manufacturing", PEARSON-Prentice Hall, Bedworth, David, Henderson, Nerk Wolfe, Philip M., "Computer-Integrated Design and Manufacturing", Mc Graw-Hill International Editions, Mechanical Engineering Series, Zeid, Ibrahim, "CAD/CAM Theory and Practice", Mc Graw- Hill International Editions, Computer Science Series, Warnock, Ian, "Programmable Controllers Operation and Application", Prentice Hall, ME 445 Integrated Manufacturing Systems 24

25 Reference Books ME 445 Integrated Manufacturing Systems 25

26 METU Catalogue Description 1. Introduction to new concepts in manufacturing engineering, 2. Group technology, 3. Process planning, 4. Integrative manufacturing planning and control, 5. Numerical control in manufacturing, 6. Measurement, analysis and actuation, 7. Computer Integrated Manufacturing (CIM) systems. ME 445 Integrated Manufacturing Systems 26

27 Chapter 1 INTRODUCTION 1.1 Production Systems 1.2 Automation in Production Systems 1.3 Manual Labor in Production Systems (Read) 1.4 Automation Principles and Strategies (Read) 1.5 Organization of this book PART I Chapters from the Textbook OVERWIEW OF MANUFACTURING Chapter 2 MANUFACTURING OPERATIONS (Read) 2.1 Manufacturing Industries and Products (Read) 2.2 Manufacturing Operations (Read) 2.3 Production Facilities 2.4 Product/Production Relationship 2.5 Lean Production ME 445 Integrated Manufacturing Systems 27

28 Chapters from the Textbook PART II AUTOMATION AND CONTROL TECHNOLOGIES Chapter 4 INTRODUCTION TO AUTOMATION Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL 6.1 Sensors 6.2 Actuators 6.3 Analog-to-Digital Converters Partly 6.4 Digital-to-Analog Converters Covered 6.5 Input/Output Devices for Discrete Data ME 445 Integrated Manufacturing Systems 28

29 Chapters from the Textbook PART II AUTOMATION AND CONTROL TECHNOLOGIES Chapter 7 NUMERICAL CONTROL ( Appendix B 7: Part Programming with APT is not included.) Chapter 8 INDUSTRIAL ROBOTICS Chapter 9 DISCRETE CONTROL USING PROGRAMMABLE LOGIC CONTROLLERS AND PERSONAL COMPUTERS MT I ME 445 Integrated Manufacturing Systems 29

30 Chapters from the Textbook PART IV MANUFACTURING SYSTEMS Chapter 18 CELLULAR MANUFACTURING Chapter 19 FLEXIBLE MANUFACTURING SYSTEMS PART V QUALITY CONTROL IN MANUFACTURING SYSTEMS Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING 20.1 Quality in Design and Manufacturing 20.2 Traditional and Modern Quality Control 20.3 Process Variability and Process Capability 20.4 Statistical Process Control ME 445 Integrated Manufacturing Systems 30

31 Chapters from the Textbook PART VI MANUFACTURING SUPPORT SYSTEMS Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS Chapter 26 JUST IN TIME AND LEAN PRODUCTION MT II ME 445 Integrated Manufacturing Systems 31

32 What to Do? 1. Attend classes, follow lectures! Attendance will be taken regularly. 2. Take notes when necessary 3. Read the textbook 4. Refer reference books 5. Study regularly 6. Attend CIM Laboratory work; get acceptable grades ( 60/100) ME 445 Integrated Manufacturing Systems 32