Q1) Manufacturing process design

For this process design related problem, a process for manufacturing looking a handle part, which is 6061 aluminum component, must be developed that is cost effective, and produces high quality parts. The projected volume for this part 250000 and 500000 parts per year for 3 years. If the product line is expanded, the production will double after this time. The facility is open 50 weeks in the year, and in the year, and is a two-shift operation, 8 hours per shift.

You must develop a comprehensive process plan to manufacture this part, after analyzing the problem, management must be informed of your final decision in order to implement your solution. How would you go about determining an effective process plan to sell to the management team? You need to make assumption, and preform calculation based on your assumption and support your argument. You may suggest ‘ design for X' improvements.

• State your assumption
• List the key elements that you would focus on.
• What information would you require that is not provided in this question that is necessary for a complete, detailed answer?
• Prepare an operation sequence with the appropriate information
• You don't need to determine detailed information but list processes/features/parameters of concern which would influence your outcome.

Given:

-Material for the handle: 6061 Aluminum

-Number of parts to be manufactured 250000 to 500000 parts each year

-After three years volume of manufacturing 750000 to 1500000 parts per year.

- 50 weeks of working in a year , and two shifts

- 8 hours for one shift.

- facility operates 16 hours/ day find:

-comprehensive process plan

- analyze the problem

-make assumption

- preform calculation based in your

- you may design for X for improvement

-list key elements that you would focus on

- what information would you required that is not provided in this this question that is necessary for a complete answer?

Q2) select process and generate process plan (flow chart , built list) for the following part based on the information provided in table 1. Clearly state all assumption and justify your selections.

What additional information should be added to drawing? What should be modified, or additional information required reducing processing time and costs initial assumptions

• All general tolerance are +/0.5 mm

• Machine time 100.00 $ /hr

• Labor costs: 50$/hr (including benefits )
• Assume other process production related costs using the machining process a reference

• Carbide tool are 4 X more expensive than HSS tools

Q3) Introduction the RT. Hon. Herb gray Parkway

The RT. Hon. Herb Gray parkway(formaly the Windsor Essiex Parkway) is a majore $1.4 billion highway infrastructure project under construction in the municipalities of Windsor. Lasalle and Techumseh in Ontario Canada. This once- in- a generation undertaking that will improve traffic flow at Canada's premier trade gateway is unprecedented in its community enhancement and environmental features for any highway in Ontario.

Q4.1) at each bridge there will be sign with a label such as brave or honesty that will be laser cut with the words presented in English or French. Each bridge crossing sign will also have a symbol such as a deer or bear also included. Why would they use laser cutting? What would you consider as process alternative ?explaine your answer.

Q4.2) At various points in the bridge/ support structure some letters and words are molded? How is the letter Y (illustrated here )made? Explain all of the process steps.

Q4.3) Obviously there will be welding operation associated with the infrastructure development. What welding operations would you expect? What type of joints would be used? What other factors need to be taken into consideration? Provide (2) appropriate welding symbols complete with ‘ best estimate' relevant information, and explain why choses these.

Q5) Advanced Manufacturing and traditional manufacturing

You have been exposed to many process in this course. Make a table to compare and constracts traditional and advanced manufacturing processes. Consider capabilities, flexibility or expandability, cost, material types and their mechanical & physical characteristic required in- process planning requirements, expertise quality, time, and skills, use sketches to illustrate key discussion points. Hint: use your lab and project for example.

Q6) manufacturing process selection

A small job shop has hired you as a manufacturing engineer and your company requires some expertise related to subcontracting work, and/ or expanding the existing facilities. This company manufactures a verity of different products. The volume range from 1 to 1000 pieces per order, but can vary to accommodate slightly higher volume. The products contains of (2)basic mills which have no CNC controls,(1) lathe, (1) drill presses, (2) band saw, (2) surface grinders and other related manual equipment/tools that are necessary to produce a Varity of components. Because of increasing competition, cost and time reduction challenges and other related issues must be addressed, and potential new business needs to be generated. The owners have asked you to generate a plan to upgrade the facilities to develop a supply base. They wish to focus on non-conventional processes as well as improving upon the recourses that they already have - what processes should they consider?

Consider the following elements

a) identify that main focus areas that you would target, and justify why. Consider both products and fabrication related aspects ( hint: areas of application for each process, considering feature capability , surface finish, surface geometry, surface integrity, material removal rate , environmental issues, and skill requierments)

b) identify that anticipated tangible and intangible benefits and savings to be used by management for both strategic and economic justification for your proposal.