Meen40030

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SEMESTER I EXAMINATIONS - 2015/2016

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School of Mechanical and Materials Engineering
MEEN40030
Manufacturing Engineering II
Professor Fionn Dunne
Professor Michael Gilchrist
Professor Denis Dowling*

Dr. Eamonn Ahearne
Professor Gerry Byrne
Time Allowed: 2 hours
Instructions for Candidates
Answer three questions
All questions carry equal marks. The distribution of marks in the right margin
give an approximate indication of the relative importance of each part of the
question.
Instructions for Invigilators
Non-programmable calculators are permitted.

No rough-work paper is to be provided for candidates.
Page 1 of 4
Question 1 (33⅓ marks)
Q1 a) Write brief notes to explain how sustainable manufacturing differs from

conventional manufacturing.
(5 marks)
Q1 b) Provide an overview of the global trends which have led to a focus on

achieving more sustainable manufacturing.
(6 marks)
Q1 c) It has been highlighted that “Life Cycle Thinking can help people find new
ways to improve environmental performance, image, and economic benefits.” Explain
what is meant by “Life Cycle Thinking” and highlight its impact on manufacturing.
(12⅓ marks)
Q1 d) Explain how the Life-cycle analysis approach can be used to measure the
environmental impact of manufacturing.
(10 marks)
Q2 a) While there has been a general decline in manufacturing employment in

developed economies over the past 20 years, manufacturing however still remains
important. Briefly summarise the reasons for the importance of manufacturing for an
economy.
(8 marks)
Q2 b) Industry 4.0 is a smart manufacturing project of the German Government.

Provide an overview of Industry 4.0 and detail its potential impact on manufacturing.
(14⅓ marks)
Q2 c) Two of the critical elements of smart manufacturing are “the Internet of

Things" and Data Analytics. Write brief notes on the current and potential impact of
both the Internet of Things and Data Analytics on manufacturing.
(11 marks)
Q3 a) The laser powder bed fusion process has been the most dominant processing
technique used for the fabrication of metallic parts using Additive Manufacturing
(AM). With the aid of a diagram, describe this AM technique.
(8 marks)
Q3 b) Write brief notes on potential applications of three components that could be

fabricated using metallic Additive Manufacturing.
(6 marks)
Page 2 of 4
Q3 c) Highlight the factors limiting the wider adoption of additive manufacturing in
the fabrication of industrial components.
(9 marks)
Q3 d) The cost of additive manufacturing remains relatively high compared with

competing technologies, however costs are declining. Provide an overview of the
main costs associated with an AM process and highlight reasons for the gradual
reduction in finished part costs over time.
(10⅓ marks)
Q4 a) Define the term ‘Surface Integrity’ and describe the physio-chemical

characteristics of the surface and sub-surface layers of a machined metal component.
Indicate why surface integrity is important for critical mechanical components and
rationalise its increasing importance as component sizes reduce to micro and even
nano scales.
(13 marks)
Q4 b) Write detailed notes on the mechanical stylus method used for the measurement
of the topographical profiles of machined surfaces.
(5 marks)
Q4 c) Chemical Mechanical Polishing (CMP) is a critical process in semiconductor

manufacturing. With reference to the process schematic shown in Figure Question
4(c), write detailed notes on the key features and limitations of this process. Write
down and discuss Preston’s Equation. Describe an inherent source of variation in the
CMP process with regard to the applied pressure and some design measures to reduce
this.
(15⅓ marks)
Figure Question 4 (c) - Chemical Mechanical Polishing
Page 3 of 4
(a) Differentiate between an “idea”, an “invention” and an “innovation”, providing

one illustrative example of each.
(8 marks)
(b) “Henry Ford fundamentally changed the face of transportation, not because he
invented the motor car, nor because he developed the manufacturing process to put
one together. His contribution was to change the underlying model from one which
offered a handmade specialist product to a few wealthy customers to one which
offered a car for Everyman at a price they could afford!”.
With reference to the Craft Production era, describe the main innovations in the
evolution of the mass production system that enabled the realisation of Fords goal.
(12 marks)
(c) Based on the evidence of research reported by Womack et al in "The Machine

that Changed the World", compare the definitive mass and lean production systems in
terms of the differences in approach to; customer / market, quality, product design,
production system organisation and human resources, supplier relationships and “key
performance measures”.
(13⅓ marks)
“oOo”
Page 4 of 4

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____________________________________

SEMESTER I EXAMINATIONS - 2015/2016

School of Mechanical and Materials Engineering

Professor Fionn Dunne

Professor Michael Gilchrist

Professor Denis Dowling*

Time Allowed: 2 hours

Instructions for Candidates

Answer three questions

Instructions for Invigilators

Non-programmable calculators are permitted.

Q1 a) Write brief notes to explain how sustainable manufacturing differs from

Q1 b) Provide an overview of the global trends which have led to a focus on

Question 2 (33⅓ marks)

Q2 a) While there has been a general decline in manufacturing employment in

Q2 b) Industry 4.0 is a smart manufacturing project of the German Government.

Q2 c) Two of the critical elements of smart manufacturing are “the Internet of

Question 3 (33⅓ marks)

Q3 b) Write brief notes on potential applications of three components that could be

Q3 d) The cost of additive manufacturing remains relatively high compared with

Question 4 (33⅓ marks)

Q4 a) Define the term ‘Surface Integrity’ and describe the physio-chemical

Q4 c) Chemical Mechanical Polishing (CMP) is a critical process in semiconductor

Figure Question 4 (c) - Chemical Mechanical Polishing

(a) Differentiate between an “idea”, an “invention” and an “innovation”, providing

(c) Based on the evidence of research reported by Womack et al in "The Machine

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