Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division Second Semester 2011-2012 Course Handout

Course Number Course Title Instructor Course Description : EA ZC412 : Flexible Manufacturing Systems : Maheshwar Dwivedi

Introduction of automation, overview of FMS, system hardware and general functions, material handling system, work holding systems, cutting tools and tool management, physical planning of system, software structure functions and description, communications and computer networks for manufacturing, Group technology and cellular manufacturing, automated assembly lines Scope and Objective In recent years the manufacturing industries are facing problems of survival and maintaining a long term competitive advantage due to uncertainty in environmental conditions. The ideal production for such environment are FMS, which are considered to meet the demand for a variety of products with improvement of productivity in midvolume manufacturing. This course will highlight the fundamentals of FMS and modelling for design, planning and control of FMS. Prescribe Textbook T1. Groover, Mikell P., Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall of India, 3rd Ed., 2007

EA ZC412

(Course Handout)

Second Semester 2011-2012

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Plan of self study Week No. 1 2 3-5 6 7 8 9 Topic Introduction to Automation Industrial Control Systems Numerical Control Industrial Robotics Material Handling & Transport Systems Storage Systems Review Session Syllabus for Mid-Semester Test (Closed Book): Topics in Week. No. 1 to 9 10 11 12-13 15-15 16 17 18 Introduction to Manufacturing Systems Single Station Manufacturing Cells Group Technology and Cellular Manufacturing Flexible Manufacturing Systems Manual Assembly Lines Transfer Lines and Similar Automated Manufacturing Systems Automated Assembly Systems Review Session
Syllabus for Comprehensive Exam (Open Book): All topics given in Plan of Self Study Evaluation Scheme: EC No. EC-1 Evaluation Component & Type of Examination Assignment/Quiz

Reference to Text book Chapter 4 Chapter 5 Chapter 7 Chapter 8 Chapter 10 Chapter 11

Chapter 13 Chapter 14 Chapter 18 Chapter 19 Chapter 15 Chapter 16 Chapter 17

Duration
** Details to be announced on LMS Taxila website by Instructor 2 Hours 3 Hours

Weightage 10%

Day, Date, Session,Time ** Details to be announced on LMS Taxila website by Instructor Saturday, 11/02/2012 (AN)* 10 AM 12 Noon Saturday, 07/04/2012 (AN)* 9 AM 12 Noon

EC-2 EC-3

Mid-Semester Test (Closed Book)* Comprehensive Exam (Open Book)*

30% 60%

** Please check the details by January 2nd Week on LMS Taxila web site. * Legend: AN: AfterNoon Session; FN: ForeNoon Session Closed Book Test: No reference material of any kind will be permitted inside the exam hall. Open Book Exam: Use of any printed / written reference material (books and notebooks) will be permitted inside the exam hall. Loose sheets of paper will not be permitted. Computers of any kind will not be allowed inside the exam hall. Use of calculators will be allowed in all exams. No exchange of any material will be allowed.

EA ZC412

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Second Semester 2011-2012

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Note: It shall be the responsibility of the individual student to be regular in maintaining the self study schedule as given in the course handout, attend the online/on demand lectures as per details that would be put up in the BITS LMS Taxila website www.taxila.bits-pilani.ac.in and take all the prescribed components of the evaluation such as Assignment (Course Page on LMS Taxila), Mid Semester Test and Comprehensive Examination according to the Evaluation Scheme given in the respective Course Handout. If the student is unable to appear for the Regular Test/Examination due to genuine exigencies, the student must refer to the procedure for applying for Make-up Test/Examination, which will be available through the Important Information link on the BITS WILP website on the date of the Regular Test/Examination. The Make-up Tests/Exams will be conducted only at selected exam centres on the dates to be announced later. Instructor-in-Charges

EA ZC412

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Second Semester 2011-2012

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Lecture Details Session No. 1 Learning Objective Introduction to Automation is discussed with industrial application Learning Objective Understanding basics of Industrial Control Systems and their types Topics Topics Continuous versus discrete control Types of continuous control system Event and time driven changes of discrete control Use of computers in process control Topics Topics Topics Statistical modeling of positioning systems Introduction to part programming Turning part programs with example Fundamentals of NC technology Basic components Motion control systems Advantages and disadvantages Direct and Distributed NC, CNC Control requirements Capabilities of computer control Forms of computer process control Basic elements of automated system Advanced automation functions Levels of automation

Session No. 2

Session No. 3

Learning Objective Role of computers in industrial control

Session No. 4

Learning Objective Introduction to Numerical Control

Session No. 5

Learning Objective Concepts of precision in NC positioning and part programming.

Session No. 6

Learning Objective Milling part programs

Topics Milling part programming codes Solved Examples

EA ZC412 Session No. 7

(Course Handout)

Second Semester 2011-2012 Topics Robot anatomy Robot configurations Industrial applications

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Learning Objective Brief background of industrial robotics

Session No. 8

Learning Topics Objective Robot accuracy and repeatability Derivation of accuracy and repeatability Examples Learning Objective Material Handling & Transport Systems Topics Design considerations in material handling The Ten Principles of Material Handling AGV, SGV and Conveyors Vehicle Guidance and Management Analysis of Material Transport Systems (AGVs and Conveyors) Topics Storage system location and location strategies Storage methods Automated storage systems (AS/RS only) Engineering Analysis of AS/RS (Both Randomized and Class Based) Topics Topics Single station manned cells Single station automated cells Analysis of single-station systems Components of a Manufacturing System Classification of Manufacturing System Overview

Session No. 9-10

Session No. 11-12

Learning Objective Discussion on modeling of Storage System

Session No. 13

Learning Objective We will discuss basic introduction to manufacturing system

Session No. 14

Learning Objective We will discuss and analyze single-station manufacturing cells

EA ZC412 Session No. 15-16

(Course Handout)

Second Semester 2011-2012 Topics

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Learning Objective A comprehensive discussion is made in explaining the concept of group technology andanalyzing cell formation

Part families Part Classification and coding Composite part concept Production flow analysis and Rank order clustering Machine cell design

Session No. 17-18

Learning Topics Objective We will discuss the implementation FMS components issues of FMS followed by FMS Application and Benefits an engineering analysis of Planning and Implementation Issues FMS Quantitative Analysis Learning Objective Here the learning objective is to analyze line balancing problems of manual systems Learning Objective In this chapter emphasis will be made to analyze empirically automated production lines Topics Topics Introduction and application of automated transfer lines Analysis of transfer lines with examples Topics Introduction to automated assembly systems Analysis of automated assembly systems with examples Analysis of single model assembly lines Line balancing algorithms with examples

Session No. 19-20

Session No. 21-22

Session No. 23-24

Learning Objective The emphasis will be to quantitatively analyze automated assembly systems