NR 422001 C Automation in Manufacture

Set No.
Code No.422001
IV-B.Tech. II-Semester Examination April, 2003 1
AUTOMATION IN MANUFACTURE
(Production Engineering)
Time: 3 hours Max.Marks:80
Answer any FIVE questions
All questions carry equal marks
---
1.a) Define Automation. List and explain the types of automation.

b) List down the reasons for automating.
2.a) What is an automated flow line? Mention the objectives of the use of flow line
automation.
b) Explain the following linear transfer mechanisms:
i) Walking beam system.
ii) Powered roller conveyor system.
3.a) An eight-station rotary indexing machine operates with an ideal cycle time of 20
seconds. The frequency of line stop occurrences is 0.06 stop/cycle on the average.
When a stop occurs, it takes an average of 3 min to make repairs. Determine the
following:
i) Average production time Tp
ii) Average production rate Rp
iii) Line efficiency E
iv) Proportion of down time D.
b) Write a note on partial automation.
4. A proposal has been submitted to replace a group of assembly workers, each

working individually, with an assembly line. The following table gives the
individual work elements.
Element Te(min) Immediate
predecessors
1 1.0 -
2 0.5 -
3 0.8 1,2
4 0.3 2
5 1.2 3
6 0.2 3,4
7 0.5 4
8 1.5 5,6,7
The demand rate for this job is 1600 units/week (assume 40 h/week) and the
current number of operators required to meet this demand is eight using the
individual manual workers.
(Contd…2)
Code No.422001 -2- Set No.1
a) Construct the precedence diagram from the data provided on work elements.
b) Use the largest-candidate rule to assign work elements to stations. What is the
balance delay for the solution?
c) The initial cost to install the assembly line is Rs.20,000. If the hourly rate for
workers is Rs.5/hour, will the assembly line be justified using a 3 year service
life? Assume 50 weeks/year, use a rate of return=10%.
5.a) Explain different types of material handling equipment.

b) Discuss the factors to be considered in the analysis for material handling systems.
6.a) What is an automated storage/retrieval system? Explain the categories of

automated storage/retrieval systems.
b) Explain the following features in automated storage/retrieval systems:-
i) Aisle transfer cars
ii) Full/empty bin detectors.
7.a) Explain adaptive control system with a block diagram.

b) What are the two types of adaptive control? Explain briefly. List the benefits of
adaptive control machining.
8.a) What is Business process Re-engineering? How are ERP and BPR related?
Explain.
b) Discuss the importance of concurrent engineering approach in limiting design
changes.
*** *** ***

Set No.
Code No.422001
---
1.a) Define Automation. Explain the different types of automation.

b) Write a note on pneumatic component circuits.
2.a) What is Buffer storage? Explain the reasons for the use of Buffer storage zones.
b) Explain the following rotary transfer mechanisms:
i) Ratchet and pawl
ii) Geneva mechanism
3.a) The following data apply to a 12-station in-line transfer machine:

P = 0.01 (all stations have an equal probability of failure)
Tc = 0.3 min
Td = 3.0 min
Using the lower-bound approach, compute the following for the transfer machine:
i) F, the frequency of line stops.
ii) Rp, the average production rate.
iii) E, the line efficiency.
What proportion of work parts are removed from the transfer line.
b) Write a note on Flexible assembly lines.
(Contd…2)
4. The following list defines the precedence relationships and element times for a
new model boy:

predecessors
1 0.5 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
8 0.5 3,5
9 0.3 7,8
10 0.6 6,9
a) Construct the precedence diagram for this job.
b) If the ideal cycle time is to be 1.0 min, what is the theoretical minimum number of
stations required to minimize the balance delay?
c) Determine the assignment of work elements to stations using the ranked
positional weights (RPW) method. How many stations are required? Compute the
balance delay.
5.a) What is an automated guided vehicle system? Explain different types of

automated guided vehicle systems (AGVS).
b) Explain vehicle guidance and routing in an automated guided vehicle system.
6.a) Explain the interfacing of handling and storage systems with manufacturing.
b) List the areas of application of automated storage/retrieval systems. Explain in
brief.
7.a) Explain adaptive control with constraints.

b) Discuss the application of adaptive control in machining operations.
8.a) What is ERP? Explain. Explain important modules in a typical ERP software.
b) Explain Rapid prototyping.
*** *** ***

Set No.
Code No.422001
IV-B.Tech. II-Semester Examination April, 2003
3
---
1.a) Discuss the strategies of Automation.

b) Write a note on Tool changing.
2.a) Explain the functions that are utilized to control the operation of an automated
transfer system.
b) Explain the factors to be considered in designing and building an automated flow
line.
3.a) Discuss the ways to improve the line balance.

b) A circular indexing machine performs 10 assembly operations at 10 separate
stations. The total cycle time, including transfer time between stations, is 10
seconds. Stations break down with a probability P = 0.007, which can be
considered equal for all 10 stations. When these work stoppages occur, it takes an
average of 2 min to correct the fault. Parts are not normally removed from the
machine when these stops occur. Compute the proportion of down time, the
efficiency, and the production rate of this circular indexing machine.
new modal toy:
predecessors
1 0.5 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
8 0.5 3,5
9 0.3 7,8
10 0.6 6,9
c) Determine the assignment of work elements to stations using the largest-candidate
rule. How many stations are required? Compute the balance delay.
(Contd…2)
5.a) Discuss the categories of applications of automated guided vehicle systems.

b) Explain the traffic control and safety in a automated guided vehicle system.
6.a) List and explain basic components of an automated storage/retrieval system

(AS/RS).
b) Write a note on AS/RS controls.
7.a) What are the two types of adaptive control? Explain briefly. List the benefits of
adaptive control machining.
b) Explain adaptive control system with a block diagram.
8.a) What is rapid prototyping? Discuss the importance of rapid prototyping.

b) Write short notes on the following:-
i) Logistics
ii) BPE.
*** *** ***

Set No.
Code No.422001
---
1.a) Explain the different automation strategies.

b) Write a note on mechanical feeding.
2.a) What are the methods of transporting work pieces on flow lines? Explain them.
b) Briefly explain the use of pallet fixtures.
3.a) The following data apply to a 10-station in-line transfer machine:

P = 0.01 (all stations have an equal probability of failure)
Tc = 0.3 min
Td = 3.0 min
Using the upper-bound approach. Compute the following for the transfer machine:
iv) F, the frequency of line stops.
v) Rp, the average production rate.
vi) E, the line efficiency.
b) List the major categories of the processes used to accomplish the assembly of
components. Explain the same.
(Contd…2)
new model boy:

predecessors
1 0.6 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
8 0.5 3,5
9 0.3 7,8
10 0.9 6,9
c) Determine the assignment of work elements to stations using Kilbridge and
Wester method. How many stations are required? Compute the balance delay.
5.a) Explain the factors influencing the design of a material handling system.
b) List the attributes of conveyor systems. Explain roller conveyors.
6.a) Explain the reasons that justify the installation of an automated storage system for
work-in-process.
b) Explain the following features in automated storage/retrieval system:-
i) Sizing stations
ii) Load identification stations.
7.a) Explain adaptive control with optimization.

b) Discuss the application of adaptive control in machining operations.
8.a) What is Rapid prototyping? Explain the techniques of rapid prototyping.

b) How will concurrent engineering will help to reduce product development time?
Explain.
*** *** ***

NR 422001 C Automation in Manufacture

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Set No.

1.a) Define Automation. List and explain the types of automation.

4. A proposal has been submitted to replace a group of assembly workers, each

5.a) Explain different types of material handling equipment.

6.a) What is an automated storage/retrieval system? Explain the categories of

7.a) Explain adaptive control system with a block diagram.

*** *** ***

1.a) Define Automation. Explain the different types of automation.

3.a) The following data apply to a 12-station in-line transfer machine:

Element Te(min) Immediate

5.a) What is an automated guided vehicle system? Explain different types of

7.a) Explain adaptive control with constraints.

*** *** ***

1.a) Discuss the strategies of Automation.

3.a) Discuss the ways to improve the line balance.

5.a) Discuss the categories of applications of automated guided vehicle systems.

6.a) List and explain basic components of an automated storage/retrieval system

8.a) What is rapid prototyping? Discuss the importance of rapid prototyping.

*** *** ***

1.a) Explain the different automation strategies.

3.a) The following data apply to a 10-station in-line transfer machine:

Element Te(min) Immediate

7.a) Explain adaptive control with optimization.

8.a) What is Rapid prototyping? Explain the techniques of rapid prototyping.

*** *** ***

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