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IENG 475 - Lecture 01

Introduction to Computer-Controlled Manufacturing

Systems

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IENG 475 Instructor:

• D. H. Jensen• 308 Industrial Engineering & Research Bldg• (605) 394-1278• Dean.Jensen@sdsmt.edu

• Office Hours:• M: 1:00 – 1:50 PM• W: 1:00 – 1:50 PM and 4:30 – 5:30 PM

• Class Meetings:• Mon, Wed, but NOT Fri: 2:00 PM – 2:50 PM, 205 IER

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IENG 475 Labs:

• Manufacturing Inductive Learning Lab (MIL Lab)• Rm 310 Industrial Engineering & Research Bldg• As Arranged: 4 person Lab Teams

• Tuesday:

• 1:00 – 2:20• 2:30 – 3:50• 4:00 – 5:20

• Thursday:

• 1:00 – 2:20• 2:30 – 3:50• 4:00 – 5:20**

** last choice!

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Course Overview See Schedule Page for Details:

• Basic manufacturing problem solving tools including PC&C, process planning, and CNC programming are covered on Exam I.

• Sensors, control logic and PLC programming, robotics/automation principles and ethics are covered on Exam II.

• Project covers automated material handling and computer-integrated control in addition to demonstrating abilities of the TEAM.

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Materials Textbook: NOT REQUIRED

• Groover, M. P. (2008). Automation, Production Systems, and Computer-Integrated Manufacturing (3rd ed.). Upper Saddle River NJ: Prentice-Hall. 856pp. ISBN 0-13-239321-2

Engineering Notebook TWO REQUIRED• 9-3/4" x 7-1/2", 5x5 quad-ruled, 80-100 pp. (approx.).

Engineering Problems Paper REQUIRED• 8-1/2" x 11", three hole drilled, ruled five squares/division,

50 pp. (approx.).

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Engineering Notebook Anything you can copy, cut, staple, paste, glue, or

otherwise persuade to live permanently within the covers of your engineering notebook may be used on the exams …

… EXCEPT old exams and other’s notebook pages.

One notebook for class/exams One notebook for lab/project

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Recommended Materials Engineering/Scientific calculator

Mechanical Pencil• 0.5 mm, HB or B lead with comfortable grip

Plastic-based Eraser • clickable pen-style suggested

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Expectations Grading Scale:

A 90% B 80% C 70% D 60%F < 60%

Weighting: Homework 20% Project 30% Midterm Exam I 25%

Midterm Exam II 25%

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Expectations Assignments & Project Components:

• Each question / project component is graded on a 10 point basis. Each assignment is equally weighted.

Exams:• Exams are open Engineering notebook; and closed

textbook and homework. • Necessary tables are identified/provided – store in your

engineering notebook.

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Expectations Due Dates / Late Work:

• Assignments and project work are due at the start of class on the due date (see Schedule page).

• Unapproved late assignments turned in more than one class period after the due date will not be graded and will not receive any credit. Unapproved late assignments turned in before the next class period will be held until the end of the term.

• If the student’s grade is borderline, then the held assignment will be graded and assessed 50% of the earned credit.

• Borderline is defined as within 1.5% of the next highest grade without considering the late assignment

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Expectations Make-up Work:

• Make-Up work is the student’s responsibility, and is arranged at the lecturer’s discretion.

• Policies:• Foreseeable Circumstances - contact the lecturer as far

in advance as possible (e-mail).

• Unforeseeable Circumstances - contact the lecturer as soon as practical (leave phone message).

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Expectations Academic Honesty:

• OK to work together on HW and Labs for this class:• as long as what appears on your sheet is your work,

your words, and your writing

• OK to copy my materials for this class:• download and print slides to your engineering notebook

for this class• download and use my spreadsheet templates for your

assignments and practice in this course

• Exams are always individual work

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Questions & Issues Students with special needs or requiring

special accommodations should contact the instructor, Dr. Jensen, at 394-1278 and/or the campus ADA coordinator, Jolie McCoy, at 394-1924 at the earliest opportunity.

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Data Collection

Name IENG 475Preferred name SPR 2014E-mail addressStudent ID # Your major

Hometown

Anything else the instructor should know about you

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COURSE ORGANIZATON ISSUES Schedule Needed for Lab Times:

(Back of Card)1st Choice Lab Time2nd Choice Lab Time3rd Choice Lab Time4th Choice Lab TimeList any lab times with a class conflict*

Preferred Lab Partners (2 choices)

Non-Preferred Lab Partner (if any)

Lab Times:

Tuesday 1:00 - 2:20 2:30 - 3:50 4:00 - 5:20

Thursday 1:00 - 2:20 2:30 - 3:50 4:00 - 5:20

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Lab Schedule Lab team/time assigned, e-mailed by 10:00 PM tonight Review Lab assignment off of Materials Page Meet in MIL Lab (need to start/stop labs on time)

• Take notes during lab in Lab Engineering Notebook (everyone)• Lab assignments (1 per team) – usually due next lab

• brief summary and documentation of design/exercise• short answer to questions (if any)• EP pages from everyone

• 5S at end of each lab Primary result of lab exercises is to complete project

• Open Lab times as necessary• Open class and lab periods reserved at end of term• Use Finals Week for project documentation & demo

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Manufacturing Operations What competitive trends exist?

• Where are products being made?• What kind of products are being made at these locations?• How are products being made at these locations?

What is the basis for manufacturing competitiveness? • Competitive Advantage(s):

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Levels of Automation1. Manual Production – using single station manned

cells operating independently

2. Automated Production – using single station automated cells operating independently

3. Automated, Integrated Production – using multi-station automated systems with automated material handling

The appropriate level of automation is situational – there is no universal best answer!

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Manufacturing Operations Mfg Plant Limitations & Capabilities:

• Technological Processing Capabilities• Physical Production Capabilities• Production Capacity Limits

Conditions for Appropriate Automation:• Predictable, stable / expanding market• Need to satisfy business objectives of firm• Technology must be available at the right:

• Performance• Cost• Maturity

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Reasons for Automating Increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or eliminate routine manual tasks To improve worker safety To accomplish processes that cannot be done

manually To improve product quality To reduce manufacturing lead time To avoid the high cost of not automating

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Reasons NOT to Automate Task is too technologically difficult to automate Product life cycle is too short Product is too customized Product demand is too variable To reduce the risk ($) of product failure

To deal with these aspects, use the USA Principle:• Understand• Simplify• Automate