me6703 computer integrated manufacturing …opitz part coding system – production flow analysis...

REGULATION: 2013 ACADEMIC YEAR: 2018-2019

JIT-JEPPIAAR/MECH/Dr.D.MURUGANANDAM /IVth Yr/SEM 07 /ME 6703/COMPUTER INTERGRATED MANUFACTURING/UNIT I-5/QB+Keys/Ver1.0

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ME6703 COMPUTER INTEGRATED MANUFACTURING SYSTEMS L T P C

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OBJECTIVES:

To understand the application of computers in various aspects of manufacturing viz., Design,

Proper planning, Manufacturing cost, Layout & Material Handling system.

UNIT I INTRODUCTION 10

Brief introduction to CAD and CAM – Manufacturing Planning, Manufacturing control-

Introduction to CAD/CAM – Concurrent Engineering-CIM concepts – Computerized elements

of CIM system –Types of production - Manufacturing models and Metrics – Mathematical

models of Production Performance– Simple problems – Manufacturing Control –Simple

Problems – Basic Elements of an Automated system – Levels of Automation – Lean Production

and Just-In-Time Production.

UNIT II PRODUCTION PLANNING AND CONTROL AND COMPUTERISED

PROCESS PLANNING 10

Process planning – Computer Aided Process Planning (CAPP) – Logical steps in Computer

Aided Process Planning – Aggregate Production Planning and the Master Production Schedule –

Material Requirement planning – Capacity Planning- Control Systems-Shop Floor Control-

Inventory Control –Brief on Manufacturing Resource Planning-II (MRP-II) & Enterprise

Resource Planning (ERP) -Simple Problems.

UNIT III CELLULAR MANUFACTURING 9

Group Technology(GT), Part Families – Parts Classification and coding – Simple Problems in

Opitz Part Coding system – Production flow Analysis – Cellular Manufacturing – Composite

part concept –Machine cell design and layout – Quantitative analysis in Cellular Manufacturing

– Rank Order Clustering Method - Arranging Machines in a GT cell – Holier Method – Simple

Problems.

UNIT IV FLEXIBLE MANUFACTURING SYSTEM (FMS) AND AUTOMATED

GUIDED VEHICLE SYSTEM (AGVS) 8

Types of Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS Planning

and Control– Quantitative analysis in FMS – Simple Problems. Automated Guided Vehicle

System (AGVS) – AGVS Application – Vehicle Guidance technology – Vehicle Management &

Safety.

UNIT V INDUSTRIAL ROBOTICS 8

Robot Anatomy and Related Attributes – Classification of Robots- Robot Control systems – End

Effectors – Sensors in Robotics – Robot Accuracy and Repeatability - Industrial Robot

Applications –Robot Part Programming – Robot Accuracy and Repeatability – Simple Problems.

TOTAL: 45 PERIODS



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OUTCOMES:

Upon completion of this course, the student can able to understand the use of computers

inprocess planning and use of FMS and Robotics in CIM

TEXT BOOK:

1. Mikell.P.Groover “Automation, Production Systems and Computer Integrated

Manufacturing”, Prentice Hall of India, 2008.

2. Radhakrishnan P, Subramanyan S .and Raju V., “CAD/CAM/CIM”, 2nd Edition, New Age

International (P) Ltd, New Delhi, 2000.

REFERENCES:

1. Kant Vajpayee S, “Principles of Computer Integrated Manufacturing”, Prentice Hall

India,2003.

2. Gideon Halevi and Roland Weill, “Principles of Process Planning – A Logical Approach”

Chapman & Hall, London, 1995.

3. Rao. P, N Tewari &T.K. Kundra, “Computer Aided Manufacturing”, Tata McGraw Hill

Publishing Company, 2000.



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Subject code: ME 6703 Year/ Semester : IV/07

Subject Name: Computer Integrated Manufacturing Systems

Subject Handler: Dr.D.Muruganandam

UNIT I INTRODUCTION

Brief introduction to CAD and CAM – Manufacturing Planning, Manufacturing control-

Introduction to CAD/CAM – Concurrent Engineering-CIM concepts – Computerised elements

of CIM system –Types of production - Manufacturing models and Metrics – Mathematical

models of Production Performance – Simple problems – Manufacturing Control – Simple

Problems – Basic Elements of an Automated system – Levels of Automation – Lean

Production and Just-In-Time Production.

PART * A

Q.No. Questions

1. List any two reasons for using a CAD system. (BTL 2)

• To increase the productivity of the designer.

• To improve the quality of design.

• To improve communication

• To create a database for engineering

2 What are the components of a CAD system? (BTL1)

• Geometric modeling.

• Design analysis and optimization

• Design review and evaluation and

• Documentation and drafting.

3 List any two benefits of CIM. (BTL2)

Tangible benefits Intangible benefits

• Higher profits

• Improved quality

• Shorter flow times

• Reduced inventory levels

• Shorter vendor lead time.

• Improved customer service.

• Greater flexibility

• Greater responsiveness

• Improved competitiveness

• Safer working environment

4 Define CIM.(BTL1)

CIM is the integration of the total manufacturing enterprising through the use of integrated

systems and data communications coupled with new managerial philosophies that improve

organizational and personal efficiency.

5 Is CIM a concept or a technology? (BTL1)

CIM is both a concept and technology.

For top management, CIM is a concept, a blue print for success. For middle managers and line

managers, CIM is a technology, a physical realization of resources that are more capable and flexible.

6 What are the concepts of CIM?(BTL1)

Combination of separate applications, such as computer aided design (CAD), computer aided

http://www.businessdictionary.com/definition/combination.html

http://www.businessdictionary.com/definition/application.html

http://www.businessdictionary.com/definition/computer-aided-design-CAD.html

http://www.businessdictionary.com/definition/computer-aided-engineering-CAE.html



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engineering (CAE), computer aided manufacturing (CAM), robotics, and manufacturing resource

planning (MRP-II). Its objective is to streamline the manufacturing processes and to integrate them with

other business functions (such as accounting, financing, distributing, marketing).

7 Define automation.(BTL1)

Automation maybe defined as the process of having machines follow a predetermined sequence

of operations with little or no human labour, using specialised equipment and devices that perform and

control manufacturing process.

8 What are the main objective of CIM?(BTL1)

• CIM is to use the advanced information processing technology into all areas of manufacturing

industry.

• Increase product reliability.

• Decrease the cost of production and maintenance relating to the manufacturing system as well as

to the product.

• Reduce the number of hazardous jobs and increase the involvement of well-educated and able

humans in the manufacturing ability and design.

9 What do you mean by “Islands of Automation”?(BTL1)

The individually automated workstations or processes are called as Islands of automation. In

other words the term represents the various technologies that facilitate manufacturing automation in

isolation, without having integrated with other manufacturing technologies.

10 Differentiate between the islands approach to automation and CIM. (BTL2)

The primary difference between the islands approach to automation and CIM is that the CIM is global

and the other is local. CIM represents the logical evolution of the islands of automation concept.

11 What is the role of CIM in manufacturing?(BTL1)

CIM is most closely associated with functions in manufacturing engineering such a process

planning and numerical control (NC) part programming.

12 Define CAD and CAM.(BTL1)

CAD may be defined as any design activity that involves the effective use of computer to create, modify

or document engineering design.

CAM may be defined as an effective use of computers and computer technology in the planning,

management and control of the manufacturing function.

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What do you mean by island of software?(BTL1)

When computer software is restricted in its ability to link to other computer software it is known

as island of software.

14 What are the important applications of CIM in manufacturing planning?(BTL1)

• Manufacturing planning

• Manufacturing control

15 What are the important applications of CIM in manufacturing control? (BTL1)

• Quality control includes a variety of approaches to ensure the highest possible quality levels in

the manufactured product.

• Shop floor control refers to production management techniques.

16 What is management? (BTL1)

Management is the process of making decisions and directing the activities of personnel to achieve

stated objective. The objectives are successfully met when efforts are organized by communicating

http://www.businessdictionary.com/definition/computer-aided-engineering-CAE.html

http://www.businessdictionary.com/definition/computer-aided-manufacturing-CAM.html

http://www.businessdictionary.com/definition/robotics.html

http://www.businessdictionary.com/definition/manufacturing-resource-planning-MRP-II.html

http://www.businessdictionary.com/definition/manufacturing-resource-planning-MRP-II.html

http://www.businessdictionary.com/definition/objective.html

http://www.businessdictionary.com/definition/streamline.html

http://www.businessdictionary.com/definition/manufacturer.html

http://www.businessdictionary.com/definition/process.html

http://www.businessdictionary.com/definition/integrate.html

http://www.businessdictionary.com/definition/business-function.html

http://www.businessdictionary.com/definition/accounting.html

http://www.businessdictionary.com/definition/financing.html

http://www.businessdictionary.com/definition/marketer.html



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appropriate information for control and readjustment.

17 What is MAP? (BTL1)

Manufacturing automation protocol (MAP) is an implementation of the OSI model. It is the

hardware cum software implementable set of rules that facilitate information transfer among networked

computers and computer based equipment’s.

18 What are the goals of automation in manufacturing industry? (BTL1)

• Process Integration

• Improve Productivity

• Economize on floor space

• Improve quality

19

Define EDI.(BTL1)

Electronic data interchange (EDI) may be defined as the electronic transfer from the computer to

computer (or application to application) of commercial or administrative transactions using an agreed

standard to structure the transaction or message data.

20

What are dedicated and open systems? (BTL1)

The dedicated system refers to a computer system that is dedicated for a specific

application/purpose/machine. Open systems enable any type of computer system to communicate with

any other.

21 What are the benefits of EDI? (BTL1)

Properly installed EDI offers benefits in terms of reduced data errors through the avoidance

of double entry of data, reduced costs through improved business processes, reduced lead time,

better service and customer support through faster and better business processes.

22 What are the key functions of a manufacturing company? (BTL1)

• Marketing

• Engineering

• Production planning

• Plant operations

• Physical distribution

• Business and financial management

23 What is production planning and production control? (BTL1)

Production planning is the preproduction activity. It is the predetermination of the manufacturing

requirements such as manpower, materials, machines and manufacturing process.

Production control, through control mechanism tries to take corrective action to match the planned and

actual production.

24 What is meant by physical distribution? (BTL1)

It may be defined as the broad range of activities concerned with different movement of finished

products from the end of the production line to the customers. These activities include freight

transportation, inventory control, plant warehouse site selection, order processing, and market forecasting

and customer service.

25 What are the responsibilities of facilities engineering? (BTL1)

The responsibilities of facilities engineering include plant automation, planning the installation of new

equipment, planning materials flow and related work handling equipment’s, planning inventory staging

space and arranging storage for materials and tools.



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26 List the activities carried out by financial department of a manufacturing industry. (BTL2)

• Company services

• Payroll

• Accounts payable, billing and accounts receivable

• Cost accounting

• Financial planning and management

• Strategic planning

PART * B

1. (i) Explain any two drawing features in CAD. (13M) BTL2

Answer: Page 1.68 -Dr.V.Jayakumar

Some of important drawing features in CAD are; (5M)

Scaling; Rotation; Translation; Editing; Dimensioning; Labelling; Zoom ; Redraw

Explanation of any two above drawing features :

(ii) Name the types of modeling in CAD? Explain about any one of them. (3M) (BTL 1)

The types of modeling in CAD are:

Geometric modeling; Wireframe modeling; Surface modeling and Solid modeling. (2 M)

Explanation any one ( 3 M)

2 Explain in detail the various types of automation. (13M),(BTL2)

Answer:Page.1.68 - Dr.V.Jayakumar

Description : (13 M)

Applied to accomplish a process or procedure without human assistance.

Technology concerned with application of mechanical, electrical and computer-based system

to operate and control system.

Program of instructions and a control system (sensors and actuators) for program execution

Increase production rate and labour productivity

3 Explain the different levels of automation with necessary application. (BTL2)


Description : (13 M)

Level 1: Device level – Lowest level in automation

Level 2: Machine level – Hardware assembled into individual machine. Control functions at

this level include performing the sequence of steps in the program of instruction

Level 3:Cell or system level – Under instruction from the plant level

Level 4: Plant level – Receives instruction from the corporate information system and

translates from into operational plans for production

Level 5: Enterprise level - Highest level in automation, it consist of the corporate information



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system.

4 Explain the computerized element of CIM.(13 M),(BTL2)


Description : ( 13 M)

Computerised integration of all aspects of design planning, manufacturing, distribution and

management.

It includes all the engineering functions of CAD/CAM

5 Write in detail about production performance matrices.(13M), (Nov/Dec-2016) ,(BTL1)


Description : ( 8 M)

• Quantitatively measure the performance of the reduction facility or a manufacturing

company.

• Measure that facilities the quantification metrics is a system of related measures that

facilities the quantification of some particular characteristics of production

• To make good decisions, track performance of the production systems

Manufacturing matrix: ( 5 M)

• Production performance measure

• Manufacturing cost

6 Discuss pull system of production control in JIT. (13 M),(BTL2)


Description : 8 M

Eliminate sources of manufacturing waste by producing right part in the right place at the right

time.

Reducing inventory, Improving product quantity, Reducing production and delivery lead time.

Objectives and Elements: zero defects, zero inventories,, zero break down

Sketch : (5 M)

Kanban systems – Page 1.91, Dr.V.Jayakumar

7 Explain the concept of lean manufacturing and just in time production systems.

(13M),(BTL2)

Answer:Page.1.80&1.90 - Dr.V.Jayakumar

(5M)

• In its most basic form, lean manufacturing is the systematic elimination of waste from

all aspects of an organization’s operations, where waste is viewed as any use or loss

• In many industrial processes, such non-value-added activity can comprise more than

90 percent of a factory’s total activity.

• (4 M)

There are numerous methods and tools that organizations use to implement lean production

systems. Eight core lean methods are described briefly below. The methods include:

• Kaizen Rapid Improvement Process

• 5S



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• Total Productive Maintenance (TPM)

• Cellular Manufacturing / One-piece Flow Production Systems

• Just-in-time Production / Kanban

• Six Sigma

• Pre-Production Planning (3P)

• Lean Enterprise Supplier Networks (4 M)

PART *C

1 Explain the various mathematical models used to evaluate production performance

(15 M),(BTL3)


Production rate ( 2 M)

Cycle time (3 M)

Mass production &Production capacity (5 M)

Utilisation and availability (5 M)

2 Describe the application of computers for design. (BTL2)


1. Design (3 M)

Assembly layout, New part design, Standard part library, Tolerance specification, Interface

and clearance specification, Part relations in an assembly.

2. Analysis (3 M)

Interference checking, Fit analysis, Weight and balance, Volume and area properties,

Structural analysis, Kinematics analysis, Tolerance stacking

3. Documentation (3 M)

Drawing generation, Technical illustration, Bill of materials, Image rending

4. Manufacturing (3 M)

Process planning, NC part program generation, NC part program verification, NC machine

simulation, Inspection programming, Robot programming and verification, Factory layout

5. Management (3 M)

Review and release, Engineering changes, Project control and monitoring, Selection of

standard parts and assemblies, Design standards

3 Discuss about the lean production with illustrative example. (15M),(BTL2)

Answer:Page.1.68 ,Dr.V.Jayakumar

Description : (8 M)

Adaptation of mass production in which workers and work cells are made more flexible and

efficient by adopting methods that reduce waste in all forms.

Defects and waste, cycle time, Inventory levels, Labour productivity, flexibility and output



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UNIT II: PRODUCTION PLANNING AND CONTROL AND

COMPUTERISED PROCESS PLANNING

Process planning – Computer Aided Process Planning (CAPP) – Logical steps in Computer

Aided Process Planning – Aggregate Production Planning and the Master Production Schedule

– Material Requirement planning – Capacity Planning- Control Systems-Shop Floor Control-

Inventory Control – Brief on Manufacturing Resource Planning-II (MRP-II) & Enterprise

Resource Planning (ERP) - Simple Problems.

Q.No. Questions

PART - A

1 What are the steps involved in Process planning? (BTL1)

• Preliminary analysis and Product design evaluation

• Selection of manufacturing process

• Selection of Machine Tool Selection of Tooling and Process parameters

• Final operation sequence selection

2 What arc the prerequisites need for process planning? (BTL1)

• Part list

• Annual demand/ batch size

• Accuracy and surface finish requirement.

3 What is engineering change control? (Nov/Dec-2009) (BTL1)

Engineering changes frequently occur and should be communicated to all the personnel

concerned. Because engineering changes can affect other aspects of manufacturing, companies

often implement systems, which are driven by engineering changes.

4 Describe variant process planning. (BTL2)

• Its similarity among components to retrieve the existing process plans.

• It’s used by a family of components is called a standard plan.

• Standard plan is stored permanently with a family number as its key.

5 Describe generative process planning. (BTL2)

• Synthesizes process information in order to create a process plan for a new component

automatically.

• Process plans are created from information available in manufacturing database

without human intervention.

• Upon receiving the design model, the system can generate the required operations and

operation sequences for the component.

• Knowledge of manufacturing must be captured and encoded into efficient software

6 Give the main component of generative CAPP systems. (BTL1)

• CAPP system contains of two main components.

• Manufacturing data base (part description, machine tool library etc.)

• Decision logic (to represent the process planner)

Key principles: ( 5 M)

Recognition of waste, Standard process, continuous flow, pull –production, quality at the

source



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• Process optimization data (as cross reference)

7 List out the benefits of Computer Aided Process Planning. (Nov/Dec-2010) (BTL1)

• Process rationalization:

• Increased productivity of process planners:

• Reduced turnaround time

• Improved legibility.

• Incorporation of other application programs

8 Define Material requirement planning (MRP). (May/June-2012) (BTL1)

• Material Requirement planning (MRP) is a planning system that does not do detailed

scheduling.

• Computer based production planning and inventory control system.

• Requires fixed lead times which might actually vary with batch Size.

9 What is meant by CAPP? (May/June-2012) (BTL1)

• Computer-aided process planning.(CAPP) is used to overcome the drawbacks of

manual process planning.

• With the use of computers in the process planning, one can reduce the routine clerical

work of manufacturing engineers.

• Opportunity to generate rational, consistent and optimal plans.

10 What is CMPP system? (May/June-2013) (BTL1)

• CMPP- Computer Managed Process Planning. It is a generative system capable of

automatically making process decisions.

• An extensive interactive capability is provided which permits the use to examine and

modify a process plan as it is developed.

• Plan the fabrication of cylindrical parts involving processes such as: Turning, grinding,

and honing, broaching, milling, electrical discharge machining, and drilling used to

produce flats, slots, holes, gear teeth, and other non-cylindrical features on a cylindrical

part.

11 List any two benefits of CAPP. (Nov/Dec-2011) (BTL2)

• Process rationalization and standardization

• Increased productivity of process planners

• Reduced lead time for process planning.

12 What are the basic approaches of CAPP? (BTL1)

• Retrieval (or variant) CAPP system

• Generative CAPP system.

13 Differentiate the underlying concepts of variant and generative CAPP systems.

(May/June 2012) (BTL2)

• A process plan for a new part is created by recalling, identifying and retrieving an

existing plan for a similar part, and making the necessary modifications for the new

part.

• Whereas the generative CAPP system automatically generates the process plan based

on decision logics and pre-coded algorithms.



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14 Differentiate product simplification with product diversification. (BTL3)

Product simplification is the process of reducing the variety of products manufactured i.e.,

variety reduction.

Product diversification is completely opposite to simplification. Product diversification

involves adding new products or lines products to achieve a balanced product range.

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List the Objectives of Planning and Control. (May 2015) (BTL2)

• Production planning is an activity that is performed before the actual production

process takes place.

• Determining the schedule of production, sequence of operations, economic batch

quantities, and also the dispatching priorities for sequencing of jobs.

• Production control is mainly involved in implementing production schedules and is the

corollary to short-term production planning or scheduling.

16 What is Master Production schedule? (BTL1)

It is a detailed plan that states how many end items will be available for sale or distribution

during specific periods.

17 Define the term machine loading & job sequencing. (BTL1)

Allocating orders to work canters is known as machine loading. Determining the priority in

which the jobs should be processed is termed as job sequencing

18 What is SFC? (BTL1)

Shop floor control s concerned with release of production orders to the factory. Monitoring &

Control

19 What is scheduling, dispatching and expediting? (BTL1)

• Scheduling: Assigning specific job to specific work centres as based on delivery

schedule.

• Dispatching: Issuing individual orders to the machine operators.

• Expediting: Comparing actual Progress vs Production schedule.

20 What are the phases of SFC? (BTL1)

• Order release

• Order scheduling

• Order progress

21 What is MRP II? (BTL1)

Manufacturing Resource Planning(MRPII) is a computer based system for planning,

scheduling and controlling the materials, resources and supporting activities to meet master

production schedule.(MPS)

22 Define Production Planning.(Nov-2016) (BTL2)

Translating demand forecasts into production and capacity levels over a fixed planning horizon

it can plan demand forecasts accurately and fairly.

23 Define Manufacturing resource planning. (Nov-2016) (BTL2)

Computer based system for planning, scheduling and controlling the materials, resources and

supporting activities to meet master production schedule.(MPS)

PART * B

1 Explain activities of process planning.(13 M) (BTL2)




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(8M)

Description :

• Drawing interpretation

• Evaluation evaluation/Process selection

• Selection of machines, tooling, work holding devices

• Setting parameters

• Selection of quality assurance methods

• Cost estimating

• Preparing the process planning documentation

• Communicating the manufacturing knowledge to the shop (5M)

3 List out the inventory types. Explain them. (13M) (BTL2)



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Types:

• Fixed- order quantity models, and

• Fixed- time period models (3M)

1.Fixed Order Quantity Models: This model is also known as the economic order quantity

model, Q model, re-order point inventory system/perpetual inventory system.

• Re-ordering system - the size of the order (order quantity) is predetermined / fixed -

time of its placement (ordering time) - allowed to vary depending upon the fluctuation

in demand.

• To use the fixed-order model, the inventory remaining must be continually monitored,

thus the fixed- order quantity is a perpetual system.

• Every time a withdrawal from inventory or an addition to inventory is made - records

must be updated to ensure that the reorder point has or has not been reached. (5M)

2. Fixed- Time Period Models:

• The periodic system, periodic review system, fixed- order interval system / p-model.

• In a fixed – time period system, periodic review of inventories are made and an order is

invariably placed in that period.

• P-model has a fixed ordering interval, - size of the order quantity may vary with the

fluctuation in demand.

• The ordering procedure consists of reviewing the inventory position after a fixed

period of time, known as review period.

• At each review period, an order is placed for an amount equal to the difference between

a fixed replacement level and the actual inventory level. (5 M).

4 Explain manufacturing resource planning (MRP II).(13M) (BTL2)


MRP II:

(MRP II) represents the natural evolution of closed-loop MRP (materials requirements

planning).

MRP II is an integrated information system that synchronizes all aspects of the business.

• System coordinates sales, purchasing, manufacturing, finance and engineering by

adopting a focal production plan and by using one unified database to plan and update

the activities in all the systems. (5

M)

Important MRP II system functions include:

• Management planning-business strategy, aggregate production planning master

production scheduling, rough-cut capacity planning, and budge planning.

• Customer services-sales forecasting, order entry, sales analysis, and finish goods

inventory.

• Operations planning-purchase order and work order release.

• Operations execution-purchasing, product scheduling and control, work-in process

inventory control, shop floor control, and labour hour tracking.



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• Financial functions cost accounting, accounts receivable, accounts payable general

ledger, and payroll. (8 M)

5 Explain the phases SFC.(13M) (BTL2)

Answer: Page 2.49-Dr.V.Jayakumar

Phases of SFC: (3 M)

• Order Release.

• Order Scheduling.

• Order Progress.

Description of each: (10 M)

• Order release phase provides the documentation needed to process a production

order through the factory

• Order scheduling module, which follows directly from the order release module.

• Order phase monitors the status of the various orders in the plant

6 What are the various approaches of CAPP? Explain them. (13M) (BTL2)


The two basic approaches or types of CAPP system are ( 3 M)

• Retrieval(or variant)CAPP system

• Generative CAPP system

Retrieval CAPP system:

• In this system, a process plan for a new part created by recalling,

• Identifying and retrieving an existing plan for a similar part making the necessary

modifications for the new part. ( 5 M )

Generative CAPP systems.

• To synthesize or generate each individual process plan automatically and without

reference to any prior plan.

• The human role in running the system includes:

• inputting the GT code of given part design

• monitoring the function ( 5 M)

PART * C

1. Discuss ERP with suitable modules. (BTL3) (15 M)


ERP : (2 M)

List of different Modules: Finance module

• Manufacturing module

• Distribution module

• Service module

• Transportation module

• Process module

• Project module

• Tools module ( 5 M)



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Explanation of any two modules

• Accounting – oriented information system

• Effective planning and control (8M)

2 Explain master production schedule with suitable illustrative example. (BTL4) (15 M)


(7M)

(8M)



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3 What is MRP? Explain the inputs of MRP. (Nov/Dec 2016) (BTL2) (8M)


Material requirements planning (MRP) is a computational technique that converts the master

schedule for final products into a detailed schedule for the raw materials and parts used in the

final products. (2 M)

The following information are needed for MRP:

• Demand for all products.

• Lead times for all finished goods, components, parts and raw materials.

• Lot sizing policies for all parts.

• Opening inventory levels.

• Safety stock requirements.

• Any orders previously placed but which haven't arrived yet. (4 M)

The three important inputs to MRP are:

• Master production schedule,

• Bill of materials file, and

• Inventory record file. (2 M)

(ii)Enumerate Shop Floor Control System. (BTL3)(7 M)

Shop Floor Control system’s functions: ( 4 M)

• Assigning priority of each shop order (Scheduling)

• Maintain work-in process quantity information (Dispatching)

• Conveying shop order status information to the office (Follow up)

• Providing actual output data for capacity control purposes

• Providing quantity by location by shop order for work in process inventory and

accounting purpose

Phases of SFC:

• Order Release

• Order Scheduling and

• Order Progress ( 3 M)

UNIT III CELLULAR MANUFACTURING

Group Technology(GT), Part Families – Parts Classification and coding – Simple Problems in

Opitz Part Coding system – Production flow Analysis – Cellular Manufacturing – Composite

part concept – Machine cell design and layout – Quantitative analysis in Cellular

Manufacturing – Rank Order Clustering Method - Arranging Machines in a GT cell – Holier

Method

Q.No. Questions

PART - A

1 Define Group Technology (GT). (BTL1)

Identical or similar components grouped processed together during design,



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process planning and manufacturing so that a wide variety of components can be manufactured, at the

least expense of time, inventory, man hours and material handling.

2 List out the stages in Group Technology.(BTL2)

• Production planners to setup the GT database.

• Grouping the parts or components into part-families with some similar characteristics.

• Re-design the shop-floor arrangement according to common shape, function or manufacturing

process and tooling.

3 Define Part family. (BTL1)

collection of parts which are similar in terms of geometric shape, size,

and similar processing steps required in manufacturing, so flow of materials through the plant

improves"

4 List the general methods used for grouping parts into families.(BTL2)

• Visual Inspection

• Parts classification and coding system

• Production flow analysis.

5 What is Production Flow Analysis (PFA)? (BTL1)

Identifying part families and associated machine groupings that uses the information contained on

production route sheets rather on part drawings.

6 List the steps involved in PFA.(BTL2)

• Data Collection

• Sortation of process routings

• Preparation of PFA chart

• Cluster analysis.

7 What are the 3 basic code structures used in GT applications?(BTL1)

• Hierarchical codes

• Attribute codes

• Decision tree-codes.

8 What is the main difference between hierarchical codes and attribute code structures? (BTL1)

Interpretation of each symbol in the sequence depends on the value of preceding symbols. Whereas in

attribute / polycode structure, the interpretation of each symbol in the sequence does not depend on the

value of preceding symbols.

9 List any six coding systems that are widely recognised in industries.(BTL2)

• Optiz classification system

• MICLASS system

• DCLASS system

• KK-3 System

• CODE system

• CUTPLAN system

10 What is cellular manufacturing? (BTL1)

Application of GT in which dissimilar machines have been aggregated into cells, each of which is

dedicated to the production of a part family.



3- 18

11 List any four design considerations guiding the cell formation. (BTL2)

• Parts/products to be fully completed in the cell.

• Higher operator utilisation

• Fewer operations than equipment

• Balanced equipment utilisation in the cell.

12 What is Process planning? (BTL1)

• Preparing a set of instructions that describe how to fabricate apart or build an assembly

which will satisfy engineering design specifications.

• Systematic determination of the methods by which product is to be manufactured, economically

and competitively.

13 List the activities associated with process planning. (BTL2)

• Analysing finished part equipment’s

• Determining operating sequence

• Selecting machines

• Selecting material parameters

• Calculating process times

• Documenting process planning

14 What is meant by CAPP? (BTL1)

CAPP refers to computer aided process planning. CAPP is used to overcome the drawbacks

of manual process planning. With the use of computers in the process planning, one can reduce the

routine clerical work of manufacturing engineers. Also it provides the opportunity to generate rational,

consistent and optimal plans.

15

What are the approaches the CAPP will recognize? (BTL1)

• Two approaches to CAPP are traditionally recognized: the variant approach and the

generative approach.

• Many CAPP systems combine both approaches.

16 Why CAPP systems are called as variant system? (BTL1)

• The investment is less and the development time is shorter. Especially for medium sized

companies which want to establish their own research groups.

• The development costs and hardware costs are lower. Especially for some small companies

where the products do not vary much and who still have process planners.

17 Give the main component of generative CAPP systems. (BTL1)

CAPP system contains of two main components.

• Manufacturing data base (part description, machine tool library etc.)

• Decision logic (to represent the process planner)

18 What are the basic approaches of CAPP? (BTL1)

• Retrieval (or variant) CAPP system

• Generative CAPP system.

19 What are the results of Process Planning? (BTL1)

• Routings which specify operations, operation sequences, work centres, standards, tooling and

fixtures.

• Process plans which typically provide more detailed, step-by-step work instructions including

dimensions related to individual operations, machining parameters, set-up instructions, and

quality assurance checkpoints.



3- 19

• Fabrication and assembly drawings to support

20 What are the factors should be considered in selection of tooling? (BTL1)

• The type and amount of the material to be cut.

• The surface finish required

• The rigidity and shape of the part.

• The capacity and condition of the available equipment

21 What are the prerequisites for process planning? (BTL1)

• Part list

• Annual demand/ batch size

• Accuracy and surface finish requirement

• Equipment details

• Data on cutting fluids, tools, jigs and fixtures, gauges.

• Standard available stock sizes.

• Machining data, data on handling and setup.

22 What is the weakness of PFA? (BTL1)

Data used are derived from production route-sheets. But the process-sequences have been prepared by

different process lanners and the difference is reflected on to these route-sheets.

23 List some commercially available CAPP. (BTL2)

• Some of the commercial variant CAPP systems include CUTPLAN. COMCAPP V, DCLASS

and INTELLICAP.

• Some of the commercial generative CAPP systems include AUTAP, CMPP, GENPLAN and

LO CAM.

24 What is CMPP?(BTL1)

CMPP stands for computer-managed process planning.

It is a commercial generative process planning system capable of automatically making process decisions.

PART – B

1 Explain the various DCCLASS coding systems. (13M) BTL2

Answer: Page.1.68 - Dr.V. Jayakumar

• The first segment(three digits) is used to denote the basic shape (2M)

• The second segment(4th digit) is used to specify the complexity of the parts (2M)

• The third segment (5th digit) is used to specify the overall size of the coded part. (2M)

• The fourth segment (6th digit) represents precision. (2M)

• The final segment (two digits) is used to denote the material type. (2M)

Explanation of coding system (3M)



3- 20

2 Explain OPTIZ CODING system?(13M) BTL2


Optiz (7 M)

Classification System: (4 M)

The optiz system was developed by H. Optic of Aachen University, Germany. In fact it was

the most popular and one of the first published classification and coding systems schemes for

mechanical parts.

This system uses alpha numeric symbols to represent the, various attributes of the part.

The optiz coding system uses the following digit sequence: (4 M)

Example: 12345 6789 ABCD.

The first five (12345) digits code the major design of the part and are called the "Form Code".

The next for digits (6789) are for coding manufacturing related attributes and are called

"Supplementary Code".



3- 21

3 Give the form code for the part family using any one coding system.(13M) BTL2


Coding is a systematic process of establishing an alphanumeric value for parts based on

selected part features. Classification is the grouping of parts based on code values. (3M)

Design and manufacturing attributes (2M)

• Systems based on part design attributes

• Systems based on part manufacturing attributes

• Systems based on both design and manufacturing attributes.

Coding system (2M)

• Hierarchical codes

• Attribute codes

• Decision tree codes

Explanation of any one system : OPTIZ / MICLASS / DCLASS (6M)

4 Discuss how group technology is used in designing manufacturing cells. (13M) BTL2


• Once parts have been grouped into part families by parts classification and coding or

production flow analysis, the next problem would be determining how to arrange the

machines in the shop. (2 M)

• Facility layout, also known as plant layout, refers to the physical arrangements of

production facilities. It is the configuration of departments, work centres, and

equipment in the conversion process. (2M)

• The objective of facility layout is to design a physical arrangements that most

economically meets the required output quantity and quality. (2M)

There are three basic ways to arrange machines in a shop. They are (2M)

• Line (or product) layout,

• Functional (or process) layout

• Group (or combination) layout.

Explanation of any one layout (5M)

PART – C

1. Discuss ERP with suitable modules. (15 M) BTL3


ERP : Enterprise Resource Planning (2 M)

List of different Modules: Finance module

• Manufacturing module

• Distribution module

• Service module

• Transportation module

• Process module

• Project module

• Tools module (5M)

Explanation of any two modules

• Accounting – oriented information system

• Effective planning and control (8M)



3- 22

2

Briefly discuss various benefits of implementing a GT in a firm. Also bring out the advantages

and

limitations of using group technology. (13M) BTL3


Benefits of group technology

• Product design

• Tooling and setups

• Materials handling

• Production and inventory control

• Process planning

• Management and employees ( 5 M)

Advantages of GT

• GT facilitates: efficient retrieval of similar parts

• GT encourages standardization of designs, tooling, fixing and setups

• GT facilities: Development of a computer-aided process planning (CAPP)

• Times and costs for material handling and waiting between stages are reduced.

• Production planning and control is simplified

• Part and product quality are improved

• Better employee involvement and increases workers satisfaction (10 M)

3 Discuss arranging machines in a GT Cell in detail with holier method.(15M) (BTL3)

After part-machine groupings have been identified (by rank order clustering algorithm) and next

problem is to

arrange the machines into the most logical sequence.

Design the cellular manufacturing system are:

• The determination of the most logical machine sequence in each cell

• The development of a feasible layout plan for each cell

Literature to determine the most logical machine in a GT Cell, the Holier method 2 (7M)

Procedure of Holier method 2

• Develop the From-TO chart from part routing data

• Calculate the “’From/To ratio” for each machine

• Arrange Machines in a GT Cell in order of decreasing “From/To ratio” (4M)

Performance measures for Machine sequences in a GT Cell

• Percentage of In sequences in a GT Cell

• Percentages of Bypassing moves

• Percentages of backtracking moves (4M)

4 Explain composite part concept in cellular manufacturing. (May/June 2013). (15M) (BTL2)

Answer:Page.1.68 Dr.V.Jayakumar

(3M)

A composite part is a hypothetical part which includes all of the design and manufacturing

attributes of a family. The composite is a single hypothetical part that can be completely



3- 23

processed in manufacturing cell .(3M)

Let us consider that there are four number of parts as shown in figure a, all of whom have

similar machining operations to be done, Then it is possible to construct a new composite part

as shown in figure b that has all the features identified in the four parts from figure b

(4 M) (8M)

UNIT IV FLEXIBLE MANUFACTURING SYSTEM (FMS) AND

AUTOMATED GUIDED VEHICLE SYSTEM (AGVS)

Types of Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS

Planning and Control– Quantitative analysis in FMS – Simple Problems. Automated Guided

Vehicle System (AGVS) – AGVS Application – Vehicle Guidance technology – Vehicle

Management & Safety.

Q.No. PART - A

Questions

1. List the major objectives of a Production Management Systems (PMS). (BTL1)

The two major objectives of a production management system (PMS) are planning and controlling of the

manufacturing operations. The Planning Stage deals initial Production planning, development of master

schedule, capacity planning, and MRP.

2 Define SFC. (BTL1)

Shop Floor Control (SFC) is defined as the important manufacturing activity that will control flow of the

product and materials on the factory flow involving the quantities, types of parts, schedule dates, priorities

and the status of jobs and orders.



3- 24

3 What are the primary functions of SFC? (BTL1)

Functions of SFC system

• Priority control and assignment of shop orders

• Maintain information on work in process for MRP

• Monitor shop order status information

• Provide production output data for capacity control purposes

4 What are the phases of SFC? (BTL1)

The three phases or modules are:

• Order Release

• Order Scheduling

• Order Progress

5 What is the purpose of FDS? (BTL1)

The purpose of the Factory Data Collection (FDS) system in shop floor control is to provide basic data for

monitoring order progress. In a computerized SFC system these data are submitted to the order progress

module for analysis and generation of work order status reports and exception reports.

6 What is an Automatic Data Capture (ADC) method? (BTL1)

Identification methods is also known as Automatic Data Capture (ADC) it is refers to the technologies that

provides direct entry of data into the computer or other control systems without using a keyboards. These

technologies require no human involvement in the data capture and entry process.

7 What are the technologies used in ADC? (BTL1)

• Optical

• Magnetic type

• Electromagnetic type

• Smart card

• Touch techniques

• Biometric

8 What Bar code consists? (BTL1)

The bar code consists of a thick and narrow coloured bars separates thick and narrow spaces separating

the bars. The pattern of bars and spaces is co to represent alphanumeric characters.

9 What are the types of Bar code? (BTL1)

Bar codes divide into two basic types:

• Linear, in which the encoded data are read using a linear sweep of the scan

• Two-dimensional, in which the encoded data must be read in both directions

10 write a short note ON scheduling? (BTL1)

Operation scheduling is concerned with the problem of assigning specific jobs to specific work centers on

a weekly, daily, hourly basis.

Operation scheduling = Machine loading + Job sequencing

11 What is dispatching?(BTL1)

Dispatching is the function concerned with issuing the individual orders to the machine operators.

12 List out the types Of AGV’s(Nov/Dec 2016) (BTL2)

• Load Carriers

• Pallet Towing Vehicle

• Unit Trucks

• Forklift Trucks



3- 25

• Light Load Transporters

• Assembly Line Vehicles

13 What is the philosophy of just in time?(BTL1)

It is a management philosophy that strives to eliminate sources of manufacturing waste by producing the

right part in the right place at the right time.

14 What do you mean by priority control in PPC? (BTL1)

The term priority control is used in production planning and control to denote the function that maintains

the appropriate levels for the various production orders in the shop.

15 Define term machine loading and job sequencing.(BTL1)

Allocating orders to work centers is knows and machine loading Determining the priority in which the

jobs should be processed is termed as job sequencing.

16 What is the purpose of factory data collection system?(BTL1)

The purpose of the Factory Data Collection (FDS) system in shop floor control is to provide basic data for

monitoring order progress. In a computerized SFC system these data are submitted to the order progress

module for analysis and generation of work order status reports and exception reports.

17 What is FDS?(BTL1)

The factory data collection system consists of various paper documents, terminals and automated devices

throughout the plant for collecting data on shop floor operations.

18 What is DAS?(BTL1)

A data acquisitions system (DAS) is a computer system used to automatically collect data from a process

or piece of equipment. They either perform an analysis data or transmit the data to another

computer for processing and analysis.

19 Define FMS.(BTL1)

A Flexible Manufacturing System (FMS) is an individual machine or group of machines served by an

automated materials handling system that is computer controlled and has a tool handling capability.

20 What are the Objectives of FMS?(BTL1)

• To provide flexible manufacturing facility for pan family components.

• To provide the benefits of grouping the operation in single location.

• To provide the flexibility in producing small and medium parts.

• To maximize the utilization of facilities.

• To have a good management control.

21 What are the components of FMS?(BTL1)

• Processing stations or workstations

• Material handling and storage

• Computer control system

• Human labour

22 What are the FMS layout configurations?(BTL1)

• In-line layout

• Loop layout

• Ladder layout

• Open fie1d 1ayout

• Robot-centred cell.

23 List the functions of computers in FMS. (BTL1)

• Workstation control



3- 26

• Distribution of control instructions to workstations

• Production control

• Traffic control

• Shuttle control

• Work piece monitoring

• Tool control

• Performance monitoring and reporting

• Diagnosis

24 List any two advantages and disadvantages of FMS implementation.(BTL2)

Advantages

• Faster, lower-cost changes from one part to another which will improve capital utilization.

• Lower direct labour cost, due to the reduction in number of workers.

Disadvantages

• Substantial pre-planning activity.

• Expensive, costing millions of dollars.

25 List the applications of FMS . (BTL2)

• Machining

• Assembly

• Sheet-metal press-working

• Forging

• Plastic injection moulding

• Welding

• Textile machinery manufacture

• Semiconductor component manufacture

26 What is AGV? (BTL1)

AGVs are battery-powered, automatically steered vehicles that follow defined pathways in the

floor. The pathways are unobtrusive. AGVs are used to move unit loads between loads and

unload stations in the facility

27 What are the technologies used for vehicle guidance? (BTL1)

• Imbedded guide wires

• Paint strips

• Self-guided vehicle

28 What are the issues to be taken on vehicle management? (BTL1)

Traffic control, Vehicle dispatching, safety to human.

29 Write the advantages of AGVS in FMS. (BTL2)

• Flexibility

• Real time monitoring and control

• Safety

PART- B

1. What are the phases of shop floor control system? Explain them in detail.(13M) BTL 2

The three important phases of SFC are

1. Order Release

This order release phase provides the documentation needed to process a production order

through the factory.



3- 27

The collection of documents is sometimes referred as the shop packet.

The shop packet for an order consists of:

• Route sheet – used to list the sequence of operations and tools required.

• Material requisitions- used to get necessary raw materials from inventory.

• Job cards- used to report the labour for each operation on the route sheet.

• Move tickets – used to move the parts between the work centres.

Part lists – required for assembly jobs. (4M)

2. Order Scheduling

• The second phase of shop floor control is the order scheduling module, which follows

directly from the order release module.

• In this phase, the order scheduling module assigns the production orders to the various

work centres in that plant. In other words, order scheduling executes the dispatching

function in production planning and control.

• The order scheduling module prepares a dispatch list that indicates which production

order should be accomplished at the various work centres.

• To determine the sequence, priorities are given to the jobs in the queue, and the jobs are

processed in the order of their relative priorities.

• Priority sequencing rues, also known as dispatching rules, have been develop to

establish priorities for production orders in the plant. Some of the commonly used

priority sequencing rules. (6M)

3. Order progress

• The third and final phase of SFC is order progress phase.

• The order progress phase monitors the status of the various orders in the plant.

• Work-in-progress, and other characteristics that indicate the progress and performance

of production. (3M)

2 List the components of an FMS. Explain in detail (13M) BTL 2

Four basic components of a FMS are:

1. Workstations (4M)

2. Material handling and storage system (3M)

3. Computer control system (3M)

4. Human resources (3M)

3 Explain about FMS workstation. List the applications of FMS. (Nov/ Dec 2015) (13M)

BTL2

The work stations/processing stations used in FMS depends upon the type of product

manufactured by the system.

The types of work stations that are usually found in FMS are,

• Load/unload stations

• Machining stations

• Assembly work stations

• Inspection stations and

• Other processing stations (5M)

Explanation of all stations (8M)

4 List the functions performed by the FMS computer control system.(13M) BTL2

• Workstation/processing station control. Computer control system controls the



3- 28

operations of the individual processing or assembly stations in the factory. For

controlling the machine centres, CNC is used.

(2M)

• Distribution of control instructions to workstations.

A direct numerical control (DNC) Is used in a machining FMS to download the part

programs to the machines. The DNC computer control system also stores the programs,

allows entering and editing of programs. (2M)

• Production control. Computer control system, based on data entered into the

computer, helps to take decision on part mix and rate of input of the various parts onto

the system.

(2M)

• Material handling system control. Computer control system controls the material

handling system and coordinates its activities with those of thee workstations. (2M)

• Work piece monitoring. The computer control system also monitors the status of

each cart and/or pallet in the primary and secondary handling systems. (2M)

• Quality control. This function of computer control system ids to detect and possibly

reject defective work units produced by the system. (1M)

• Safety Monitoring. This function of computer control system is to protect both

human workers in operating the system and the equipment comprising the system.

(1M)

• Failure diagnosis. This function of computer control system involves diagnosing

equipment malfunction, preparing preventive maintenance schedules, and maintain

spare parts inventory. (1M)

5 How the issue of vehicle safety is managed? (13M) BTL2

For 1,2,3 (3M) each

4 & 5 (2M ) each

6 Write in detail the three types of AGVS vehicles.(13M) BTL2



3- 29

(3M)

(3M)

(3M)

(2M)



3- 30

(2M)

PART C

1. Bring out the various functions that are performed by the FMS computer control system.

(15M) (BTL2)

(4M)

(3M)



3- 31

(6M)

2 Explain quantitative analysis of flexible manufacturing system in detail.(15M)(BTL3)

Deterministic model: to provide gross estimation of system parameters such as production

rate, capacity and utilization.

These models are not used for complex systems such as the build-up of queues and other

dynamic than an impair system performance.

Example : bottleneck model is an example of deterministic model (5M)

Queuing models: based on the mathematic theory of quenes.These models address the issues

of queuing that are not examined in deterministic models.

These models examine various simple system configurations. (5M)

Discrete event simulation: to determine the most accurate methods for modelling specific

attributes of the FMS. The characteristics of the system such as layout configuration, number of

pallet in the system and production scheduling rules can be included.

Other techniques: mathematical programming, heuristic approaches, and a number of

operations research (OR) techniques. (5M)

3 Explain the Vehicle guidance technology of AGVs (Nov /Dec 2016) (15M) BTL2

\ (4M)

(3M)



3- 32

(4M)

(4M)

UNIT V INDUSTRIAL ROBOTICS

Robot Anatomy and Related Attributes – Classification of Robots- Robot Control systems –

End Effectors – Sensors in Robotics – Robot Accuracy and Repeatability - Industrial Robot

Applications – Robot Part Programming – Robot Accuracy and Repeatability – Simple

Problems.

Q.No. PART * A

Questions

1. Define End effectors.( Nov/Dec 2012 )BTL1

End effector is a device that is attached to the end of the wrist arm to perform specific tasks.



3- 33

2 What are the methods of Robot programming? (May/June 2013) BTL1 Lead through methods, Textual robot programming, and Mechanical Programming.

3

What is a teach pendant? (May/June 2012) BTL1

The teach pendant is usually a small handheld control box with combinations of toggle

switches, dials and buttons to regulate the robot’s physical movements and program

capabilities.

4 What is a tactile sensor? List the types of Tactile Sensors. (May/June) 2009 BTL1

Tactile sensor is a device which indicates the contact between themselves and some other solid

objects. Types of Tactile sensors are Touch digital Sensors and Force Analog Sensors.

5

Define Pitch, yaw and roll .(Nov/Dec 2016)BTL1

Pitch is rotation around X axis, Yaw is around the Y axis and roll is around the Z axis. Pitch is

up and down movement, yaw is side to side swing around an axis and roll is rotary motion

about an axis.

6

What is Accuracy and Repeatability in industrial robot? (Nov/Dec 2016) BTL1

The ability of the robot to reach a reference point within the robot’s full work volume is

known as accuracy of the robot, Repeatability refers to the ability to return to the

programmed point when it is commanded to do so again and again.

7 What is meant by Robot anatomy? BTL1

Study of structure of robot is called robot anatomy.

8 Write the classification of robot. BTL1

Coordinate Systems/Frames - Cartesian • Cylindrical • Spherical, SCARA Robot.

9 Name the different types of robot control system. BTL1

Non-servo Control, Feedback Control Loop, Feed forward Control, Adaptive Control

10 What is meant by work volume and work envelope? BTL1

The volume of the space swept by the robot arm is work volume.

11 What is meant by repeatability of robot? BTL1

Repeatability refers to the ability to return to the programmed point when it is commanded to

do so again and again.

12 What is meant by Accuracy of the robot? BTL1

The ability of the robot to reach a reference point within the robot’s full work volume is known

as accuracy of the robot.

13 List the applications of robot in manufacturing area. BTL2

Material transfer, Loading and unloading, processing operations, assembly and inspection.

14 What is a Sensor? BTL1

Sensor is a device that is used to make the measurement of a physical variable of interest.

15 List some of the Robot programming languages. BTL2

WAVE, AL, AML, MCL, VAL, PAL, RAIL, HELP

16

Differentiate between a transducer and a sensor. BTL2

Transducer is a device that converts the one form of information in to another form without

changing the information content. Sensor is a transducer that is used to make a measurement of

a physical variable of interest.

17 What are the types of mechanical grippers? BTL1

• Linkage Actuation gripper



3- 34

• Gear and rack actuation gripper

• Cam actuation gripper

• screw actuated gripper.

18

Write any two laws of robotics. BTL1

A robot may not injure humanity, or through inaction, allow humanity to come to harm.

A robot must obey orders given to it by human beings, except such orders would conflict with

a higher order law.

19

State limitations of stepper motor as a drive system for a robot. BTL2

The control of stepper motor is dependent on the ability of the switching electronics to switch

the windings at precisely the right moment.

If the windings are switched very quickly, the motor will not keep up with the command signal

and perform erratically.

The speed-torque degrades badly at certain frequencies of operation.

20 What is a Vision Sensor? BTL1

It is a advanced sensor system used in conjunction with pattern recognition and other technique

to view and interpret event occurring in the robot work space.

21

List out any four methods of entering commands in to the robot controller memory.

BTL2

• Manual programming method

• walk through programming method

• lead through method or teach pendant

• Off-line programming method.

22 Write some motion commands in VAL II. BTL2

MOVE P1, MOVES P1, APPRO P1, 50, DEPART 50.

23 Define Manipulator. BTL1

Robot manipulator is a device used to manipulate the materials. Manipulator comprises the

robot body, arm, wrist and different joints.

PART* B

1

Describe the classifications of sensors and the factors to be considered for its selection.

(13M) BTL 2


(4 M)

Internal sensors: feedback information internally to ascertain their present conditions.

Examples: potentiometers and optical encoders are used to control the position of the robot

arm



3- 35

External sensors : Physically mounted on the robot or on process equipment in the robot

cell so that they can be usually seen. (3M)

Example: four most common external sensors are:

The microswitches, the touch or tactile sensors, the photoelectric and the proximity sensors

Contact sensors: it also known as tactile sensors , are devices used in robotics to obtain

information associated with physical contact between a manipulator hand and objects in

workspace.

Two types: touch sensors and force sensors (3M)

Binary or touch sensors: To indicate whether contact has been made between two objects

or not to the regard to the magnitude of the contacting for force.

Examples: limit and microswitches

Noncontact sensors: Measure the condition of an object without physically touching the

part.

Examples: range, proximity and vision (3M)

2

Explain the different types of programming methods in detail.13M BTL 2

Answer: Page 5.52 - Dr.V.Jayakumar

(2M)

Manual programming: the operators setup program by fixing limit switches, stops, cams

etc., (2M)

Teach-Pendantor Lead -through Programming: also known as lead-through

programming, uses a teach pendant to instruct a robot to move in working space.

By using toggle switches and dials, the programmer power drives the robot on to the

desired positions in sequence. Each motion is recorded into memory for future playback

during the work cycle. (3M)

Walk-through programming: is commonly used for playback robots with continuous

path control.

The programmer or the operator physically grasps the end-effector and manually moves it

through the motion sequence, recording the path into memory. (3M)

Off line programming: the robot program using the textual language off-line in a manner



3- 36

like NC part programming.

Off line robot programming is typically accomplished on a remote computer terminal.

After the program has been prepared, it is entered the robot memory for use during the

work cycle (3M)

3

Discuss various programming languages used in computer-controlled robot. (13M) BTL 3

Answer : Page 5.54 - Dr.V.Jayakumar

(5M)

(4 M)

(4 M)

4

Discuss in detail the various applications of industrial robots. (13M) BTL 2

Answer : Page - 5. 42 Dr.V.Jayakumar



3- 37

(3 M)

(3 M)

(3M)

(2M)



3- 38

(1M)

(1M)

PART *C

1

Explain the four common Robot configurations with neat sketch.(15M) BTL 2

Answer: Page :5.42 - Dr.V.Jayakumar

Cartesian coordinate robot: also known as rectilinear robot or gantry robot consists of three

sliding joints, two of which are orthogonal.

The 3 slides are parallel to X,Y and Z axes of the cartesian coordinate system

(4M)

Cylindrical robot : has two linear axes and one rotary axis

The cylindrical coordinate system incorporates three degrees of freedom, or three axes:

The base rotation axisƟ

The reach axis the in-and out axisR



3- 39

The up – and -down axis Z

(4M)

Polar Coordinate Robotsor Spherical Robots: one linear axis and two rotary axes.

The rotational axisƟ

The reach axis R

The break up – and -down axis β

(4M)

joined – arm or Articulated robots : Three rotational axes connecting three rigid links

and a base.

The joined-arm or revolute coordinate system is identified by three axes:

The Ɵ axis waist rotation



3- 40

The β axis shoulder rotation

The ∞axis elbow rotation

( 3M)

2

Analyse robot accuracy and repeatability for different robot configurations. (15M) BTL 5

Answer : Page - 5.55 Dr.V.Jayakumar

Accuracy : the difference between where its control point goes and where it is instructed or

programmed to go. (4M)

Repeatability : the ability of the robot to reposition itself to a position to which it was

previously commanded or taught. (4M)

Configuration of various types of robot :

• Cartesian coordinate robot

• Cylindrical

• Polar

• Joined-arm (7M)

3

Explain various types of robot programming . Analyse a Program for pick and place robot. (15M)

BTL 4

Answer : Page -5.87 Dr.V.Jayakumar

Joint level programming (4M)

Robot level programming (3M)

High level programming (3M)

Pick and place robot program (5M)

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