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Q1:Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the ‘Traditional approach’ is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation. See Answer
Q2:I hereby confirm that I have watched at least three videos for materials lab experiments as listed below. List at least three experiments that you have watched. For example, metal tensile testing experiment. 1- 2- 3- To pass the component complete this form and submit it to the Blackboard site. Links to videos https://www.youtube.com/watch?v=cDFwFEUR7rk&list=PLAzjGxrba https://www.youtube.com/watch?v=laZiK34RxLM&list=PLAzjGxrba Ob74Ze712THF 1iutlEjchH https://www.youtube.com/watch?v=9auMxrMYV8U&list=PLAzjGxrba OZ4 NLttfh2k86mSNNDvIxk https://www.youtube.com/watch?v=GT1aZ Civd21&list=PLAzjGxrba Oa Qy0DehKNLv CYNur 9ESg https://www.youtube.com/watch?v=lw68ilveqHQ&list=PLAzjGxrba OaHcbGimpnBBnZdWBGfxRDr OaFlxMjNKZ5EL4Rt4YMII OSee Answer
Q3:Assignment 2 - Reverse-Engineering: Functional Analysis, Design for Manufacture, and Environmental Impacts In this assignment, you are asked to undertake the reverse-engineering of a consumer durable (or similar product) in order to consider its overall design and that of its individual components. Central to the activities you undertake will be the analysis of its design for manufacture, the construction of a function hierarchy (Functional Analysis), and lifecycle analysis. There is a selection of very cheap toasters, irons, and hand-mixers available, and the disassembly is done in groups of four or so, (in order to economize on the number of products destroyed!). However, if you are able to find some other defunct product to use in this exercise, you are welcome to use that, (subject to checking suitability with me). Additionally, if you provide your own product, you can select your own disassembly group size and members. Health and safety are paramount in doing this exercise. It is important that the product you use for this disassembly is disposed of after this exercise. If the product you plan to disassemble uses mains electricity, it is a condition of using it for this exercise that before commencement you cut to electrical lead as close to the product as possible to prevent subsequent use. In conducting the reverse-engineering exercise, you should review the operation and performance of the product and consider how each of the components contributes functionally to the operation of the product. Use this to construct a functional hierarchy./nYou should then select two components from the product and produce a brief report on each discussing the design choices they embody. You should also use the software, Open CL, (to which you will be introduced), to estimate the environmental impacts of your two components. Ensure that the components you choose represent different manufacturing processes, and thus different DFM and potentially different environmental impact issues. (For example, do not select two injection molded components; for maximum marks you need to show an understanding of a wide range of DfM considerations, and even if different components, two components of similar manufacture will tend to embody the same points.) If you are sharing a product, ensure that you chose different components to discuss than those of your colleagues. Probable reasons for the choice of material and choice of manufacturing process should be briefly explained, but far and away more important is that you should highlight features of the component which have been designed to aid manufacture or assembly, (or perhaps compromises in this regard to satisfy other product characteristics). Nota Bene: The DfM/LCA submission should solely focus on those aspects of the components. You should not include a discussion of how you disassembled the product; it is not of interest here. Moreover, whilst you are expected to identify the manufacturing processes used, and the reasons for their selection, you may assume that the reader is familiar with the processes. Generic explanations of the processes are NOT required, and will not gain any marks.See Answer
Q4:Part 2: Designing Lift Arm Assembly In Part 2 of this OEMP project you will be designing two aspects of the Lift Arm Assembly while ensuring functionality of your design. You will be selecting the length of parallel members CD and EB, as well as the height of chair assembly DEF. Throughout this project, all team's will be using US Customary units (pounds, slugs, feet, inches). E LOF do H d hu hg hc Figure 1: Side View (x-y plane) of Pool Lift with variable dimensions The lift arm assembly consists of a four-bar linkage, BCDE, where members CD and BE are the same length and remain parallel to one another at all times. The four-bar linkage ensures that the seat mount/chair DEF will maintain a vertical orientation throughout its motion. The goal of this OMEP is to develop your team's most competent Pool Lift Model allowing for a variety of users to comfortably enter and exit the pool safely. To limit the scope of this project, all teams will use the following dimensions: hc=56 inches and do = d = 2 inches, where he represents the height of pin C above the pool deck, hg represents the height of pin B above the pool deck, and de and d represent the length of hinges G and H, respectively, from the pin to the centerline of the member to which each hinge is attached. The lift arm assembly must be designed to successfully achieve your chair's selected vertical range of motion while limiting the necessary operating range of a angles (suggested less than 60°). Consider how the length of the parallel members and the height of the chair assembly affect the chair's vertical position. • Design the length of parallel members CD and BE (lcp in figure 1). Design the height of chair assembly DEF (DF in figure 1). Select the height of pin B above the pool deck (hg in figure 1). Based on your design, use geometry to find the a angles corresponding to your maximum and minimum chair positions. If your range of operating a angles is greater than 60° you need to consider redesigning lcD and lor as large ranges of angles may cause the hydraulic cylinder to overextend.See Answer
Q5:4. There are many different gears in this tool. Find a gear model that is made using Powdered Metal. a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Powdered Metal Manufacturing. How does this manufacturing process fulfill each of the functions listed above? 5. c. How did you know this part was made using Powdered Metal? d. The engineers at DeWALT designed this part with Powdered Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. ii. 111. iv. Material selection (including the base material, and any additional material impregnation) PM Chamfer N530050 Detent Washer a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Sheet Metal Stamping/Bending. How does this manufacturing process fulfill each of the functions listed above? i. ii. Uniform cross section for even compaction Draft angles (are the draft angle requirements different for PM, and why is that important for this particular part?) c. The engineers at DeWALT designed this part with Sheet Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: 111. Material thickness Hole location and sizing (look up specific requirements for holes in relation to material thickness) Bend radii (look up specific requirements for bends in relation to material thickness)See Answer
Q6:Problem 1 (10 marks) Minimise: Subject to: f = 2x₁ - 6x₂ + 3x3 + 4x4 + 7x5 + 3x6 + 2x7 91 = x2 + 5x3 + 3x4 x5 + 2x6 + 3x7 ≥ 65 92 = -6x₁3x₂ − 2x3 + x4 + 2x5 - 2x6 ≥ -73 93-7x₁4x2 + 3x3 X₁, X₂ € (2,5,7,8), X3, X4 € {3,4,6} X5, X6 ≥ 0, X7 ER 4x4 + 3x5 - 2x6 x7 ≤-66See Answer
Q7:Problem 2 (10 marks) An I-beam is shown in the figure to the right. Given the following equations and constraints, develop a mathematical model and find the dimensions of a beam with a minimal cross sectional area. Cross sectional area: Section modulus: Bending moment: Axial force: Bending stress: Axial stress: Stress constraint: Buckling constraint: X₂ ↓ X4 TH A = x₁x₂ + 2x3x4 - 2x₂x4 S = X₁ (X3X4+*1X2) M = 350 P = 140 Og = Op -142* 1000M S OB + Op- 10P A 180 ≤0 (1+%² 1+171 SO And subject to the following constraints on plate thickness and width: x₁:38,40,41 x₂: 1.9, 2.2, 2.4 x3: 28,30,33 X4: 1.1, 1.3, 1.5 ·X₂ cm² cm³ kNm kN MPa MPa MPaSee Answer
Q8:It is desired to design and manufacture continuous and aligned glass fiber- reinforced epoxy having a tensile strength of at least 1250 MPa in the longitudinal direction. The maximum possible specific gravity is 1.50. Using the following data, determine whether such a composite is possible. Justify your decision. Assume a value of 20 MPa for the stress on the matrix at fiber failure.SSee Answer
Q9:Question 2 ‘Smoothtools’ manufacturing company want to enter the ‘woodworking tools’ market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After ‘reverse engineering’ the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at ‘Smoothtools’ have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products (5 Marks) b) The ‘line design’. (5 Marks) c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? (6 Marks) d) If a ‘short fat’ layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? (6 Marks) e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? (12 Marks) f) What are the advantages and disadvantages of both ‘long thin’ and ‘short fat’ layouts? See Answer
Q10:Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the 'Traditional approach' is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.See Answer
Q11:Question 2 'Smoothtools' manufacturing company want to enter the 'woodworking tools' market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After 'reverse engineering' the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at 'Smoothtools' have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products b) The 'line design'. c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? d) If a 'short fat' layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? f) What are the advantages and disadvantages of both 'long thin' and 'short fat' layouts? See Answer

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