DEDAN KIMATHI UNIVERSITY

OF TECHNOLOGY

University Examinations 2015

FIFTH YEAR SECOND SEMESTER EXAMINATION FOR THE DEGREE OF BACHELOR OF

SCIENCE IN MECHATRONIC ENGINEERING

EMT 2512: MANUFACTURING PROCESS PLANNING

DATE:

INSTRUCTIONS

1. This paper contains FIVE (5) questions.

2. Question ONE is compulsory.
3. Answer Question ONE and attempt ONE question from SECTION A and ONE question from
SECTION B
4. Question ONE carries 30 marks, the rest carry 20 marks each.

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QUESTION 1: [30 Marks]

A) In order to be effective in the role of a process planner, the manufacturing engineer must possess
a variety of skills and knowledge. In few words, discuss the main eight (8) activities undertaken
during process planning. [16 Marks]

B) For Just-In-Time (JIT) manufacturing philosophy/method, discuss four (4) different points of
view about the elements that led the approach to productivity. [4 Marks]

C) Machining processes involve the removal of material from the workpiece and there is a variety of
processes that fall into this category. These can be broken down further into two broad sub-
categories; Traditional and Non-traditional machining processes. With the well labelled sketches,
discuss the working principle of the following non-traditional machining processes: [10 Marks]

(i) Chemical milling

(ii) Electrochemical machining (ECM)
(iii) Electrical-discharge machining (EDM)

SECTION A

QUESTION 2: [20 Marks]

A) For the component shown below, determine what tooling would be required to turn it. The brass
billet is represented by the rectangle that is 100XΦ20 mm. Therefore, the material to be removed
is the shaded area in both Fig.3.Question 4A and Fig.4.Question 4A. The part is to be turned on
a small bench lathe. To produce this part four distinct operations have been identified as detailed
below. Identify the tooling required to produce this part. [12 Marks]

Fig.3.Question 4A Facing and roughing out of the part

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 Fig.4.Question 4A Finishing and parting off the part

B) If we can agree that in manufacturing system, two organizations cannot implement the same
manufacturing strategies in the same way. Discuss the following key activities: [4 Marks]

(i) Assemble the project team and leader

(ii) Define system scope and implementation phases

QUESTION 3: [20 Marks]

A) Different approaches have been proposed to cope with different forms of uncertainty.
Differentiate between the following manufacturing process models: [8
Marks]
(i) Conceptual models and Analytical models
(ii) Artificial intelligence models and Simulation models

B) Consider a low alloy steel bar (Specific cutting force ranging between 2500–3300N/mm2) is
being roughed to size on a lathe. The depth of cut is 5mm and the width of the cut is 1mm. The
cutting speed for the roughing is 10m/min (Fig.1.Question 1C), Calculate: [8 Marks]
(i) The cutting forces should be carried out for the operation
(ii) The minimum machine power required

Fig.1.Question 1C Low alloy steel bar

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 C) The simplest and clearest way of relating cost, volume and profit is through the use of a break-
even chart. Interpret the typical break-even chart shown in Fig.2.Question 1D. [4 Marks]

Fig.2.Question 1D Break-even chart

SECTION B

QUESTION 4: [20 Marks]

A) Every company typically has business “pains” that call for a manufacturing system antidote, such
as an inability to expand operations, an inoperable system, or an eroding customer relationship
etc. With aid of examples (Case-study), discuss the following business pains: [6 Marks]

(i) Multiple drivers of change

(ii) Individual needs to collective requirements
(iii) Partner perspectives

B) In repetitive manufacturing, explain the reason why the Just-In-Time (JIT) and Manufacturing
Resource Planning (MRP II) should always be implemented together, and never alone. [8 Marks]

C) A manufacturing process is usually carried out as a unit operation, which means that it is a single
step in the sequence of steps required to transform the starting material into a final product. With
the aid of well labelled diagram explain the types of manufacturing operations. [6 Marks]

QUESTION 5: [20 Marks]

A) The inspection method employed will be heavily influenced by the inspection location. With the
aid of well labelled diagram differentiate between hundred per cent (100%) inspection and
sampling inspection [8 Marks]

B) The material itself will limit the manufacturing processes that can be used, as not all materials are
suitable for all processes. With the aid of well labelled diagram discuss the criteria can be used in
the selection of manufacturing processes [12 Marks]

Good Luck!!!
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