FT 2010

EMM516

M.S RAMAIAH SCHOOL OF ADVANCED STUDIES

POSTGRADUATE ENGINEERING AND MANAGEMENT PROGRAMME (PEMP)

Department: Mechanical and Manufacturing Engineering Course: MSc [Engineering] Engineering and Manufacturing Management Module Code: EMM516 Module Title: Automation in Manufacturing and System Simulation Module Leader: Prof. Ramdas Chandrashekar Assignment
INSTRUCTIONS TO CANDIDATES: 1. 2. 3. 4. 5. 6. 7. 8. 9. This assignment has 3 parts Part A, B and C Part A (30 marks), Part B (30 marks), Part C (40 marks) Assignment has to be word processed as per prescribed format Maximum length of the report (30 A4 Pages) Last date of submission 26th August 2011 ARENA simulation software should be used for relevant parts of assignment All the units of measurement wherever applicable should be SI Units only Method of evaluation will be based on your knowledge comprehension and presentation Group work is not permitted and it is expected that your solutions will exhibit original content.

10. At the end you are required to comment on a. Benefits you have derived by solving this assignment b. Whether assignment was able to assess module learning outcomes or not?

< August 2011>

Form 43

Ver: 1

Date: 01-11-2007

Page 1 of 4

FT 2010

EMM516

Introduction: In todays context, Automation in Manufacturing and System Simulation deals with the automation of machinery, processes, production lines, etc.; thereby enabling their efficient performance. This efficient performance is needed for enabling speed, accuracy and repeatability of operations of the equipment. The assignment (in 3-parts) is aimed at evaluating the understanding and application of automation techniques for manufacturing systems and analysis of their effectiveness through discrete event simulation. This assignment is designed to link the various facets of operations of work-piece handling, assembly systems and manufacturing processes, against the backdrop of associated automation components, product and sub-systems; as well as analytical techniques like simulation. Part A of the assignment is a debate on strategies of automation vendors with respect to the kind of manufacturing industries being serviced by them. Part B is an analysis of an application of automation in a manufacturing process and Part C is implementing a simulation model for an application, followed by an interpretation and analysis exercise. Part-A Problem statement In todays context of Industrial automation, control systems are used in Continuous Process industries as well as in Discrete Manufacturing industries. One of the trends seen in the industry is the advent of the Programmable Automation Controller (PAC). This product line has a broad application level context. Present a debate on the following statement Distributed Control System (DCS) and Programmable Logic Control (PLC) systems can be replaced with a PAC; thereby satisfying the requirements of both process industries and discrete manufacturing industries. Present your argument based on the following points: 1) Introduction to the debate and explicit statement of stance, 2) Requirements of continuous process applications, 3) Requirements of discrete manufacturing applications, and 4) Technical capability of the PAC to meet the requirements for both classes of applications (30 marks)

Part-B Problem statement Select any one discrete manufacturing assembly inspection application based on literature survey of Emerald Insight magazines like Assembly Automation, other magazines like Control engineering, web-sites of vendors, etc. in consultation with module leader. 1) Present an analysis with respect to the system requirements. (8 marks) 2) Identify automation components and give a brief note on the contribution of each component to the solution. (7 marks)

Form 43

Ver: 1

Date: 01-11-2007

Page 2 of 4

FT 2010

EMM516

3) Describe how the ARENA modeling environment could be used to model the selected application. (7 marks) 4) Write a note on methods of improvement in the automation system for the selected application. You may consider that throughput has to be improved while preparing your note. (8 marks) Part C Background After a monthly meeting the management decides to initiate a project that brings down the cost of the product made in a production line having five machines. The rework is one of the major reasons for high manufacturing cost. Now they would like to give an optimal rework target in terms of probabilities to each machine in the line to reduce manufacturing cost. About the line The line is having 5 machines arranged in series, parts inter-arrival times are UNIF (13, 15) minutes .The unique aspect of this line is that parts can be routed back to preceding workstation for rework. The probability of revisiting a workstation is independent in that the same part could be sent back many times with and we will assume that all transfer times are negligible. The existing rework probability is P1 (5), P2 (6), P3 (7), P4 (8) in percentages. The processing times at each workstation are obtained from a data collection activity previously done and cost for busy hour for all machines will be given to each delegate. Construct an executable Arena simulation model and run 6 runs of 10000 minutes for all the possibilities given in the table below. The model should also consider that the rework transfer will happen through a material handling conveyor/transporter with assumption of suitable times. Comment on manufacturing cost and cycle time .Recommend a target rework probabilities to engineering team that results in reduced manufacturing cost. MACHINE NUMBER M2 REWORK PROBABILITY
P1 P2 P1 P1 P1

M3
P2 P1 P3 P2 P2

M4
P3 P3 P2 P4 P3

M5
P4 P4 P4 P3 P5

Manufacturing Cycle Cost time

Guidelines for Submission In Part A, you will have to take a stance and debate descriptively, justifying your stance with appropriate arguments. Limit your argument to 3 pages. Your debate will be judged on the following points: 1) Brevity (not exceeding four pages) 2) Introduction and Clarity of stance 3) Argument synopsis (including points 2, 3, 4 of debate points mentioned in Part A problem description) 4) Debate 5) Concluding remarks to rest your case

Form 43

Ver: 1

Date: 01-11-2007

Page 3 of 4

FT 2010

EMM516

In Part B, the question has been framed in an open-ended manner. This has been deliberately done so that you are able to show-case application of thought and usage of a good methodology in your work. Please state all the assumptions that you make clearly. (The section of assignment report that you will prepare for part B could be around 15-18 pages). In Part C: This part of the assignment framed so that you can explore the features and capabilities of Arena simulation tool and analyze results. A block diagram of the proposed system is required. An executable Arena simulation model has to be submitted. Processing times are to be derived by using Arena Input analyzer .After running simulation for given possibilities the resultant manufacturing cost must be recorded .Your conclusions and recommendations for part C may be unique depending on the individual data file that is given to you. Attach the resultant table.* All time units are in minutes It is essential that all the sources used in preparation of the assignment be suitably referenced in the report. Marking Scheme
S.N. Assignment Question Max marks/ Question 3 5 8 9 5 8 7

Part A

a) Conciseness (not exceeding four pages) b) Introduction and Clarity of stance c) Argument synopsis (including points 2, 3, 4, of debate points mentioned in Part A description) d) Debate e) Concluding remarks to rest your case a) Presentation of analysis with respect to the system requirements b) Identification of automation components and documenting a brief note on the contribution of each component to the solution c) Describing a plausible ARENA model for the selected application d) Note on methods of improvement in the automation system for the selected application
a) Block diagram of the proposed system b) Selection of processing times using input analyzer c) Executable Arena Model : Snap Shot d) Manufacturing Cost and cycle time for all possibilities given in the table (Attach resultant table ) Comments on the results e) Formatting + Feedback on learning outcomes TOTAL

Part B

7 8 02 05 15 05 03 5+5 100

Part C

Form 43

Ver: 1

Date: 01-11-2007

Page 4 of 4