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INDIAN INSTITUTE OF TECHNOLOGY, BOMBAY Department of Mechanical Engineering
Course : ME-714Computer-Integrated Manufacturing Instructor : K.P. Karunakaran Date : January25, 2010 (Monday) 9:30PM
L-T-P-C : 3-0-0-6 II Semester 2009-10
Duration : 1 hr. Instructions:
Answer all the questions; answer as briefly as possible.
Roll No
Marks /??
TEST - 1 (Chapter 1: Introduction)
Part A
(1 mark each) 1. List the three fundamental requirements for implementing CIM.
1. Computer control of all functions 2. Networking of all these computer systems
3. Communication protocols and secure access control
2. Automotive components are mostly castings and forgings whereas aerospace uses mostly machined components. Do you agree or disagree? Justify your answer.
Automotive is cost-sensitive whereas aerospace is weight-sensitive. As castings and forgings can simultaneously realize several features, they are cheaper than machined parts.
3. Which is the most accurate casting method? Why?
4. Sort the following processes in the decreasing order of specific energy:
[i] sheet metal forming [ii] forging [iii] machining [iv] casting
5. Which of the following processes are suitable for objects with undercuts and deep features?
[i] 3-axis CNC machining [ii] forging [iii] casting [iv] RP
6. Which of the following processes are suitable for components/assemblies with high fatigue life?
[i] machining [ii] forging [iii] casting [iv] sheet metal forming
7. List the four significant applications of RP.
Conformal Cooling.
Components with Functionally Gradient Materials (FGMs)
Assemblies without joints
Shapes impossible or difficult by other processes.
8. Give an example for [i] fixed detachable assembly and [iii] movable permanent assembly.
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9. Distinguish between adjusted parts assembly and fitted parts
assembly.
Adjusted Parts Assembly Fitted Parts Assembly
Simple way of obtaining fine
fit.
Simple way of obtaining
tight fit.
The desired fit is achieved
during assembly using certain
adjustmentelements like, set
screws, washers, spacers,
wedges,shims, putty etc
The desired fit is achieved
during assembly by
adjusting one of the matching dimensions by
filing, cutting, chiseling,
scrapping, lapping etc
10. What category of assembly is usage of washers or shims?
Adjusted Parts Assembly
11. Distinguish between Product Design and Industrial Design.
12. Explain the significance of the figure in the context of product
design.
14. How is fixed-position layout different from job shop layout? Ans -
In fixed-position layout, the factory moves to the product’s place
15. List the contributions of F.W. Taylor
Part B (Weightage is given against each)
1. Define CIM comprehensively. Explain how it is different from CAD/CAM. [2]
1. CIM is the integration of the enterprise’s(imp plan’s) upstream, mainstream and downstream
activities of product development and life cycles into one self-regulating system with the help of connected computer systems and a common corporate data repository(a place where things
are stored and can be found ).
2. CIM is more often a strategy, direction, vision or a management(SDVM)philosophy.
3. CIM is a tool to achieve defined corporate goals or strategies. 4. CIM is a way of doing business that emphasizes(to show or state that something is very
important or worth giving attention to) an automated coordination of information and effort
throughout all the functional areas of a corporation. 5. CIM is the use of information technology to improve manufacturing.
6. CIM is rarely available as a product or system from a vendor. Each organization has to
build its own. At best, they may be able to hire consultants in selection and implementation.
2. Draw the block diagram of CIM that depicts all its building blocks. [2]
Any of the following will do.
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2. Discuss the positive and negative aspects of open sourcing.
Advantages: immense scope of improvement
It leads to better penetration of the biz in the market
Disadvantage: Security of the software is at question(hackers)
There’s no tab over how the software is used [2]
3. Define and distinguish between out-sourcing and in-sourcing. Use examples/ case studies to
explain.
Y2k vs UPS
out-sourcing in-sourcing
Getting things done where it is the best
and by whom does it the best. People retain
their core-competency with themselves and out-source all else as far as possible. This led
to lean and agile mfg’s
Complementing organizations working
together
It started with information processing. Thanks to Y2K problem which helped India
emerge as IT superpower. At that time, it
was “body-shopping”.
Logistic companies such as FedEx, UPS train their customers in packaging so as to
minimize transit damages. They tie up with
insurance companies and offer insurance
along with transport charges. UPS’s slogan is “Your world is synchronized”
India’s problems of huge population, lack of
a common Indian language and democracy turned into our advantage. Setting up of IITs,
NITs and thousands of Govt and
UPS even repairs of Toshiba computers and
returns to the customers
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pvt.Colleges enabled us to churn out good
quality engineers (10 lac/yr)
This was further enabled by connecting continents through fibre-optic cables. Speed
and bandwidth increased
The banks depute people to builders and automobile outlets
It is no longer body-shopping. It happens within the same country
All automotive companies working together on mutually beneficial projects like alternate
fuel systems etc
Now this has extended to product
development and manufacturing also
[4]
4. Define off-shoring and discuss its implications. Also explain how it is different from out-
sourcing.
Setting up factories abroad where it is cheaper to make. Another approach is to produce in
locations closer to the customer which is cheaper due to less transportation cost, tax benefits
and better service. Companies become global.
This is an offshoot(something which has developed from something larger which already
existed) of out-sourcing. The difference between out-sourcing and off-shoring is just the ownership
[4]
5. Give two examples for the primary industries, [two + two] examples for the secondary industries identifying them with its two types and two examples for tertiary industries. [3]
Primary Secondary Tertiary
Discrete Process
Agriculture Aerospace Paper Education
Fishing Automotive Cement Entertainment
6. What is selective assembly? When is it used? What are its limitations?
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tight tolerances that go beyond the process capability - More time spent on inspection
No interchangeability
Definition: Most practicable for extremely tight tolerances that go beyond the process capability. Produce both matching parts in large number. Measure each and fit. Eg.: Ball bearings, slip gauges Advantages: + Cheap to manufacture individual parts. Limitations: - More time spent on inspection - No interchangeability. Hence, both mating parts shall be replaced. - If the process of the individual components are not under control, one may land up accumulating more unused components. [3]
7. Reproduce the following table and fill in the empty cells. [2]
Type of Manufacture Type of Layout Type of Automation
Job shop production Job shop and Fixed position layout Fixed Automation
Batch production Process layout Flexible Automation
Mass production Flow & fixed layout Programmable Automation
8. What are the considerations in selecting a layout? Compare the three layouts based on these. [2]
Consideration –
The goal in layout is primarily minimization of material movement and WIP(work in progress). For
the same product, different layouts are feasible for different subassemblies and components
Job shop and Fixed position layout Process layout Flow & fixed layout
material movement &
WIP
?? High Low
9. Present the comparison of stationary manufacturing or quantity production and progressive
manufacturing or flow production. [2]
Stationary manufacturing or Quantity
production
Progressive manufacturing or flow production
All tools required come to the same place
and perform their task
Workstations are spread out and the raw material
of the part/ assembly-in-progress moves from one
station to the next till all operations are over
This is more suitable for discrete parts
manufacture wherein the volume keeps
reducing as the activities progress.
Limited to simple parts/assemblies only due to the limited number of
operations/tools
This is more suitable for assemblies since the
volume keeps increasing and becomes unwieldy as
the activities progress. Furthermore, the assembly
tools are large and varied in shape. Suitable for
complex
Eg.: Consider assembling a book from its pages available as bundles. Arrange the
bundles of the pages around you with a
table in the middle. Take one page after the
other and place on the middle table to assemble the book. Finally staple it
Eg.: Consider assembling a book from its pages available as bundles. Arrange the bundles of the
pages in line on a long table. Move from one end to
the other picking one page each and assemble the
book. Finally staple it
Eg.: CNC machining (tools stored in ATC
come to the blank one after the other to do
Eg.: Assembly of automotive engines or bodies.
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the job; PCB assembly
10. Any manufacturing process requires the continuous control of slide motions and the control of
switching functions such as spindle control, tool change, coolant control etc. Fill the 4 boxes in
the following table: [2]
Function
Element(s) used to control this
function in hard automation is
(are)
Element(s) or code(s) used to
control this function in soft automation is (are)
Slide motion
Switching functions
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