INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY Department of Mechanical Engineering Course : ME-714Computer-Integrated Manufacturing Instructor : K.P.

Karunakaran Date : January25, 2010 (Monday) 9:30PM Instructions: Answer all the questions; answer as briefly as possible. L-T-P-C : 3-0-0-6 II Semester 2009-10 Duration : 1 hr. Roll No Marks

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TEST - 1 (Chapter 1: Introduction) Part A (1 mark each) 1. List the three fundamental requirements for implementing CIM. 1. Computer control of all functions 2. Networking of all these computer systems 3. Communication protocols and secure access control 2. Automotive components are mostly castings and forgings whereas aerospace uses mostly machined components. Do you agree or disagree? Justify your answer. Automotive is cost-sensitive whereas aerospace is weight-sensitive. As castings and forgings can simultaneously realize several features, they are cheaper than machined parts. 3. Which is the most accurate casting method? Why? 4. Sort the following processes in the decreasing order of specific energy: [i] sheet metal forming [ii] forging [iii] machining

[iv] casting

5. Which of the following processes are suitable for objects with undercuts and deep features? [i] 3-axis CNC machining [ii] forging [iii] casting [iv] RP 6. Which of the following processes are suitable for components/assemblies with high fatigue life? [i] machining [ii] forging [iii] casting [iv] sheet metal forming 7. List the four significant applications of RP. Conformal Cooling. Components with Functionally Gradient Materials (FGMs) Assemblies without joints Shapes impossible or difficult by other processes. 8. Give an example for [i] fixed detachable assembly and [iii] movable permanent assembly.

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9. Distinguish between adjusted parts assembly and fitted parts assembly. Adjusted Parts Assembly Fitted Parts Assembly Simple way of obtaining fine Simple way of obtaining fit. tight fit. The desired fit is achieved during assembly using certain adjustmentelements like, set screws, washers, spacers, wedges,shims, putty etc The desired fit is achieved during assembly by adjusting one of the matching dimensions by filing, cutting, chiseling, scrapping, lapping etc

10. What category of assembly is usage of washers or shims? Adjusted Parts Assembly 11. Distinguish between Product Design and Industrial Design. 12. Explain the significance of the figure in the context of product design. 14. How is fixed-position layout different from job shop layout? Ans In fixed-position layout, the factory moves to the products place 15. List the contributions of F.W. Taylor

Part B (Weightage is given against each) 1. Define CIM comprehensively. Explain how it is different from CAD/CAM. [2]

1. CIM is the integration of the enterprises(imp plans) upstream, mainstream and downstream activities of product development and life cycles into one self-regulating system with the help of connected computer systems and a common corporate data repository(a place where things are stored and can be found ). 2. CIM is more often a strategy, direction, vision or a management(SDVM)philosophy. 3. CIM is a tool to achieve defined corporate goals or strategies. 4. CIM is a way of doing business that emphasizes(to show or state that something is very important or worth giving attention to) an automated coordination of information and effort throughout all the functional areas of a corporation. 5. CIM is the use of information technology to improve manufacturing. 6. CIM is rarely available as a product or system from a vendor. Each organization has to build its own. At best, they may be able to hire consultants in selection and implementation. 2. Draw the block diagram of CIM that depicts all its building blocks. Any of the following will do. [2]

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2. Discuss the positive and negative aspects of open sourcing. Advantages: immense scope of improvement It leads to better penetration of the biz in the market Disadvantage: Security of the software is at question(hackers) Theres no tab over how the software is used

[2]

3. Define and distinguish between out-sourcing and in-sourcing. Use examples/ case studies to explain. Y2k vs UPS out-sourcing in-sourcing Getting things done where it is the best Complementing organizations working and by whom does it the best. People retain together their core-competency with themselves and out-source all else as far as possible. This led to lean and agile mfgs It started with information processing. Logistic companies such as FedEx, UPS train Thanks to Y2K problem which helped India their customers in packaging so as to emerge as IT superpower. At that time, it minimize transit damages. They tie up with was body-shopping. insurance companies and offer insurance along with transport charges. UPSs slogan is Your world is synchronized Indias problems of huge population, lack of UPS even repairs of Toshiba computers and a common Indian language and democracy returns to the customers turned into our advantage. Setting up of IITs, NITs and thousands of Govt and

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pvt.Colleges enabled us to churn out good quality engineers (10 lac/yr) This was further enabled by connecting continents through fibre-optic cables. Speed and bandwidth increased It is no longer body-shopping. It happens within the same country Now this has extended to product development and manufacturing also

The banks depute people to builders and automobile outlets All automotive companies working together on mutually beneficial projects like alternate fuel systems etc

[4] 4. Define off-shoring and discuss its implications. Also explain how it is different from outsourcing. Setting up factories abroad where it is cheaper to make. Another approach is to produce in locations closer to the customer which is cheaper due to less transportation cost, tax benefits and better service. Companies become global. This is an offshoot(something which has developed from something larger which already existed) of out-sourcing. The difference between out-sourcing and off-shoring is just the ownership [4] 5. Give two examples for the primary industries, [two + two] examples for the secondary industries identifying them with its two types and two examples for tertiary industries. [3]

Primary Agriculture Fishing

Secondary Discrete Aerospace Automotive

Tertiary Process Paper Cement Education Entertainment

6. What is selective assembly? When is it used? What are its limitations?

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tight tolerances that go beyond the process capability - More time spent on inspection No interchangeability

Definition: Most practicable for extremely tight tolerances that go beyond the process capability. Produce both matching parts in large number. Measure each and fit. Eg.: Ball bearings, slip gauges Advantages: + Cheap to manufacture individual parts. Limitations: - More time spent on inspection - No interchangeability. Hence, both mating parts shall be replaced. - If the process of the individual components are not under control,
one may land up accumulating more unused components. [3] 7. Reproduce the following table and fill in the empty cells. Type of Manufacture Type of Layout Job shop production Job shop and Fixed position layout Batch production Process layout Mass production Flow & fixed layout [2] Type of Automation Fixed Automation Flexible Automation Programmable Automation

8. What are the considerations in selecting a layout? Compare the three layouts based on these. [2] Consideration The goal in layout is primarily minimization of material movement and WIP(work in progress). For the same product, different layouts are feasible for different subassemblies and components Job shop and Fixed position layout Process layout Flow & fixed layout material movement & ?? High Low WIP 9. Present the comparison of stationary manufacturing or quantity production and progressive manufacturing or flow production. [2] Stationary manufacturing or Quantity Progressive manufacturing or flow production production All tools required come to the same place Workstations are spread out and the raw material and perform their task of the part/ assembly-in-progress moves from one station to the next till all operations are over This is more suitable for discrete parts This is more suitable for assemblies since the manufacture wherein the volume keeps volume keeps increasing and becomes unwieldy as reducing as the activities progress. the activities progress. Furthermore, the assembly Limited to simple parts/assemblies only tools are large and varied in shape. Suitable for due to the limited number of complex operations/tools Eg.: Consider assembling a book from its Eg.: Consider assembling a book from its pages pages available as bundles. Arrange the available as bundles. Arrange the bundles of the bundles of the pages around you with a pages in line on a long table. Move from one end to table in the middle. Take one page after the the other picking one page each and assemble the other and place on the middle table to book. Finally staple it assemble the book. Finally staple it Eg.: CNC machining (tools stored in ATC Eg.: Assembly of automotive engines or bodies. come to the blank one after the other to do
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the job; PCB assembly

10. Any manufacturing process requires the continuous control of slide motions and the control of switching functions such as spindle control, tool change, coolant control etc. Fill the 4 boxes in the following table: [2] Element(s) used to control this Element(s) or code(s) used to Function function in hard automation is control this function in soft (are) automation is (are) Slide motion Switching functions

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