GROUP 7

ADVANCED MANUFACTURING SYSTEM

TASK 2 PRESENTATION

Abdul Rahman B Mohd sapawi

Ryan Raymond
Faffa Zamizza Bt Zamri
Mohammad Shukery B Yusof

PART A: Manufacturing of Ultra-Precise Metal

Mould
Problem
Our company has just been awarded a contract to
manufacture ultra-precise metal moulds but we have no
experience in producing it.
Solution
-Propose a new process flow
-Propose a new plant layout
-Propose a new quality control system
-Propose a new tool condition monitoring technique

Process Flow

1. Customer Order
- The mould will be made according to specifications provided by
the customer.
2. Design
- Group of design experts will develop the design of the mould.
- The design will be analyze and go through all the checklist
parameter.

3. Raw Material
- Choose a material that allow us to get the job done quickly and
efficiently as possible
- Characteristics that need to be consider = hardness,
machinability,
resistance to
corrosion
4. Manufacturing Process
Vertical CNC Milling
Machine
- To turn the
material into
desired
dimension

5-Axis CNC Milling Machine

- To make the mould
component shape
(cavity, holes,pins)
CNC Surface
Grinder
- To produce a
smooth finish

5. Inspection
- To make sure the mould meet the quality requirements (the
method will be further explain in the next section)
6. Storage
- To store the finished product
- Use Automated Storage/Retrieval Systems
7. Delivery
- The completed metal mould will be deliver to the customer

Inspection

Automated Vision Inspection

Flexible, Convertibility, Low cost
Operate similar as human vision

Position of Inspection
Input Material Inspection
To prevent any defective input material to go through
the machining process.
Finished Product Inspection
To prevent any defective product to be package and
deliver to costumer.

Method of Automated Machine Vision Inspection

System
First Step: Acquisition of mold image
Second Step: Image Processing
Third Step: Decision-making process
Output of system
Pass: Object go through the next process
Fail: Object rejected and go to rejected product
section

Quality Control Systems

Online Inspection & Monitoring
Real time process (online) mode to prevent and
increase quality of production during the
process.
Offline Inspection& Monitoring
Collected data used to perform statistical
analysis(Taguchi Method) to enhance the
productivity.

Taguchi Method
Specific Loss Function
- To reduce the variance of production. Supply
specific target for production to reduce any
losses.

Taguchi Method
Offline Quality Control
- Eliminate variation in production during the mold
designing process.
- Specific parameter of mold design to minimize
variance during removal process.
Design of Experiment
- Designing an experiment theories that aimed to
allow greater understanding of variations of the
product.

Tool Condition Monitoring

Sensor-less condition monitoring
- Monitored machine tools utilizing the existing
sensors and signals in the machine tool.
Advantages
- Additional complexity is kept to minimum
- Reducing the cost of condition monitoring
system

Internal Drive Signals

Using non-intrusive Hall Effect sensors to
measure the internal drive signals (spindle
motor and feed drive current) to indirectly
measuring the cutting force.
Using spindle power consumption signal and
feed drive current signals to estimate tool
wear in high speed milling.

Online and Offline Monitoring

Plant Layout
-Company annual production = 8000-10 000 units of metal
mould (medium production)

Cellular Manufacturing
Each cell is specialize in production of a given similar parts.
Cellular manufacturing is an application of group technology.
Similar parts are identified and group together to take advantage of their
similarities
Processing steps for each group will be the same

Flexible Manufacturing System (FMS)

Decentralized Automation

Conclusion
All of the recommendations in this proposal are very useful in order for us to start
producing ultra-precise metal mould.
Automation system should be implemented to get a product with high quality.
Our product will be much more competitive in the market and we will be able to
become one of the most highly in demand manufacturer of our very own products.

Advanced Manufacturing System

Task 2 part B

Obsolete and New Product

Obsolete and New Product

Available in 3 size only

8-, 5 - and 3 -inch
Consist of flat, circular plates made of metal or plastic and coated with iron oxide.
Information are magnetically imprinted on the coating
Capacity:
High Density: 1.44 MB
Superdisk: 240 MB

Small-size, light weight, hot-swappable and rewritable.

Consist of flash memory and USB
Transfer rate of data: USB 1.1 (500Kbps-10Mbps), USB 2.0 (25Mbps -400Mbps)
and USB 3.0 (> 4.8Gbps)
Information are store in the flash memory.
Capacity:
from 32MB to 64GB

The manufacturing Process

Automated: Disk,
Semi-auto: Jacket, Case
Manual: Assembly

All process in one plant.

The manufacturing Process

(Lexar)
Almost all process are automated except the assembly of the parts.

Memory Chips produce in USA (Micron Tech. Company)

Assembly plant in Asia.

Reason for changes

USB

flash drives has a higher storage capacity.

Most of the latest computer does not support floppy disk.
The rise of file sharing and media file which encouraged
the use of files that more than floppy disk can support.
USB flash drives has a much faster transfer rates.
USB flash drives has a more attractive design.