1 flexible manufacturing manufacturing teams copyright © texas education agency, 2012. all rights...

1

Flexible ManufacturingManufacturing Teams

Copyright © Texas Education Agency, 2012. All rights reserved.

Manufacturing Teams

• Manufacturing companies have different types of teams:– Design Team– Safety Team– Production Team

2Copyright © Texas Education Agency, 2012. All rights reserved.

Design Team

Manufacturing Companies use teams to develop their production plans. The teams take the customer’s designs or ideas and decide the best methods of production. The schedule of production is charted.


Design Team

The customer wants a driving device to force pins and bolts from holes. The end of the device has to be flat and ¼” diameter.

4

1/8 CHAMPER

1 1/4

TAPER TO 1/4 DIA.

1/2 DIA. TOOL STEEL ROD5

DRIVE PUNCH


Safety TeamThe member of this team will

review the production process for product safety and personal safety. The Occupational Safety & Health Administration (OSHA) and other manufacturing regulations are followed in order to have a safe work place.


Safety Team

The safety team has to research the OSHA site and the manufacturing site for up to date safety data. Other sites such as the ones listed below can also be checked for regulations.

-Fabricators and Manufacturers Association -American Welding Society -The Machinery's Handbook


Safety Requirements

• “Will the equipment in the factory safely produce the punch?” should be the first consideration.

• The heat treating furnace will have to be safely loaded and unloaded and the punches will have to have a cooling time.


Safety Regulations

• What waste materials will be produced when making the punches?

Turning the punch will produce metal shavings. The lathe may use a turning fluid to keep the part cool while being made.


Machining Waste• How will the waste materials be safety disposed

of without harming the environment? The metal shavings are sharp and need to be recycled. This fluid will have to be treated to remove harmful chemicals and the clean water is fed back into the water system.


Production TeamProduction costs are figured using the following:

equipment operation cost and labor cost. Time management techniques are used to prepare a work schedule. The team has to communicate with the customer and production staff so the product can be manufactured quickly and safely for a comparative price.


Production Team

The plans are sent to the production team to review for machine steps. The manufacturing flow chart is established for the parts and machine costs are calculated.

11

Cost of Parts

Machine Operating Cost

Labor Cost

Overhead Expense


Production Team

The part will have to be turned on a lathe to be produced. The punch will have to be heat treated for hardness after machining is finished.

12

1/8 CHAMPER

5

1 1/4

TAPER TO 1/4 DIA.

1/2 DIA. TOOL STEEL ROD


WHEN DO I HAVE TO WORK?


Work Schedules

• Manufacturing work schedules are the times workers should be on the job.

• There are four basic types of work schedules:– Fixed– Flexible– Non fixed– Rotating


Work Schedules

• Fixed is the same work time each week. This is the 8 to 5 daily time most people work.

• Flexible is when the employee has the ability to select the time they work their 40 hour work week.


Work Schedules

• Non fixed is a work schedule that has no required hours per week or required start/end time.

• Rotating work schedules have a fixed work week for a week or month, then the shift changes to a different time. An example of this is 7 to 4 for a week, then 4 to 12 for the next week.


Understanding a Drawing or Plan

17

3.5

1/4 -20 X 3/4”

1/4” dia. Rod

1/4 -20 X 3.4” Both Ends

4

3

1.37

1.250

0.375

.750.750

.250

1/4 - 20 X 3.4”


Understanding a Drawing or Plan

Using your handout, answer the questions about the four drawings on the following slides.


Punch

19

1/8 CHAMPER

1 1/4

TAPER TO 1/4 DIA.


5

1 1/2

1/8 CHAMPER


Center Punch

Drive Punch

5


Small Hammer

20

3.5

1/4 -20 X 3/4”

1/4” dia. Rod

1/4 -20 X 3.4” Both Ends

6

3

1.37

1.250

0.375

.750.750

.250

1/4 - 20 X 3/4”

Handle

Shaft

Head

½” Dia.


Tablet Computer Stand

21

60

30 60

I PAD STAND

171 5 10

1/2

90 BEND

60 BEND

30BEND60

BEND6


Welded Angle Shelf

22

44 12

12

CUT ENDS AT A 45 DERGEE ANGLE

¾” ANGLE IRON IS USED TO MAKE THE SHELF


SHEET METAL MATERIALS


Types of Metal

• Metal is usually divided into two groups: non- ferrous and ferrous metal.

• Non-ferrous metals are metals that do not have any iron particles in them. These are also non magnetic.

ex: copper, aluminum, brass and bronze• Ferrous metals have iron and are magnetic. ex: iron, steel, stainless steel


Non-ferrous MetalsKind Natural/Alloy Color Use

Copper Natural Reddish orange

Plumbing and electrical

Brass Alloy of copper and zinc

Yellowish Musical instruments and hardware

Bronze Alloy of copper and tin

Medium brown

Tools, coins

Aluminum Natural Silvery to dull gray

Wire, building material


Ferrous MetalsKind Natural/Alloy Color Use Carbon %

Iron Natural Gray Covers and engine blocks

2% to 4 %

Mild steel Alloy iron and carbon

Silver Sheets, wire, pipe

0% to 0.25%

Medium carbon steel

Alloy iron and carbon

Silver Rails, plates, structures

0.25% to 0.45%

High carbon steel

Alloy iron and carbon

Silver Tools, springs,instruments

0.45 to 1.50%

Stainless steel Alloy iron and chromium, nickel

Silver Utensils, cutlery, watch cases


Shapes• Round diameter 3/16 – 9 inches• Square ¼ by ¼ to 4 ½ by 4 ½• Flats (rectangular shapes) 1/8 by 5/8 to 3 by 4 inches• Hexagons (six sided) from ¼ to 4 inches across flat

sides• Octagon (eight sided) ½ to 1 ¾ inches across flat sides• Sheet thickness 0.0060 to 0.2391 inches , 38 to 3

gauges• Plate thickness 3/16 to 10 inches


WELDING PROCESSES


Fundamentals of Oxy-fuel Processes

• The thickness of the metal determines the size of torch used.

• The American Welding Society does not have a standard tip size. Each manufacturer sizes their own tips.

• The chart on the next slide uses number drill sizes to size the tips.


Welding Tip Size

30

Metal Thickness

Tip Drill Size Diameter of Rod Oxygen Psi Acetylene Psi

1/32 70-80 1/16 2 2

1/16 60-69 1/16-3/32 3 3

3/32 55-59 1/16-1/8 3 3

1/8 54-57 3/32-1/8 4 5

3/16 52-55 1/8 4 4

1/4 44-52 5/32-3/16 4 4

3/8

40-50 3/16-1/4 5 5


Different Types of Acetylene Tips

• Welding tips are used for welding metal together.

• Cutting torch tips are used to heat the metal, then furnish a blast of oxygen to cut the metal.

• Rosebud tips are used to heat metal for straightening or bending.


SMAW - Stick Metal Arc Welding

• Sheet metal welding using an arc rod method is challenging to master.

• The thin metal burns through easily if too much amperage is used.

• The metal can overheat and distort ( warp, twist or bend).


Welding Sheet Metal

• Select the lowest welding amperage the machine has to prevent burn through.

• Use a 1/8” E6013 electrode because of the ease of welding with that rod.

• Weld several spots down the joint to help with distortion.


Welding Sheet Metal

• When the spot welds are in place, chip the flux away from the spots and weld the joint together.

• Watch for warping and twisting.• Weld through the spots making a single bead.


ASSIGNMENTS


Welding Assignments• Practice welding beads on sheet metal 1/16”

thick with oxygen/fuel torch and an SMAW welder.

Assignments to be graded• Weld a butt joint in 1/16” thickness using

oxygen/fuel welding. • Weld a butt joint using 1/16” thickness metal

using a SMAW welder.


Welding Assignment Rubrics

37

The rubrics below will be used for the sheet metal welding assignments. The handout has two rubrics for grading both the Oxygen/Fuel and the SMAW assignments.

Oxygen/Fuel Welding Joint AssignmentUniformity of beads

max 40 points

Penetration of weld

max 40 points

Overall appearance

max 15 points

Weld splatter max 5 points

Grade:


SMAW Welding Joint AssignmentUniformity of beads

max 40 points

Penetration of weld

max 40 points

Overall appearance max 15 points

Weld splatter max 5 points

Grade:

Machining Assignments

• Use one of the drawings in this lesson and turn a punch or a hammer.


Machining: Punch Rubrics

39

Center Punch Measurement Section Points

Total length

End taper

Taper length

Finish

Grade

Lath Project: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance the section receives 10 points. If the section is not within tolerance the points can be from 0 to 10. Add the points for a grade.


Drive Punch

Total length

End taper

¼” dia. end

Finish

Grade

Machining: Hammer Rubrics

40

Lath Project: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance the section receives 10 points. If the section is not within tolerance the points can be from 0 to 10. Add the points for a grade.


Hammer

Measurement Section Points Measurement Section Points

Handle length Head length

Handle taper Head taper

Handle thread Assemble

Shaft length Finish

Shaft threads Grade

Shaft threads

Resources

American Welding Society • http://www.aws.orgFabricators and Manufacturers Association• http://fmanet.org/Occupational Safety & Health Administration• http://www.osha.gov/


http://www.aws.org/technical/errata/A2.4errata.pdf

http://www.aws.org/

http://www.aws.org/

http://fmanet.org/

http://www.osha.gov/

1 flexible manufacturing manufacturing teams copyright © texas education agency, 2012. all rights...

Documents