MM 323 - Manufacturing

Systems
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Assignment Title
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Sample Report

Team Members

Group Member 1 Name

Group Member 2 Name

Group Member 3 Name

Group Member 4 Name

MM 323 – Manufacturing Systems

DECLARATION OF ORIGINALITY

This report is our own original work. It was not copied nor was it written in collaboration with
any other person or group.

____________________

Team Member 1 Name

ID #

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Team Member 2 Name

ID #

____________________

Team Member 3 Name

ID #

____________________

Team Member 4 Name

ID #

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ACKNOWLEDGEMENT

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ABSTRACT

Abstract is the last thing that you write. By reading your abstract I should be able to know what
the assignment was about and the key findings of the assignment upon completion. For
example,

A company wishes to set-up an assembly line which produces an electronic-based product used
in automotive industry. Thus, this assignment gives a design solution for an assembly line in
form of a suitable and most appropriate layout to meet the production rate. The layout is
supported by calculations for production rate and balance delay of the line. A more detailed
analysis is also done on the design of the conveyor system that delivers parts to the stations.
The production cost of this conveyor system is highlighted in the report. The layout was drawn
in AutoCAD and FlexSIM was utilized to compare the results which showed good agreement.

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TABLE OF CONTENT

ABSTRACT ---------------------------------------------------------------------------------------Page #

LIST OF FIGURES -----------------------------------------------------------------------------Page #

LIST OF TABLES -------------------------------------------------------------------------------Page #

PROBLEM STATEMENT---------------------------------------------------------------------Page #

INTRODUCTION -------------------------------------------------------------------------------Page #

LITERATURE REVIEW ----------------------------------------------------------------------Page #

METHODOLOGY-------------------------------------------------------------------------------Page #

BOTTLE WATER FACTORY DESIGN ---------------------------------------------------Page #

You may include your sub-topics here.

ANALYSIS ----------------------------------------------------------------------------------------Page #

CONCLUSION -----------------------------------------------------------------------------------Page #

REFERENCE--------------------------------------------------------------------------------------Page #

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LIST OF FIGURES

Figure 1 Fiji water bottle Page #

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LIST OF TABLES

Table 1 Mapping of Final Design Page #

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1. PROBLEM STATEMENT

Write problem statement here in your own words and understanding. Do not copy
directly from the assignment.

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2. INTRODUCTION

Introduction should give an insight to what the assignment is about, why is it being done and
what will be done.

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3. LITERATURE REVIEW

Please put your text here….

A water bottle is a container used to hold water for consumption. [1] (In text reference)

Sub Heading

Please put your text here….

The design of a typical Fiji Water bottle is shown in Fig. 1 (Citing the figure in the text and

explain the figure if possible.)

Fig. 1 Fiji water bottle [2]

Example

The continuous growth in the automotive industry nowadays demands for intelligent and
electronic-based products and production of these parts must meet market demands and set
standards. This has led to the invention of the assembly lines whereby work is distributed in
stations along a line to reduce production time and costs [1].

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Parts or finished products have to be transported from stations to stations by some means, and
the current material transporting system used mostly in production industries is the power and
free conveyor systems.

3.1 Assembly Line

An assembly line is a production process whereby parts are assembled or added to a part
finished product using innovative logistics to complete a product faster than hand -crafting
process. Assembly line takes into consideration of sequential arrangement of workers,
machines, tools or parts. Movement of workers is minimized to least possible. In modern
assembly lines, parts are handled by material transport systems such as conveyors or cranes to
transport parts from one station to the next while human workers do simpler jobs such as
controlling the machines by remote controls or computer [2].

Assembly lines are also used widely due to certain advantages which are stated below:

 Increased production and uniformity, that is, assembly lines enable faster production
rate and efficiency as well as task limiting. Thus, most assembly lines manufacture
products much faster than traditional manufacturing processes.
 Cost reduction, overall cost reduces as product assembly becomes easier and quicker.
 Interchangeable part usage, parts produced from an assembly line are specifically
made to ensure near identical fittings, that is, they will be adequate to be assembled to
the same type. Assembly and repair does not require much skilled personnel and time.
 Performance improvement
 Reduction in manpower for assembly
 Higher quality and access of lower failure rate
 Level of automatic assembly can be adjusted
 Higher turnover
 Reduced waiting time
 Reduced set-up and idle time
 High efficiency and effectiveness

Modern assembly line methods made production highly automated and processes occurs
simultaneously and within shorter times. Different product follows various conveyors and only
fed into the final station of the assembly process. This is achieved by using efficient material
flow, advanced material handling equipment and continuous supply of infrastructure [3].

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Figure 1: Assembly line using power and free conveyor system [4]

3.2 Power and Free conveyors

Power and free conveyors provide a means for advancing pallet fixture products through a
manufacturing system. Pallets are free to move, stop or accumulate along a continuously
moving conveyor.

Palletized fixture transport on flat belt or multi-flexing chain enables flexible routing and
accumulation. Often, manufacturing systems require product conveyance between numerous
automated machines and this is the role of power and free conveyors.

Power and free conveyor systems are simply highly flexible material handling system. Part
manufacturing, assembly of parts, storage, packaging and unpackaging can all be done using
just one of this material handling system. These are compact design with buffer mechanism
inside the track and have flexible installation with minimum space requirements. The controls
can be linked to central plant computer system.

Power and free conveyors system are basically a twin-rail type system where a power chain is
utilized to haul the carriers. The trolley which holds the carrier has a movable cam which acts
as an interlocking source whereby the rigid dogs, that are evenly spaced out equipped with
the power chain, latches onto it. This creates an interlocking connection between them. [5]

The carriers are allowed to be automatically stopped, released and buffered with the help of
stop and contact skids. The carrier speeds and the spacing between subsequent carriers are
variable and can be adjusted to suit the stopping and moving times between stations.

3.3 Advantages of Power-and-Free conveyor system

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• Compact design with buffer mechanisms inside the track

• Flexible installation with minimum space requirements (allow for chain transfer at any
time, regardless of dog spacing)
• Can be fully automated with a user friendly visualization interface control system
• Control functions for the pallet movement can be linked to a central processing plant
computer system
• High availability due to its modular design
• Easily exchangeable and repairable components, thus reduction in downtime for the
assembly line

3.4 Power and free conveyor system components

The standards assemblies used for the power and free conveyor system components available
are selected according to the customer’s needs. Due to the compact design with in track
stacking features, power and free conveyor system requires minimum height and space [5].

The components selected according to the customer’s needs are as follows:

Chain and track

The most commonly used material to design chain and tracks for the rail are wear-resistant
steel components.

Figure 2: Chain and track [6]

Drive Mechanism

Is driven by chain drive and for safety reasons, clutches are employed in the system.

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Figure 3: Caterpillar Drive [7]

Take-up/Tension Station

Maintains a defined tension in the conveyor chain.

Figure 4: Tension station [8]

Stop/Go Unit

Are used to stop the carrier and trolleys when the conveyor chain is moving. Are mostly
electromagnetically controlled devices, which can be linked directly to the central control plant
in the assembly line.

Figure 5: Stop/Go Unit [9]

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Lift stations

Are utilized to move the transport material vertically between different levels at the pick-up
and drop-off locations, as well as processing terminals. This is due to elevation changes.

Figure 6: Lift Station [10]

Track switches

For diverting and merging of conveyor tracks. Are mostly electromagnetically controlled
devices, which can also be linked directly to the central control plant in the assembly line.

Figure 7: Track switch [11]

3.5 Lubrication

To cater for lowest possible maintenance operation (reduction in wear), and to increase
availability time of the system.

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3.6 Control system for this conveyor system

• PLC programming
• Instrumentation control and production control
• Destination control
• System visualization

Figure 8: Example of a Customized Control Configuration [5]

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4. METHODOLOGY

The assignment follows a following process to reach a final layout for the assembly line.

1. Research

The designing of the possible assembly line was all started from researching using the internet,
browsing through Google images to get a basic idea of how assembly lines were designed and
ways of implementing power and free conveyor system as a material handling tool by
other engineers. From researching we were able to get an idea of how we are going to come up
with a well-designed layout for the assembly line for our assignment.

2. Sketch

Sketching our ideas on a piece of paper is the first and main foundation of our design. The
group will design a possible layout for the assembly line to cater for the required production
rate.

3. FlexSIM

The software program was used to create the design professionally, the purpose for this
software program was not only to design a model for the assembly line, but also to show the
simulation of the working design, and more importantly to analysed to give outputs from the
individual workstations to see the production rate.

4. Calculations and Analysis

Calculations and analysis are conducted to calculate number of each station type required to
achieve the specified production rate. Calculate for final production rate, balance delay of the
system

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5. RESULTS AND DISCUSSION

5.1 Given Assignment Parameters and Requirements (summary)

5.2 Calculation and analysis

5.3 Facility Planning and Layout

5.4 Final AutoCAD Design Layout of the Facility

5.5 Bill of Materials

5.6 etc

5.7 Discussions

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6. RECOMMENDATIONS AND CONCLUSION

Sum up the assignment by highlighting the key findings. Please include recommendations as
well.

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7. REFERENCE

Report

[1] FEA (2011), “Fiji Electricity Authority Annual Report”, Fiji Electricity Authority (FEA).

[2] IRENA (2012), “IRENA Policy Brief: Policy Challenges for Renewable Energy
Deployment in Pacific Island Countries and Territories”, International Renewable Energy
Agency (IRENA).

[3] G. Owens, Best Practices Guide: Economic and Financial Evaluation of Renewable Energy
Assignments. Prepared for Energy and Environment Training Program, Office of Energy,
Environment and Technology, Global Bureau, Center for Environment, USAID, 2002.

[4] C. P. C. Dam, D. L. Kahn and D. E. Berg, “Trailing Edge Modifications for Flat back
Airfoils,” Sandia National Laboratories, University of California, California, 2008.

Journal papers

[5] M. R. Ahmed, S. Narayan, M. A. Zullah, Y. H. Lee, “Experimental and numerical studies

on a low Reynolds number airfoil for wind turbine blades,” Journal of fluids sciences and
technology, vol. 6, pp. 357-367, 2011.

[6] A. Gagliano, F. Nocera, F. Patania and A. Capizzi, “Assessment of micro-wind turbines

performance in the urban environments: an aided methodology through geographical
information systems,” International Journal of Energy and Environmental Engineering, vol.
4, pp. 43-52, 2013.

[7] A. S. Bahaj, L. Myers and P. A. B. James, “Urban energy generation: Influence of micro-
wind turbine output on electricity consumption in buildings,” Journal of Energy and
Building, vol. 2, pp. 154-165, 2007.

Conference

[8] K. R. Ram, S. Lal, M. R. Ahmed, “Airfoil optimization for small wind turbines using multi
objective genetic algorithm,” in Proc. of the ASME 2012 International Mechanical
Engineering Congress & exposition, 2012, Houston, Texas, USA.

Book

[9] J. B. Barlow, W. H. Rae and J. R. Pope, "Low Speed Wind Tunnel Testing," New York:
Wiley Interscience, 1999, pp. 44-60.

[10] E. Hau, "Wind Turbines; Fundamentals, Technologies, Application, Economics,"

Germany: Springer, 2006, pp. 66-80.
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8. Task Division by Participants

Table X: Tasks accomplished by each individual

Student 1
 Research on assembly line
 Research on conveyor system
 Determine all the given parameters and requirements for the design
 Calculation and analysis for modified layout
 Facility planning and layout calculations
 Final layout in AUTOCAD
 Check the results with simulation software (FlexSIM) for output
 Analysis based on FlexSIM output
 Summary of calculations
 Report writing and compilation

Student 2

Student 3

Student 4

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