ASSIGNMENT 5

Disassembly project:

What we did and why? What have we learnt?

Having observed the video Prof. Ranky demonstrated in class of a product disassembly, it is clear that a great deal can be learnt from taking things apart. One of the main aspects of knowledge you gain from disassembling products is greater knowledge of how they work. This is found by observing how the inner workings of the product operate and how the individual parts can make up the entire product. In the video, Prof. Ranky disassembled an “old school” telephone, one that had a receiver and base with a cord connecting the handset. The telephone also had a tape recorder for recording messages on the message machine. One of the biggest standouts was the poor-quality speaker installed in the device, and the lack of protection from the elements that cause a large amount of dust to accumulate inside the cover and the speaker. This design was clearly not up to modern design standards, but keep in mind that it was conceived and produced before CAD or other computer assistance was invented. The internal working of the base was disassembled and something that has a vague resemblance to modern pc bards was found at the heart. So, the internal working has only evolved, that basic design has not changed. This means engineers and Industrial engineers have improved on how to make the parts function more efficiently and effectively. Let’s take the speaker as an example, modern speakers in cellphones and home phones are tiny, yet produce excellent sound and can be adjusted for people that are hard of hearing (e.g. the elderly). This is in part due to the sleeker design making space more difficult to come by for the designers of the phones, and also in part due to technology making all things better/smaller/faster.

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Risk Analysis:

In the video, Prof. Ranky reduced the risk of damaging the parts of the telephone by being very gentle with the parts during the disassembly process. Being gentle is not the only aspect to reduce the risk, a knowledge of what the object should be comprised of, is also essential. If the person disassembling a specific object has a basic idea of which components should be expected in which locations, then the person disassembling the object can more effectively disassemble that object. Along with this basic understanding, the person disassembling the object will have a rough idea of how the different parts in the different locations handle (how strong they are and how durable). This is all a learning process as well, once you complete one disassembly, the next one you complete you will do better/more effectively, and so on and so forth. Therefore, being gentle the first time, then gaining knowledge in order to make the next disassembly easier and more effective. This will lead to more effective learning from the process you go through.

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Video 1:

I learnt the term Mechatronics from the first video. The practice combines mechanical and electrical engineering, and as Prof. Ranky stated in the video, the mechatronics system depends heavily on the sensors. This will be applied to my company’s factory throughout the full integration of sensors throughout the factory (monitoring every process for improvement) to ensure my company can gain the full potential benefit from this tech moving forward.

Next, I learnt the first principle of the sixteen principles of advanced sustainable manufacturing and technology management excellence. The first principle is sustainable and value adding. Lean (waste reduction and optimization), and lean six sigma (high quality, zero defect at low cost) are the second and third principles respectively. Principle four is safety, five is operator lead process control. Process and system focus are principle number 6. Principle seven is system focus, system integration focus, communication and networking. The Industrial internet of things and the internet of things are big parts of this principle. Principle eight is successful automation, flexibility, reconfigurability and leanness. Another aspect is network security and data security. Principle nine is product quality, total quality management is important here, as well as digital design and digital manufacturing. Process quality is principle number ten. Quality design must have a quality process in order to reach the ideal product. Principle eleven is visual factory management. Principle twelve, communication, a workforce highly educated in Lean principles are required. Industrial internet of things and internet of things plays into this principle. Communication between workforce and machines in factory. Energy management is principle thirteen, waste reduction, green etc. Principle fourteen is preventative maintenance. Lean and green supplier and supply chains is the fifteenth principle. The final principle, principle sixteen is intellectual property protection.  

Video 2:

Energy management was one of the sixteen principles focused on in the beginning of this video. This will be very important now, and in the future. One of the main reasons that it will be so prominent is due to climate change and all the negative impacts that it brings to the environment, and ultimately impacts all of us as humans. There are a few critical questions that manufacturing business must answer. One of these questions is how the business should align its product/process/service system design and manufacturing goals for greater flexibility and profitability. All the sixteen principles were brief revised and summarized.

Something in the video that stood out as something that must be implemented in my fifth company is bridging the knowledge gaps, using cross functional team building. This will be a big part of all manufacturing businesses going forward, and my fifth company will have to do it in order to be competitive in future markets. Another thing that stood out to me was autonomous machines in the factory, specifically, how do they impact the business in terms of efficiency, productivity, reconfigurability and profitability. This leads itself to the product/process/service system design and manufacturing goals. One thing that has been hammered home for me is the need for factories to be future ready, in terms of being able to adapt to new technological change and the ability to be flexible when achieving the manufacturing goals of the business.

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Video 3:

In this video inspection & sustainable green issues as well as material handling systems were discussed. What stood out here for me is not only the waste reduction aspect, but the better financial situation gained from these practices. 3D printing that was demonstrated in this video was very exciting for me, my 5th company will be implementing this technology. The proper name is additive manufacturing, due to the way the manufacturing occurs, by adding layer upon layer. This method of manufacturing opens many avenues that would not have been possible, as recent as 10 years ago. Additive manufacturing can also give designers more freedom when creating the new products and processes for the future. One of the main benefits of the additive engineering is creating lightweight alternatives that can offer better function.

Continuous inspection of products is an important aspect of manufacturing that assures quality and standards. My fifth company will implement continuous inspection at all stages of our manufacturing process in our manufacturing facility, in addition to inspection internally at each stage of the manufacturing process. This will ensure that my company produces a high quality, zero defect tool. If defects are detected, the source can be quickly traced and the issue resolved promptly, resulting in a lower loss of resources and a more efficient factory. Some parts on my company’s products will have to be additively manufactured, this is due to the cutting-edge nature of my product, resulting in new methods of manufacturing being required to manufacture and assemble the final product.    

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Video 4:

Video four began with materials handling systems, robotics and automation. Materials handling process improvement was discussed, the importance of it in a factory space being emphasized immensely. By consolidating and reducing the amount of unnecessary waste with respect to storage and wasted space due to an ineffective factory layout can lead to improvements in a company’s bottom line, as well as a better green company that is not as impactful on the environment by being more efficient in its operations. 

My fifth company will use the space in our factory and storage facility effectively, by creating usable space, that is space that can be useful in some manner. This will be accomplished by the layout my company chooses and where we place our materials handling equipment, to create as little wasted space as possible, thereby creating as much usable space as possible. My company will opt for the lowest possible materials handling, because the more handling that goes into the product, the less efficiently it is being produced. In other words, our products will be manufactured in such a way that the manufacturing moves the products through the factory (an example could be a movable drilling machine that transports a part, whilst machining it. Another idea that will be implemented in my fifth companies manufacturing process is consolidate work cells, this will incorporate smallest possible movement for the maximum possible value. Lastly, my fifth companies manufacturing robots will combining vision system and sensor operation for maximum efficiency and minimum waste.

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Video 5:

In this video, CNC machines were discussed at length. A lot of in-depth explanations of the technical aspects, that is the computer system controlling the CNC machines. CNC machines are essential in any manufacturing facility. My fifth company will use a CNC machine for parts on all our models, and our workforce will be trained to be proficient in the use of the CNC machine we will have in order to deliver the highest quality product, whilst ensuring the least possible depreciation on the machine (this include wear and tear, as well as preventative maintenance and future proofing training for machines).

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Video 6:

Focused on showing “un-green” engineering and business. My fifth company will have a big focus on green engineering, both in our factory and our products. Our product is actually completely self-powering, it is a fully self-sufficient unit that come complete with its own power generating unit that can supply enough power to sustain the machine, as well as power essential parts of our customers site during power outages. Our factory/manufacturing plant will also be completely off the grid, and power the operations of all my company’s business, including the admin blocks. One way our company will also be reducing our environmental impact even further is by the use of capacitors. Capacitors are devices that can store electrical energy and supply it back into a system at a later time, similar to a batter. Where capacitors and batteries differ is that capacitors can store the energy in a system, from let’s say a robot’s arm returning to a position, whereas a battery supplies electrical energy from chemical reactions that occur inside the battery.

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Video 7:

Video seven was focused on robotics and the different applications of robotics. The video showed the great variability and versatility that this technology possesses. There are still some limitations of robotics, some things that robots simply cannot do, or are not yet advanced enough to complete effectively and efficiently for a business to run where it can make a profit both financial and environmentally.

My fifth company will utilize this technology in our production and materials handling processes. In some instances, the robotics technology operates at a much faster pace than a human worker can. This technology is also much more reliable than a human worker, with repeatability very high and faults highly uncommon. Robotics is very versatile and flexible; this will be needed to cope with my fifth company’s fast pace and evolving industry competitiveness. One aspect that was demonstrated in the videos was the use of capacitors to provide more utilization of energy and energy retention in the system, reducing our environmental impact even further. Many of the robots shown in the video had interchangeable heads, therefore making the robots able to accomplish multiple different tasks in single workstation. This will also be combined with proximity and force sensing, in order to enable robot and human collaboration in the manufacturing space.

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Video 8:

Video eight focused on the 2019 New York car show. This video illustrated design and consumer safety and satisfaction. The car industry is a prime example of companies designing with the safety of the consumer/customer as one of the most important design factors. Customer/consumer satisfaction is also of paramount importance. Another aspect that came into play was green engineering/technology. In the modern age cars are becoming more environmentally friendly and have less of a carbon footprint, in the design, manufacturing, as well as usability phase of the products life.

My fifth company is primarily built on green energy and being completely self-sustainable, using only solar, wind and hydro-electric power to manufacture our products, as well as run our business. In addition to that, the products we sell to our consumers have been thoughtfully designed to minimize the environmental impact from design, manufacturing and operation. This will be achieved by ergonomic design and the complete power solution that is the M1 aircraft manufacturing machine. The machine will utilize a combination of solar, wind and hydro-electric power, coupled with capacitors and backup batteries to ensure that our customers can manufacture their products without any disturbances. All of these factors enable our customers to achieve their goals.

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CNC:

The following is an example of a code supplies by Prof. Paul Ranky. This CNC code is its own language and has its own rules. The % signs at beginning and end show that the code is all one operation and should be executed together. Other terminology can be logically discovered as to what they do, for instance, "thk." means thickness and "tool length offset" means the computer is accounting for the length of the tool in its calculations

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%
N10 O02215
N20 (Haas MiniMill Demonstration)
N30 (G54 is X Y Part Zero)
N40 (X Y Part Zero is the CENTER of the part)
N50 (Material is 4" long by 2 1/2" wide by 1/2" thk. aluminum)
N60 (Part will be profile milled to 2.200 wide by 3.700)
N70 (Set Z tool offsets T1 T2 T3 on the top of the part)
N80 (D01 is Cutter Comp for T1 .250)
N90 (T1 1/2" 4 flute End Mill)
N100 (T2 1/2" Spot Drill)
N110 (T3 #3  Drill   .213 Dia.) 
N120 (Press Option Stop for M1)
N130 G17 G40 G80 G98 (circ motion xy plane, cutter comp cancel, can cycle cancel,  R plane return)
N140 G28 G91 Z0 Y0 (machine home, incremental programming)
M01 (optional stop)
N150 (T1 1/2" End Mill)
N160 T1 M06  (tool change to T1)
N170 S2200 M03  (Spindle start, 2200 RPM)
N180 G00 G90 G54 X-2.350 Y1.700 (rapid move, absolute programming, work offset)
N190 G43 H01 Z1. M08 (tool length offset, move, coolant on)
N200 G01 Z-.150 F50. (linear move @ 50 IPM)
N210 (Begin to Mill Profile)
N220 (Activate Cutter Compensation)
N230 G42 X-1.850 D01 F50. (tool offset right, move @ 50 IPM)
N240 G01 Y-.600 F10. (move 10 IPM)
N250 G03 X-1.350 Y-1.100 R.5 (circular interpolation ccw, cut ½ radius)
N260 G01 X1.600 (linear move)
N270 G03 X1.850 Y-.850 R.25 (circular interpolation ccw, cut ¼ radius)
N280 G01 Y.430 (linear move)
N290 G01 X1.5375 Y1.100 (linear move , cut angle)
N300 G01 X-2.350 (linear move)
N310 (Deactivate Cutter Compensation)
N320 G40 G01 X-2.550 F25. (cutter comp cancel, move 25 IPM)
N330 G01 Z.100 F50. (linear move 50 IPM)
N340 (Mill 1.000 X .750 Pocket)
N350 G00 X.675 Y.125 (rapid move)
N360 G01 Z-.150 F8. (linear move 8 IPM)
N370 G01 X1.175 (linear move)
N380 G01 Y-.125 (linear move)
N390 G01 X.675  (linear move)
N400 G01 Y.125  (linear move)
N410 G01 Z.100 F50. (linear move, 50 IPM)
N420 G00 Z1. M09  (rapid move, coolant off)
N430 G28 G91 Z0. Y0. M05 (machine home, incremental, spindle stop)
M01 (optional stop)
N440 (T2 1/2" Spot Drill)
N450 (Spot Drill 4 places)
N460 T2 M06 (tool change)
N470 S2000 M03  (spindle start 2000RPM)
N480 G90 G54 G00 X-.500 Y.500  (incremental programming, rapid to 1st hole location)
N490 G43 H02 Z1. M08  (tool height offset, move, coolant on)
N500 G01 Z0.1 F50.  (linear move 50 IPM)
N510 G83 G99 Z-0.110 Q0.020 R0.1  F6. (canned drill peck cycle, depth of peck, return plane)
N520 X-1.500  Y.500 (move to 2nd hole)
N530 X-1.500 Y-.500 (move to 3rd hole)
N540 X-.500 Y-.500  (move to 4th hole)
N550 G80 G00 Z1. M09 (canned cycle cancel, rapid move, coolant off)
N560 G28 G91 Z0. Y0. M05 (machine home, incremental programming, spindle stop)
M01 (optional stop)
N570 (T3  Drill #3 holes)
N580 (Drill 4 places)
N590 T3 M06 (tool change)
N600 S2200 M03 (spindle start 2200 RPM)
N610 G90 G54 G00 X-.500 Y.500 (incremental programming, rapid to 1st hole location)
N620 G43 H03 Z1. M08 (tool height offset, move, coolant on)
N630 G01 Z0.1 F50. (linear move 50 IPM)
N640 G83 G99 Z-0.600 Q0.075 R0.1  F8. (canned drill pec cycle, depth of peck, plane return)
N650 X-1.500  Y.500 (move 2nd hole)
N660 X-1.500 Y-.500 (move 3rd hole)
N670 X-.500 Y-.500 (move 4th hole)
N680 G00 G90 Z1. M09 (rapid move, absolute programming, coolant off)
N690 G28 G91 Z0. Y0. M05 (machine home, incremental programming, spindle stop)
M30 (end of program)
%

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IE computer graphics applications in the real-world?

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At Bevan Machinery we are committed to ethical practices.

Bevan Machinery is committed to being ISO 14000 certified, ISO 14000 is a family of standards related to environmental management that exists to help organizations;

1. Minimize how their operations negatively affect the environment (i.e. cause adverse changes to air, water, or land),

2. Comply with applicable laws, regulations, and other environmentally oriented requirements,

3. Continually improve in the above.

In addition, Bevan machinery will be going above and beyond. Our entire plant will not only be carbon neutral, but will provide green energy back into the grid, reducing the load and providing green energy to reduce the need for environmentally harmful energy production sources.

Our products are entirely self sufficient and green energy producing. This means our customers are becoming better for the environment by choosing to use Bevan Machinery.

ISO 9001 sets out the criteria for a quality management system and is the only standard in the family that can be certified. It can be used by any organization, regardless of its; size, field of activity and interests. There are over one million companies and organizations in over 170 countries certified to ISO 9001.

This standard is based on a number of quality management principles including a strong customer focus, the motivation and implication of top management, the process approach and continual improvement. These principles are explained in more detail in ISO’s quality management principles. Using ISO 9001 helps ensure that customers get consistent, good-quality products and services, which in turn brings many business benefits.

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ANSI – American National Standards

Bevan Machinery will also be accredited by ANSI, American National Standards. ANSI has a mission, “to enhance both the global competitiveness of U.S. business and the U.S. quality of life by promoting and facilitating voluntary consensus standards and conformity assessment systems and safeguarding their integrity. Encompassing nearly every industry, the Institute represents the diverse interests of more than 270,000 companies and organizations, and 30 million professionals worldwide.”

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Social Networking:

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Sustainable water supply PDF:

Water is essential for life. It is not only unethical what big business are doing to the water that all the people of the world have to consume in order to remain alive. This is also an ethical matter, because it is not exactly ethical of big businesses to be doing this, yet it is because they are big businesses that they can get away with it.

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Climate change solving all issue at the same time:

It was surprising to learn all the ways that climate change action can solve all the issues the world is currently experiencing.  

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A380 being discontinued:

With every death of an iconic airplane, there is a new star that replaces it and will become the next icon. The A380 program at Airbus was having financial difficulties and the planes design is no longer functional for what modern airlines are moving towards in the future. All the big airlines are going for 2 engine long range models, like the 777x or A350, that can still carry lots of people, but are way more efficient and cost effective for big carriers.