Office Use Only

Semester Two 2016

Examination Period

Faculty of Engineering

EXAM CODES: TRC3801

TITLE OF PAPER: MECHATRONICS AND MANUFACTURING - PAPER 1

EXAM DURATION: 3 hours writing time

READING TIME: 10 minutes

THIS PAPER IS FOR STUDENTS STUDYING AT:( tick where applicable)

 Berwick  Clayton  Malaysia  Off Campus Learning  Open Learning
 Caulfield  Gippsland  Peninsula  Enhancement Studies  Sth Africa
 Parkville  Other (specify)

During an exam, you must not have in your possession any item/material that has not been authorised for your
exam. This includes books, notes, paper, electronic device/s, mobile phone, smart watch/device, calculator,
pencil case, or writing on any part of your body. Any authorised items are listed below. Items/materials on
your desk, chair, in your clothing or otherwise on your person will be deemed to be in your possession.
No examination materials are to be removed from the room. This includes retaining, copying, memorising
or noting down content of exam material for personal use or to share with any other person by any means
following your exam.
Failure to comply with the above instructions, or attempting to cheat or cheating in an exam is a discipline
offence under Part 7 of the Monash University (Council) Regulations.

AUTHORISED MATERIALS

OPEN BOOK  YES  NO

CALCULATORS  YES  NO
(only calculators with an 'Approved for Use' Faculty of Engineering' or 'Faculty of Science' stickers are permitted)

SPECIFICALLY PERMITTED ITEMS  YES  NO

if yes, items permitted are:

Candidates must complete this section if required to write answers within this paper

STUDENT ID: __ __ __ __ __ __ __ __ DESK NUMBER: __ __ __ __ __

Extra Instructions:
Page 1 of 19
  The examination paper consists of three sections (A, B and C) and contains
9 questions on 17 pages.
 Students are to attempt all Section A questions.
 Clayton campus students are to attempt all Section B questions and
Malaysian campus students are to attempt all Section C questions.
 The maximum mark for the paper is 100.

Section A
Attempt all questions.
Question 1
(a) What is the difference between a fixed and cellular factory layout? What are the advantages
and disadvantages of these types of layouts?

(b) Table 1 lists the weekly quantities and routings of ten parts that are being considered for
cellular manufacturing in a machine shop. Parts are identified by letters and machines are
identified numerically. For the data given,

Part Machine routing Part Machine routing

A 3®2®7 F 5®1
B 6®1 G 3 ®2 ® 4
C 6®5 H 3 ®2 ® 4 ® 7
D 6®5®1 I 2®4®7
E 3®2®7®4 J 5®6®1

Table 1

i. Ddevelop the part-machine incidence matrix, and

ii. Aapply the rank order clustering technique to the part-machine incidence
matrix to identify logical part families and machine groups.

(c) Four machines used to produce a family of parts are to be arranged into a GT cell.
The “ ffrom-to” data for the parts processed by the machines are shown in the Table 2.

To:

Page 2 of 19
 From: 1 2 3 4
1 0 10 0 40
2 0 0 0 0
3 50 0 0 20
4 0 50 0 0

Table 2

i. Determine the most logical sequence of machines for this data.

ii. Construct the network diagram for the data, showing where and how many
parts enter and exit the system.
iii. Compute the percentages of in-sequence moves, bypassing moves, and
backtracking moves in the solution.

(2 + 8 + 5) = 15 Marks

Page 3 of 19
Question 2
(a) Table 3 below defines the precedence relationships and element times for a new small
electrical appliance. (i) Construct the precedence diagram for this job. (ii) If the ideal cycle
time = 1.08 minutes,. repositioning time = 0.08 min, and uptime proportion is assumed to be
1.0 minute, what is the theoretical minimum number of workstations required to minimize the
balance delay under the assumption that there will be one worker per station? (iii) Use the
largest candidate rule to assign work elements to stations. (iv) Compute the balance delay for
your solution.

Work Te (min) Immediate

element predecessors
1 0.2 -
2 0.4 -
3 0.7 1
4 0.1 1,2
5 0.3 2
6 0.11 3
7 0.32 3
8 0.6 3,4
9 0.27 6,7,8
10 0.38 5,8
11 0.5 9,10
12 0.12 11

Table 3

(b) A plastic injection moulding plant will be built to produce 6 million moulded parts per year.
The plant will run three 8-hour shifts per day, five days per week, 50 weeks per year. For
planning purposes, the average batch size = 6000 mouldings, average changeover time
between batches = 6 hrs, and average moulding cycle time per part = 30 sec. Assume scrap
rate = 2 percent, and average uptime proportion (reliability) per moulding machine = 97 %,
which applies to both run time and changeover time. How many moulding machines are
required in the new plant?
(10+5) = 15 Marks

Page 4 of 19
Question 3
(a) What are the benefits of using concurrent engineering in a production cycle?

(b) What are the main differences between a process and product factory layout? What are the
advantages and disadvantages of these types of layouts?

(c) The average part produced in a certain batch manufacturing plant must be processed
sequentially through six machines on average. 20 new batches of parts are launched each
week. Average operation time = 6 min., average setup time = 5 hours, average batch size =
25 parts, and average non-operation time per batch = 10 hr/machine. There are 18 machines
in the plant working in parallel. Each of the machines can be set up for any type of job
processed in the plant. The plant operates an average of 70 production hours per week. Scrap
rate is negligible. Determine (ii) manufacturing lead time for an average part, (ii) plant
capacity, (iii)Plant utilization. (iv)How would you expect the non-operation time to be
affected by the plant utilization?

(d) A plant produces three product lines: A, B, and C. There are 6 models within product line A,
4 models within B, and 8 within C. Average annual production quantities of each A model is
500 units, 700 units for each B model, and 1100 units for each C model. Determine the
values of (i) Product variety, P (ii) Production quantity, Qf for this plant.

(3 + 4 + 5 + 3) = 15 Marks

Question 4
(a) What are the main wastes which can be eliminated by using lean manufacturing?
(b) What are the main differences between lean and agile manufacturing?
(c) How can Group Technology be used to automate process planning? Name and describe the
technique using schematic drawing.
(d) Explain how cellular manufacturing can be implemented in the robotics manufacturing
industries. Provide three advantages of this implementation.

(4 x 2.5) = 10 Marks

Page 5 of 19
Question 5
(a) Distinguish clearly between the variant and generative process plans.

(b) Obtain the Attributed Adjacency Matrix (AAM) and Attributed Adjacency Graph (AAG)
(only subgraphs) for the given part in the figure below (Figure 1). Match your findings
against the basic features supplied.

Figure 1

(c) Obtain the Attributed Adjacency Graph (AAG) (only sub graphs) for the given AAM (Table
4) below.

FACES 1 2 3 4 5 6 7 8 9 10 11
1 9 0 9 9 9 9 9 9 9 9 9
2 9 1 9 9 9 9 1 1 1 1
3 9 0 9 9 9 9 9 9 9
4 9 0 9 9 9 9 9 9
5 9 0 9 9 9 9 9
6 9 1 9 9 9 9
7 9 0 9 9 9
8 9 0 9 0
9 9 0 9
10 9 0
11 9
Table 4

(3 + 9 + 3) = 15 marks

Page 6 of 19
Section B (To be answered by Clayton
campus students only)
Question 6

(a) By using a schematic diagram, describe the basic elements of a CNC operating
machine.

(b) Write two NC programs using the attached G and M codes that could machine the
given part shown in Figure 2 from a 80 mm x 80 mm x 15 mm block. The two NC
programs are:

Program 1 which includes:

i. Face milling the top faces of the part.
ii. Drilling the holes using peck drilling cycle with Q = 4 mm.

Program 2 to finish machining the outer profile of the part.

The tools to be used in the machining processes will be a face mill of 18 mm diameter
(Tool 2), an end mill of 10 mm diameter (Tool 3), and 3 drills of 4 mm diameter (Tool
4), 5 mm diameter (Tool 5) and 6 mm diameter (Tool 6).

A spindle speed of 1100 rpm and a feed rate of 40 mm/min should be used both face
milling and end milling operations. The maximum depth of cut to be used for the
milling operations is 3 mm. The drilling operation will use a spindle speed of 720 rpm
and a feed rate of 30 mm/min.

The machine home position is located at (-50.0, 0.0, 40.0) from the coordinate system
shown in Figure 2. Remember to write a brief description to each line of the code.

(5 + 17) = 22 Marks

Page 7 of 19
 All dimensions
are in mm.

Figure 2

Page 8 of 19
Question 7
(a) Use a schematic drawing to describe how group technology can be applied in cellular
manufacturing to obtain a standard process plan.

(b) What is the difference between a hierarchical structure, chain-type structure and
hybrid-structure in a classification and coding scheme?

(c) Choose from either a hierarchical, chain or hybrid-type structure to develop a coding
system for the classification of ‘machine cutting tools’ and electronic sensors. Justify
your answer.

(d) The engineering drawings of three manufactured components are shown in the figures
below (Figure 3). Code the components using the Opitz system. The Opitz coding
system is attached in the appendix..

All dimensions
are in mm.

Figure 3-a

All dimensions
are in mm.

Figure 3-b

Page 9 of 19
 All dimensions
are in mm.
Figure 3-c

(2 + 2 + 2 + 2) = 8 Marks

Page 10 of 19
Section C (To be answered by Malaysian
campus students only)
Question 8
(a) Explain your understanding on the three machining parameters: speed, feed and depth
of cut. Support your answer with a turning example.

(b) The outline of the part (Figure 4) to be profile milled using a 30 mm diameter end mill
with four teeth. The work-piece dimension is 100 mm x 65 mm x 5 mm. The part is 5
mm thick. Cutting speed = 150 mm/min and feed = 0.085 mm/tooth. Use the lower left
corner of the part as the origin in the x-y axis system. Write the CNC part program.
Use absolute positioning. All dimensions are in mm.

Figure 4

(5 + 10) = 15 Marks

Page 11 of 19
Question 9
(a) Briefly describe the three storage location strategies.

(b) The from-to Chart in Table 5 below indicates the number of loads moved per 8-hour
day (above the slash) and the distances in ft (below the slash) between departments in a
particular factory. Fork lift trucks are used to transport materials between departments.
They move at an average speed = 275 ft/min (loaded) and 350 ft/min (empty). Load
handling time per delivery is 1.5 min, and anticipated traffic factor = 0.9. Assume
reliability = 1.0 and worker efficiency = 110%. Use an availability factor = 95% and
worker efficiency = 110%. Determine the number of trucks required under each of the
following assumptions: (a) the trucks never travel empty; and (b) the trucks travel
empty a distance equal to their loaded distance.

To Dept.
A B C D E
From Dept
A - 62/500 51/450 45/350 0
B 0 - 0 22/400 0
C 0 0 - 0 76/200
D 0 0 0 - 65/150
E 0 0 0 0 -
To Dept. A B C D E
From Dept A - 62/500 51/450 45/350 0
B 0 - 0 22/400 0
C 0 0 - 0 76/200
D 0 0 0 - 65/150
E 0 0 0 0 -

Table 5

(c) An automated storage/retrieval system for work-in-process has five aisles. The storage
racks in each aisle are 10 m high and 50 m long. The S/R machine for each aisle travels
at a horizontal speed of 2.0 m/s and a vertical speed of 0.4 m/s. Pick and deposit time
= 15 s. Assume that the number of single command cycles per hour is equal to three
times the number of dual command cycles per hour and that the system operates at
90% utilization. Determine the throughput rate (loads moved/hour) of the AS/RS.

(5 + 5 + 5) = 15 Marks

END OF EXAMINATION
Appendix continues from the
next page.
Page 12 of 19
 G Group No. Function
codes
G00 01 Rapid transverse
G01 Linear interpolation
G02 Circular interpolation motion (clockwise)
G03 Circular interpolation motion (counter
G04 00 Dwell
G10 Setting offset values
G17* 02 X-Y plane selection
G18 Z-X plane selection
G19 Y-Z plane selection
G20 06 Inch input
G21 Metric input
G28 00 Return to reference point
G40* 07 Cancelling cutter compensation
G41 Cutter radius compensation left
G42 Cutter radius compensation right
G80* 09 Cancelling cycle motion defined by G80s code
G81 Spot drilling cycle
G83 Peck drilling cycle
G85 Boring cycle
G90 03 Programming in absolute coordinates
G91* Programming in incremental coordinates
G92 00 Setting origin of machine coordinate system
G94 05 Per minute feed
G95 Per revolution feed
G98 10 Return to initial point in cycle motion
G99 Return to R point in cycle motion
G15 Polar coordinate system cancel (Off or inactive)
G16 Polar coordinate system (On or active)
G93 Polar origin selection

M Code Functions
M00 Program stop (usually used in the middle of program
M02 End of program
M03 Spindle start clockwise (milling machine)
M04 Spindle start counter-clockwise (milling machine)
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M30 End of program and memory (or tape) rewind

Page 13 of 19
M41 Lower range of spindle speed
M42 Higher range of spindle speed
M98 Call a subprogram
M99 Return to main program

Page 14 of 19
Page 15 of 19
Feature Extraction

Page 16 of 19
 Opitz Coding System

Page 17 of 19
Formula Sheet

Manufacturing Operations Storage Systems

P
Qf = Qj

n pf = PQn p
j =1
Tcs = 2Max{0v.5yL , 0.v5zH} 2Tpd
nof = PQn p no
60

Tcd = 2Max{ .0 v75y L , .0 75vzH } 4Tpd

RP =
TP
nSHR p
PC =
no
AU ( PC )( MLT )
WIP = RcsTcs  Rcd Tcd = 60U
SH
no j
Rt = Rcs  2 Rcd
(
MLT j = �Tsu ji  Q jTc ji  Tno ji
i =1
)
Single-Station Manufacturing Cells
MTBF - MTTR
A=
MTBF WL = QT c
Material Handling Systems
QTc
L L WL =
Tc = TL  d  TU  e E w (1 - q )
vc vc
AT = 60 AFt E w Q = Q0 (1 - q )
AT
RdvT =  T
n = m Tc s
T T
WL =
s
R f rTc
WL SINGLE MODEL ASSEMBLY LINES
nc =
AT
D
R pn== R f a
c 50 S H
Rdvw sh
WLn p vR
c T 1
= = = p wc
w Rf
AT sc 60 ETL
1
TU  T
w* = Minimum
Rf Integer  wc
Tc
ne n
Twc =  Tek =  Tsi
k =1 i =1

T
n � wc
Tc

CNC

Page 18 of 19
Page 19 of 19