JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD B.Tech IV Year FLEXIBLE MANUFACTURING SYSTEMS Previous Question Paper (February/March - 2022 - R18)
Answer any five questions. All questions carry equal marks.
Main
Discuss the issues in planning the FMS.
Answer
Planning an FMS is a complex task due to the high capital investment and the need for operational efficiency. Key planning issues include:
- Part Family Formation: Identifying groups of parts with similar manufacturing requirements to minimize setup times and tool changes.
- Machine Selection: Choosing machines that provide the necessary processing capabilities while maintaining sufficient flexibility for future product changes.
- Material Handling System (MHS) Design: Planning the layout and flow paths for AGVs or conveyors to ensure smooth movement between workstations without bottlenecks.
- Tooling Strategy: Determining the number of tools, tool life management, and centralized vs. decentralized storage to support diverse part mixes.
- Production Scheduling: Developing algorithms to manage real-time routing, machine loading, and sequencing to maximize throughput and machine utilization.
- System Layout: Optimizing the physical arrangement of machines and storage to reduce travel distance and floor space requirements.
Consider an automated machine cell consisting of two CNC machine tools that are loaded and unloaded by an industrial robot from a parts carousel – is it flexible? Give reasons.
Answer
An automated machine cell with two CNC machines and a robot is generally considered to have limited flexibility rather than full FMS-level flexibility. While it offers automation, it lacks the broader capabilities required for a true flexible system.
Reasons for this classification:
- Process Flexibility: The cell can handle different parts within a specific family, but it is constrained by the limited number of machines and the specific tool sets available in the CNC magazines.
- Routing Flexibility: There is minimal routing flexibility because there are only two machines; if both are occupied or down, the system cannot reroute parts to other stations.
- Volume Flexibility: The system can produce different quantities of parts, but it is limited by the fixed capacity of the two machines.
- Expansion Constraints: Unlike a full FMS, this cell is typically a 'closed' unit. It cannot easily integrate new machines or adapt to significant changes in production volume or part geometry without major reconfiguration.
In summary, while it provides machine flexibility and automation, it lacks the system-level redundancy and integration required to be classified as a fully flexible manufacturing system.
What are the three capabilities that a manufacturing system must possess to be flexible? Explain.
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What are the basic components of an FMS? Distinguish between the functions of Load/Unload Stations and Machining Stations.
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Explain the various steps in the procedure of Production Flow Analysis.
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Explain the concept of part family, with two different part families.
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What are the conditions under which the GT is most appropriately applied? Explain the major tasks that a company must undertake when it implements group technology.
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Distinguish between the Design Attributes and Manufacturing Attributes typically included in a Group Technology Classification and Coding System.
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Explain the different material transport equipment used in manufacturing.
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Define automated storage/retrieval system (AS/RS). Explain the three application areas for automated storage/retrieval systems.
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A storage system serving electronics assembly plant consists of 3 stage carousels, each with its own P and D station. Each carousel has a track that is 60 m long and 3.5 m wide. The speed at which the system revolves is 75 m/min. The P and D handling time is 0.40 min. Determine the throughput rate of the storage system if the storage transactions and retrieval transactions are equally divided during the shift. Assume bidirectional travel of the carousel.
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A flexible manufacturing system is being planned. It has a ladder layout and uses a rail guided vehicle system to move parts between stations in the layout. All work parts are loaded into the system at station 1, moved to one of the three processing stations (2, 3, or 4), and then brought back to station 1 for unloading. Once loaded onto its RGV, each work part stays onboard the vehicle throughout its time in the FMS. Load and unload times at station 1 are each 1.0 min. Processing times at other stations are: 5.0 min at station 2, 7.0 min at station 3, and 9.0 min at station 4. Hourly production of parts through the system is: 7 parts through station 2, 6 parts through station 3, and 5 parts through station 4.
Develop the From-to Chart for trips and distances.
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Develop the network diagram for this data.
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Determine the number of rail guided vehicles that are needed to meet the requirements of the flexible manufacturing system, if vehicle speed = 60 m/min and the anticipated traffic factor = 0.85. Assume reliability = 100%.
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Among the Variant and Generative CAPP approaches, which is better? Explain with reasons.
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Distinguish between contact and non-contact inspection methods.
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