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COMPUTER AIDED DESIGN AND MANUFACTURING I

INTRODUCTION 
The technology that has the greatest impact on the production system over the last decades is
computer technology. For any meaningful technological, or industrial design, or manufacturing
breakthrough in developing countries like Nigeria, it is time to abandon the old traditional ways
of manual preparation in favour of more consistent and faster tool as Computer-Aided
Design/Drafting/Manufacturing/Process Planning/Computer Aided Engineering
(CAD/CADD/CAM/CAPP/CAE), so that fast accurate data drawings and manufactured products
can be correctly obtained in good time.
The basic concepts, challenges and motivation of Computer-Aided Engineering (CAE) in
developing countries like Nigerian is looked at in this paper using twenty six (26) Industries
scattered in the Southern part of Nigeria.
National and International competition in manufacturing is causing industrial leaders to look at
new strategies for remaining competitive and improving quality in their products.
Developments in the computer industry are having profound impact on the manufacturing
industries from design to machine processing as well as the management and marketing
components.
Governments of all industrialized countries place great emphasis on the development of their
manufacturing sectors. It is great importance, not only as a means of supporting sustainable
growth, but also because of the nature of the technological developments that have taken
place particularly over the last decade. Industrialization has a particular significant role to play
in the amelioration of power and unemployment. Acceleration of industrial development of any
nation depends on maximum utilization of Industrial Automation and Computer Aided
Engineering (CAE). Therefore, the Nigerian Industries will have to imbibe the Computer Aided
Engineering and its entire facet for improved productivity and rapid product development
The trend in manufacturing call for the development of the following modern day
manufacturing systems. There are:
- Global competition in the manufacturing market;
- Customers now demanded high-quality goods, with low production cost and timely
delivery of manufacturing products.
- Increase in the variety of products produced, thereby choosing the product life
cycles to be shorter.
Therefore, the modern day technology that manufacturing systems make use of are discussed
in this write up..
Manufacturing system entails a large number of interdependent activities consisting of distinct
entities such as materials, tools, machine, power, and human beings. It is a complex system
because it is comprised of many diverse physical and, human elements. The choice are manyso the manufacturing engineers should be able to select correct which one to choose, that will
profit the whole manufacturing system.

 BASIC CONCEPTS 
Computers are widely used throughout manufacturing industry. Hence in this paper
introduction is made to all the relevant basic concepts of the computer applications to
COMPUTER
Computer is a machine that handles information with amazing speed. It works with such
information as names and address hook titles, lists of item sold in stores, mathematical
problems and weather forecasts. It handles information in the form of numbers. It solves
problems dealing numbers. The fattest computers can do millions of problems in a few seconds
(4,5,6).
A computer by definition simply adds, subtracts, compares and store data. Computers are
universally recognized as the most powerful and effective tool for improving productivity in
industry, which is the single, most important concern of every manufacturing manager.
Computers excel in three areas of manufacture namely:
- Collecting information:
- Reaching a decision; and
- Issuing and order. 

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Computer Aided Quality Control or CAQC

What is Computer Aided Quality Control or CAQC?

The use of the computers for quality control of the product is called as the computer aided quality control or CAQC. The two major parts of quality control are inspection and testing, which are traditionally performed manually with the help of gages, measuring devices and the testing apparatus. The two major parts of computer aided quality control are computer aided inspection (CAI) and computer aided testing (CAT). CAI and CAT are performed by using the latest computer automation and sensor technology. CAI and CAT are the standalone systems and without them the full potential of CAQC cannot be achieved.

The main objectives of the CAQC are to improve the quality of the product, increase the productivity in the inspection process and reduce the lead times in manufacturing. The implementation of CAQC in the company results in the major change in the way the process of quality control is carried out in the company.

Important Points and Advantages of Computer Aided Quality Control or CAQC

Here are the advantages and the highlights of the computer aided quality control process:

1) 100% testing and inspection: In the traditional manual process the testing and inspection is done by the sampling process out of the hundreds and thousands of products or parts manufactured by the company since it is not feasible to check each and every product. With CAI and CAT hundred percent inspection and testing can be accomplished without much difficulty. With 100% inspection the company does not have to depend on statistical quality control method in which it is assumed that anything less than 100% of quality is acceptable. With computer controlled inspection, it is not necessary for the quality control department to settle for less than perfection.

2) Inspection integrated with manufacturing process: In the traditional process there is separate quality control department where the manufactured product is taken for the inspection and testing. In CAQC the inspection process is integrated with the manufacturing process and it is located along the production line. Thus as soon as the product is manufactured it is tested immediately by the computerized process without moving it to some other location. This helps in reducing the overall time required for manufacturing the product.

3) Use of non-contact sensors: In the traditional process the product or the part to be inspected is handled manually since it has to be positioned properly for inspection on the desk or suitable location. In CAQC non-contact sensors are used for the inspection purpose and they inspect the product without coming in contact with the product. The non-contact sensors operated by the computer are kept along the production line and they can check the product very quickly in the fraction of seconds. In future with further advancements in the technology, the robots would be used to carry-out the inspection process thus further automating and speeding the process.

4) Computerized feedback control system: The data collected by the non-contact sensors is sent as the feedback to the computerized control systems. These systems would carry out the analysis of the data including statistical trend analysis. This helps in identifying the problem going on in the manufacturing line and find appropriate solution to it. For instance, the results from non-contact sensors may indicate that the parts manufactured are not within the acceptable tolerance limits. This would help the production or quality control personnel to find out the precise location of the problem and its exact cause. The corrective action taken quickly saves lots of time and money due to reduced wastages and also improves the quality of the product.

5) Computer aided quality control and CAD/CAM integration: Apart from inspection and testing, computers are used in a number of other areas of the quality control. All the applications of CAQC can be integrated with CAD/CAM to make the whole process of designing and manufacturing controlled by the computers converted into fully automated process.

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MANUFACTURING TECHNOLOGY GATE MATERIAL

MANUFACTURING TECHNOLOGY GATE MATERIAL

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MATERIAL SCIENCE LECTURE

Inroduction to Engineering materials from Aravind Balaji

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IES PREVIOUS YEAR QUESTION PAPER

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mechanical objective paper2

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FULL FORMS

Full FormsA.M. — Ante meridian
P.M. — Post meridian
B. A. — Bachelor of Arts
M. A. — Master of Arts
 B. Sc. — Bachelor of Science
M. Sc. — Master of Science
B. Sc. Ag. — Bachelor of Science in Agriculture
M. Sc. Ag. — Master of Science in Agriculture
 M. B. B. S. — Bachelor of Medicine and Bachelor of Surgery
 M. D. — Doctor of Medicine
M. S. — Master of Surgery
Ph. D. / D. Phil. — Doctor of Philosophy (Arts & Science)
D. Litt./Lit. — Doctor of Literature / Doctor of Letters
D. Sc. — Doctor of Science
B. Com. — Bachelor of Commerce
M. Com. — Master of Commerce
Dr. — Doctor
B. P. — Blood Pressure
Mr. — Mister
Mrs. — Mistress
M.S. — miss (used for female married & unmarried)
 Miss — used before unmarried girls)
M. P. — Member of Parliament
M. L. A. — Member of Legislative Assembly
M. L. C. — Member of Legislative Council
 P. M. — Prime Minister
C. M. — Chief Minister
 C-in-C — Commander-In-Chief
L. D. C. — Lower Division Clerk
U. D. C. — Upper Division Clerk
 Lt. Gov. — Lieutenant Governor
D. M. — District Magistrate
V. I. P. — Very Important Person
I. T. O. — Income Tax Officer
C. I. D. — Criminal Investigation Department
 C/o — Care of
S/o — Son of
C. B. I. — Central Bureau of Investigation
G. P. O. — General Post Office
H. Q. — Head Quarters
E. O. E. — Errors and Omissions Excepted
Kg. — Kilogram
Kw. — Kilowatts
 Gm. — Gram
Km. — Kilometer
Ltd. — Limited
M. P. H. — Miles Per Hour
 KM. P. H. — Kilometre Per Hour
 P. T. O. — Please Turn Over
P. W. D. — Public Works Department
C. P. W. D. — Central Public Works Department
 U. S. A. — United States of America
U. K. — United Kingdom (England)
 U. P. — Uttar Pradesh
 M. P. — Madhya Pradesh
 H. P. — Himachal Pradesh
U. N. O. — United Nations Organization
 W. H. O. — World Health Organization
B. B. C. — British Broadcasting Corporation
B. C. — Before Christ
A. C. — Air Conditioned
 I. G. — Inspector General (of Police)  D. I. G. — Deputy Inspector General (of Police)  S. S. P. — Senior Superintendent of Police  D. S. P. — Deputy Superintendent of Police  S. D. M. — Sub-Divisional Magistrate  S. M. — Station Master  A. S. M. — Assistant Station Master  V. C. — Vice-Chancellor  A. G. — Accountant General  C. R. — Confidential Report  I. A. S. — Indian Administrative Service  I. P. S. — Indian Police Service  I. F. S. — Indian Foreign Service or Indian Forest Service  I. R. S. — Indian Revenue Service  P. C. S. — Provincial Civil Service  M. E. S. — Military Engineering Service  Full Form Of Some technical Words VIRUS - Vital Information Resource UnderSeized. 3G -3rd Generation. GSM - Global System for Mobile Communication. CDMA - Code Divison Multiple Access. UMTS - Universal MobileTelecommunication System. SIM - Subscriber Identity Module . AVI = Audio Video Interleave RTS = Real Time Streaming SIS = Symbian OS Installer File AMR = Adaptive Multi-Rate Codec JAD = Java Application Descriptor JAR = Java Archive JAD = Java Application Descriptor 3GPP = 3rd Generation Partnership Project 3GP = 3rd Generation Project MP3 = MPEG player lll MP4 = MPEG-4 video file AAC = Advanced Audio Coding GIF= Graphic InterchangeableFormat JPEG = Joint Photographic Expert Group JPEG = Joint Photographic Expert Group BMP = Bitmap SWF = Shock Wave Flash WMV = Windows Media Video WMA = Windows Media Audio WAV = Waveform Audio PNG = Portable Network Graphics DOC =Document (MicrosoftCorporation) PDF = Portable Document Format M3G = Mobile 3D Graphics M4A = MPEG-4 Audio File NTH = Nokia Theme (series 40) THM = Themes (Sony Ericsson) MMF = Synthetic Music Mobile Application File NRT = Nokia Ringtone XMF = Extensible Music File WBMP = Wireless Bitmap Image DVX = DivX Video HTML = Hyper Text Markup Language WML = Wireless Markup Language CD -Compact Disk. DVD - Digital Versatile Disk. CRT - Cathode Ray Tube. DAT - Digital Audio Tape. DOS - Disk Operating System. GUI -Graphical User Interface. HTTP - Hyper Text Transfer Protocol. IP - Internet Protocol. ISP - Internet Service Provi

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Assembly-Line Balancing

Assembly-Line Balancing:   An effective  tool for improving Productivity

1. What is assembly-line balancing?

l  to a workstation within an assembly line in order to meet the required production rate and to achieve a minimum amount of idle time.

l  Line balancing is the procedure in which tasks along Assigning each task the assembly line are assigned to work station so each has approximately same amount of work.

2.  Unbalance Line and Its effect

l  High work load in some stages (Overburden)

l  Maximizes wastes (over-processing, inventory, waiting, rework, transportation, motion)

l  High variation in output

l  Restrict one piece flow

l  Maximizes Idle time

l  Poor efficiency

3.Balanced Line and its effect

l  Promotes one piece flow

l  Avoids excessive work load in some stages (overburden)

l  Minimizes wastes (over-processing, inventory, waiting, rework, transportation, motion)

l  Reduces variation

l  Increased Efficiency

l  Minimizes Idle time

4.  How Can Assembly-Line Balancing   Help Organization ?

l  Increased efficiency

l  Increased productivity

l  Potential increase in profits and decrease in costs

 5. Steps in Balancing an Assembly Line

1. List the sequential relationships among tasks and then draw a precedence diagram.
2. Calculate the required workstation cycle time.
3. Calculate the theoretical minimum number of workstations.
4. Choose a primary rule that will determine how tasks are to be assigned to workstations.
5.  Beginning with the first workstation, assign each task, one at a time, until the sum of the task times is equal to the workstation cycle time or until no other tasks can be assigned due to sequence or time restrictions.
6.  Repeat step 5 for the remaining workstations until all the tasks have been assigned to a workstation.
7. Evaluate the efficiency of the line balance.
8. Rebalance if necessary.

Example of Assembly-Line Balancing

Problem: The Model Z Bicycle is assembled in an assembly line. Four hundred and twenty  bicycles are required each day. Production time per day is 420 minutes.

            Find the balance that minimizes the number of workstations, that stays within the workstation cycle time limitation, and that complies with task precedent constraints. 

Example of Assembly-Line Balancing Cont.
1. Building the Model Z Bicycle: Assembly Steps and Times

Task	Task Time (in seconds)	Task Description	Tasks that must precede
A	50	Connect the front tire to the bicycle frame.	—
B	16	Insert the handle bar.	A
C	14	Tighten handle bar with two screws and nuts.	B
D	55	Connect the rear tire to the bicycle frame.	—
E	20	Position chain mechanism to the frame.	D
F	17	Attach right hand brake to handle bar.	C
G	17	Attach left hand brake to handle bar.	C
H	17	Attach right side pedal.	E
I	17	Attach left side pedal.	E
J	13	Position chain onto chain mechanism.	F,G,H,I
K	14	Attach seat post.	J
	250

STEP 1. List the sequential relationships among tasks and then draw a precedence diagram

STEP 2.  . Calculate the required workstation cycle time

Convert minutes to seconds because task times are in seconds.

CYCLE TIME  = (PRODUCTION TIME PER DAY) /(OUTPUT PER DAY)

                        = (60 sec. X  420 min.)  / ( 420 bicycles)  

                         = 25,200 / 420   =  60  sec.

STEP 3. Calculate the theoretical minimum number of workstations.

NUMBER OF WORK STATIONS  = ( SUM OF TOTAL TASK TIMES) / (CYCLE TIME)

=  250sec’s  /  60 sec’s

                                                        =   3.97  = 4  (rounded)

Task	Number of Following Tasks
A	6
B or D	5
C or E	4
F, G, H, or I	2
J	1
K	0

STEP 4.Choose a primary rule that will determine how tasks are to be assigned to workstations

l  For this example, our primary rule is to prioritize tasks based on the largest number of following tasks.

l  If there is a tie, our secondary rule is to prioritize tasks in the order of the longest task time.

l  In general, select rules that prioritize tasks according to the largest number of followers or based on length of time.

STEP 5. Beginning with the first workstation, assign each  task, one at a time, until the sum of the task times is equal to the workstation   cycle time or until no other tasks can be assigned due to sequence or time restrictions.

STEP 6. Repeat step 5 for the remaining workstations until all the tasks have been assigned to a workstation

STEP 7.Evaluate the efficiency of the line balance.

EFFICIENCY   =   (SUM OF ALL TASK TIMES))/(ACTUAL NO OF WORKSTATIONS)X(CYCLE TIME)

=  (250)  / (5) X (60)  

=  0.83  OR  83 %

STEPS  5& 6. Balance made according to the Largest-Number-of-Following Tasks Rule

Stations	Task	Task Time (in seconds)	Number of Following Tasks	Remaining Unassigned Time	Feasible Remaining Tasks	Task with Most Followers	Task with Longest Operating Time
Station 1	A	50	6	10 idle	None
Station 2	D	55	5	5 idle	None
Station 3	B E C	16 20 14	5 4 4	44 24 10 idle	C, E C, F,G, H, I,J None	C, E C	E
Station 4	F G H	17 17 17	2 2 2	43 26 9 idle	G, H, I H, I, J None	G, H, I H, I	G, H, or I H or I
Station 5	I J K	17 13 14	2 1 0	43 30 16 idle	J K None

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