Eliminate fasteners

Place fasteners away from obstructions; design in fastener access

Deep channels should be sufficiently wide to provide access to fastening tools;
eliminate channels if possible
Provide flats for uniform fastening and fastening ease
Ensure sufficient space between fasteners and other features for a fastening tool
Prefer easily handled parts
3) Derive the significant improvement from the adoption of a cell system of
manufacture over a functional layout based system of manufacturer.
- to help eliminate waste and provide more responsiveness to customer orders.
- low cost, low-risk, improved quality
-The advantages many companies derive from linking processes in cells include
improved quality and reduced rework costs because the material produced in one
operation is tested for fit or operation in the next process.
- For example, if a hole is drilled undersize and the next step in the cell inserts a screw
in the hole, it is quickly apparent what problem exists before several hundred pieces
have the wrong size hole.
-labour improvements are usually modest compared to other reductions in waste
-At the core of cellular manufacturing is the elimination of waste by linking each step
in the manufacturing process to the following step:
i.Waste is considered to be any resource not adding value to the product being
manufactured.
ii.waste includes all inventory that is not being processed and also the time required
to move processed material from one operation to the next
-In a cell, most work stations are close together so that little or no time is required to
move pallets of parts from one work station to the next.
-To assure that excess inventory is reduced between steps in the process, many firms
create Kanban spaces or pans that limit in-process inventory
4) Describe the characteristic of flexible automation production
Definition: A flexible manufacturing system is one manufacturing machine or
multiple machines which are integrated by an automated material handling system,
whose operation is managed by a computerized control system.
-handling each steps: (a)one or more processes or operations (b)handling of raw
materials (c)measurements and inspections (d)assembly
-Benefits of 2 system: (i) highly productive but inflexible, transfer lines (ii) job-shop
production.
Advantages:
-parts can be produced in any order, in batch size as small as one, and lower unit cost
-direct labor and inventories are reduced
-shorter lead time for product changes
-because all systems are self-correcting, production is more reliable and product
quality is uniform
Disadvantages:
-required dynamic scheduling
-high cost
-time and effort required to install and debug system
Flexible versus fixed automation
Fixed automation:
1. Low product variability product design well defined and no major changes
planned in size, shape, part count and material.
2. Predictable demand stable demand for 2- to 5-year time period.
3. High production rates number of units produced per hour or day is high.
4. Cost pressures price of product set by market conditions and manufacturer must
meet the market price to be competitive
Flexible automation is used in the following situations:
1. Product mix requires a combination of different parts and products to be
manufactured from the same production system.
2. Product family requires engineering changes that alter production requirements.
3. Product or part family will expand with similar but not identical models.
4. Production volumes are moderate, and demand is not as predictable.

5) What are the various types of layouts used in FMS design? Illustrate with a
diagram. Explain briefly about their applications.
In line layout simplest form and is used for small number of machines in a system.
The part handling at the individual workstations is performed by the transport vehicle,
which will have the necessary pallet changer.



Loop Layout- moves in a single direction in the loop similar to a conveyor, with the
ability to stop at the defined positions for transferring the parts to the workstations.

Ladder layout workstation arranged in a loop with rungs (helps in reducing the
congestion and allow for smooth part flow between machines)


Open field layout- multiple loops for appropriate arrangement of the facilities,
suitable for a large group of part to be machined.

6) Describe the advantages to be gained by the use of automated guided vehicle in
manufacturing shop.
1.Offers a Dynamic Design Solution
Through the use of advanced AGV technology and wireless routing, vehicles can be
quickly reprogrammed to change path or operation, eliminating the need for
expensive retrofitting. New directions, tasks, and work cells can be created almost
instantaneously without the need for physical equipment installation.



2.Modular System Elements
After the control system is in place, AGVs can be added as required by the growth of
the operation. A fleet can start with a single robot then grow as demand increases,
decreasing the initial investment and allowing for a gradual and seamless
implementation. AGVs can be easily integrated with robotic attachments and existing
or new material handling equipment to develop a fully automated system.

3.Safe and Predictable Technology
Through the advancement of control systems AGVs offer a safe and predictable
method of delivery, while avoiding interference with human and building factors.
AGVs can operate almost around the clock, without the need for breaks and vacation
time. In addition, AGVs operate in conditions that may not be suitable for human
operators, such as extreme temperatures and hazardous environments.

4.Increased Accuracy and Productivity
Automated Guided Vehicles, combined with RF technology, interface with the
Warehouse Control System or Warehouse Management System to improve accuracy
and efficiency. AGVs have little downtime, and operate at a fixed rate to meet a
predictable metric for operational activity.

7) What are the various guidance methods available for automated guided vehicle?
-Several methods of guidance and navigation can be implemented. The early AGVs
where tracking an inductive guide wire or an optical visible line, painted or made with
tape on the floor. The inductive guide wire is still the most used guiding system for
AGVs running on concrete floors, also for new installations
-In later years AGV guiding and navigation systems with laser scanners, microwave
transponders, inertia gyros, ultrasonic sensors, embedded magnets, camera vision
systems etc. have been launched.
- Some of the new types of guiding systems for AGVs are called free-range
navigation systems. All guiding systems for AGVs requires however guiding
references installed along or around the guide path, nothing is one hundred percent
free. Some modern guide wire systems have the guide wires used only as static
guidance reference and the AGVs can do many moves off the wire. The question of
AGV navigation is always a question of the degree of freedom, and shall be taken in
consideration in relation to system price and the costs for changes and maintenance of
an AGV-system down the road. The drawback of many free-range navigation systems
is that the software gets extensive and may become hard to maintain and change for
other people than experts.