Fall 2002 Syllabus:

Manufacturing Systems

Catalog Information:

ITDPT 303, Manufacturing Systems

3 undergraduate credit hours

(ITEDU 102 & ITEDU 108) or permission

"Manufacturing systems, tools, and processes are studied as they are applied to producing products. Laboratory experiences cover manufacturing systems emphasizing tooling design, automated manufacturing, and control systems. Includes laboratory activities."

Fall, 2002
 

August 6, 2002

Contact Information:

http://my.bsu.edu

Tues. & Thurs., 12:30 - 1:45 pm

Room 144C, Applied Technology Bldg.

Lab Hours:

(to be specified - Check the lab website.)

Lab Website:

www.bsu.edu/web/SAWARNER/final.htm

Instructor:

Jim Flowers

Professor  & Director of Online Education
Department of Industry and Technology
AT 130A
(765) 285-2879;
FAX (765) 285-2162
jcflowers1@bsu.edu

Office Hours:

M-F 9:00 - 9:50 a.m.

www.bsu.edu/web/jcflowers1/flowers.htm

Objectives:

2. Analyze manufacturing systems in terms of components, inputs, tools, processes, outputs, and impacts.

3. Apply sound principles of manufacturing engineering to solve problems related to manufacturing;

4. Develop programming to control a variety of automated manufacturing equipment.

5. Fabricate products using advanced manufacturing and design equipment.

Content Outline

1. Manufacturing inputs
2. Manufacturing support systems
3. Manufacturing processes
4. Manufacturing outputs
5. Impacts of manufacturing

1. Purpose
2. Coordination
3. Manufacturing engineering concepts
1. Precision
2. Contamination
3. Standardization and interchangeability
4. Tolerance
5. Continuity
6. Synchronization
7. Efficiency
8. Flexibility
9. Experimentation
10. Other
4. Facility
5. Quality assurance
6. Equipment
1. Tools and Machinery
2. Tooling
7. Materials Handling Engineering
8. Impacts of Manufacturing on Design
9. Workstation Design
10. Maintenance engineering
11. Disposition of waste

1. Definitions
2. Types
3. The decision to automate
4. Hardware components
5. Hardware systems
1. Computers
2. Robotic cells
3. Numerical control machines
4. Other
6. Software and programming
1. NC Programming
2. CAD/CAM
3. Statistical process control
4. Simulation
5. Other
7. Layout and routing in automated manufacturing systems

1. Rapid prototyping
2. Advanced machining
3. Other

Format:

During the three rotations, students will engage in supervised laboratory work.

Calendar by Week:

Other Information:

Methods of Student Evaluation: Major Activities, Tasks:

• Activity 1. Prepare process summaries on the use of selected programmable manufacturing machines: CAD/CAM, CNC, computer controlled laser machining, and robotic equipment, complete with sample products, drawings and programs where appropriate. (20%)

 
• Activity 2. As a group, design, set up, execute, and assess a partially automated mass production system. (20%)

 
• Activity 3. As a group, use rapid prototyping equipment to design and produce a prototype of a manufacturing product. (20%)

• Activity 4. Produce a detailed site on the World Wide Web on an approved topic in manufacturing technology. Submit the URL of both the draft and final web sites on the dates specifies. Briefly present this information to the class. (15%)

 
• Complete quizzes, class readings, activity sheets, attend field trips, participate in group work and discussion, participate in safe laboratory practice and participate responsibly in laboratory housekeeping. (5%)

 
• Perform satisfactorily on a comprehensive final examination. The final exam will only be given from noon to 2:00 pm. on Friday, the Thirteenth of December, 2002. (20%)

Grading System:

Grades presented as fractions (e.g., 17/20) can be simplified to percentages (85%).

Course Evaluation:

Text:

Laboratory Experiences and Hours:

References:

• American Psychological Association. (2001). Publication manual of the American Psychological Association (5th ed.). Washington, DC: Author.

 
• Bateson, R. N. (1993). Introduction to control system technology. New York: Macmillan.

 
• Biekert, R. (1998). CIM technology: Fundamentals and applications. South Holland, IL: Goodheart-Willcox.

 
• Dorf, R. C., & Bishop, R. H. (1995). Modern control systems. Reading, MA: Addison-Wesley.

 
• DuVall, J. B. (1996). Contemporary manufacturing processes. South Holland, IL: Goodheart-Willcox.

 
• Pickett, R. T. (1988). Feedback and control systems for technicians. Englewood Cliffs, NJ: Prentice Hall.

 
• Ritz, J. M., W. F. Hadley, & J. Bonebrake. (1990). Exploring production systems. Worcester, MA: Davis Publications.
   
• Wright, R. T. (1990). Manufacturing systems. South Holland, IL: Goodheart-Willcox.

Laboratory Policy:

• No one is to use lab equipment without the permission and direct supervision of the attendant, who may be the instructor or the trained graduate assistant.
• The instructor's permission is required for use of materials in the lab.
• All hazards, including malfunctioning equipment, are to be reported to the attendant immediately.
• Personally-owned safety glasses or other approved eye protection must be worn by all people in the lab during all lab work and demonstrations.
• Long hair, ties, jewelry and loose clothing must be secured to prevent injury.
• Shoes with non-skid soles and closed toes are required in the lab.
• Each piece of equipment is to have only one operator (who may have helpers.)
• Do not distract the operator or get too close to their machine.
• Do not operate a potentially dangerous piece of equipment if you are not fully alert.
• If you are unsure about a certain procedure, do not proceed. Instead, tell the instructor of your doubts.
• Do not operate any power tool on which you have not been trained.
• Just before you turn an a power tool for the first time ever, notify the instructor or graduate assistant.
• Food and beverages are not allowed in the laboratory.
• Bags, coats and bicycles are not to be placed in the lab while you work.
• Materials are to be used efficiently, with as little waste as possible.
• Hazardous materials are to be disposed of according to the established BSU procedure.

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The Material Processing and Construction Laboratory is a dynamic learning environment that helps to showcase the Department of Industry and Technology. Therefore, it is essential that it remains clean and orderly. Tools and materials must be returned and tables, machines and floors cleaned when work is done.

Attendance and Academic Policies:

• Students are to comply with the class attendance policy outlined in the Ball State University Undergraduate Catalog.

• Assignments that are submitted after the date and time they are due may or may not be accepted or have penalties assessed, at the instructor's discretion.

• Unless otherwise directed, all written work is to be done on a word processor. This will allow files to be easily updated and exchanged. When a style guide is appropriate, the Fifth Edition of the Publications Manual of the American Psychological Association is recommended. All written, graphic and verbal items must conform to APA and ITEA guidelines for non-sexist and non-racist language.

Audit Policy:

Special Student Needs: