M32064 – Manufacturing System Design

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Academic Year 2020/21
M32064 – Manufacturing System Design
Coursework
Deadline For Submission:
22.01.2021. before 17:00h
Submission Instructions
Submit the work in a written report via Moodle together with
Enterprise Dynamics simulation files.
Instructions for completing the
assessment:
The work involves a design of a complex production system in a virtual
environment with solutions developed and submitted in a report via
Moodle. The length of the report is suggested no more than 2000
words.
Examiners:
Dr Luka Celent
Manufacturing System Design
2020-2021 Page | 1
Aims of this work
1. To develop a systematic understanding and critical awareness of sustainable manufacturing
systems, system design approaches and planning techniques applied to industry.
2. To enhance the acquisition of analytical knowledge and practical skills gained for analysing a
complex manufacturing process or system and their integration using advanced computer
design and modelling simulation tools.
3. To explore modelling simulation techniques to help create rapidly and turn innovative ideas
timely into systems design, analysis and improvement particularly for a constraint-based
production system in a virtual environment.
4. To become an expert in coping with the system uncertainty, examining the system random
behaviour, refining the system design, and developing alternative operational management
strategies based on the developed virtual prototyping system to a real industrial case study.
Unit learning outcomes
1. Critically appraise a systematic approach with lean thinking and apply it into analysis, planning,
design and performance evaluation of a complex production system.
2. Examine modelling techniques and mathematical approaches for capturing the deterministic
and stochastic behaviours of manufacturing and prototyping systems
Assessment strategies & instructions
The overall assessment strategy is designed to test problem solving capabilities through a case
study in a virtual environment using computer-aided design and modelling simulation tools to satisfy
LO1 and LO2, with solutions developed and submitted in a report. Each student is expected to develop
their own computer models, which will be checked and questioned by the supervisor as part of the
overall assessment.
The report should include the following information:
Unit Title
– Manufacturing System Design
Unit Code
– M32064
Your Student ID Number
Unit Lecturer: – Dr Luka Celent
Date/Month/Year
1) Introduction/Background (refers to page 2-3 and your own research work)
2) Main work (refers to page 3-4)
3) Discussions and conclusions
References (if applicable)
Appendix (if applicable)
Manufacturing System Design
2020-2021 Page | 2
Assignment
Background
In order to be competitive, modern products must be designed with a view to production methods in
which a production system should to be designed in a cost-effective way and the system is able to operate
at optimal or near-optimal conditions. Nevertheless, design of a production system can be a complex
process and any small change of the system design often makes a significant impact on the overall system
performance. In the real-world industry, implementation of the entire production system is often very
expensive and the cost of ‘getting it wrong’ can be very high. For these reasons, both system and product
designers need to work together to ensure a ‘right first time’ scenario. Virtual prototyping techniques
offer a potential solution to the major difficulties involved in design, analysis and performance evaluation
of a product and a production system providing a fast delivery of alternative solutions at a minimum of
cost. Nowadays, virtual prototyping techniques are commonly used in manufacturing sectors involving
some form of computer-aided design and modelling simulation activities.
Assignment & Tasks
This assignment is based on a case study of assembling loudspeakers on a production line that needs to
be investigated. A loudspeaker manufacturer has just upgraded its loudspeaker design by incorporating
some forged parts with improved magnetic characteristics for the unit, which has additional benefits of
reduced part count and part features to facilitate automatic feeding as well as ease of manual assembly.
Figure 1 shows the basic structure of a loudspeaker and Figure 2 illustrates what is known as the motor
unit assembly together with the voice coil. Figure 3 shows a cross-section through a typical loudspeaker.
The assembly of an entire loudspeaker is illustrated in Figure 4 and 5, respectively. The parts in the whole
assembly can be grouped into two different types namely:
1. “Soft” parts:

dust cap, the diaphragm, the spider and the coil
2. “Hards” parts (These are all in the ‘motor unit’ sub-assembly)

pole piece, the magnet and the top plate together with the frame
The proposed manufacturing facilities should as far as possible incorporate automation, however, it is still
anticipated that some of the ‘soft’ parts may be assembled manually. The aim is to produce one
loudspeaker every 20s over an 8hr working day and a 5-day week (1440 units/day, 7200 units/week). The
speakers can be sold at £5/unit, giving a potential turnover of £36000/week and £1800000/year.
After an initial investigation of the system, data collection and analysis, the following system parameters
have been identified and determined:






Conveyors will be used and it may be 5, 10, 15 or 20 m long.
Each frame arrives randomly and is loaded in position (manually) in NegExp 18s.
Each pole plate can be fed/assembled in LogNormal 17s, STD: 5-15%.
The magnet can be fed/assembled in LogNormal 19s, STD: 5-15%.
The top plate can be fed/assembled between 15-18s in a uniform distribution.
Manual assembly of the spider and coil by a worker takes a time of 35-45s in a uniform
distribution.
Assembly of the diaphragm takes an average time of 18s.
Manual assembly of the dust cap takes an average time of 16s.
At the magnetisation station: 20s.
At the automated test machine (ATM): 10s.
Fork-lift trucks may be used at the end of the production line and it may travel at 2m/s.





Manufacturing System Design
2020-2021 Page | 3
Figure 1. Loudspeaker construction
Figure 2. Motor unit assembly
Figure 3. Cross-section through a typical
loudspeaker
Figure 4. Engineering drawing of the assembly of the loudspeaker together with a 3D computer design
assembly
Manufacturing System Design
2020-2021 Page | 4
In addition, the following system elements, operational activities and relevant information are
suggested below:
1. Each finished loudspeaker will be individually bagged by a worker (s) after the ATM (automated
test machine). A robot might be used to pack the finish products into a container. Each container
should hold 36 loudspeakers and filled containers should be stacked and wrapped together in
groups of 4 before being taken away by a fork-lift truck (s) to the warehouse.
2. Feeders/hoppers can be replenished automatically inside/outside the normal working hours (you
decide this). This process involves unpacking parts manually and placing them on a single long
conveyor that runs to a centrally located robot which can intelligently pick up correct parts and
place these parts on short conveyors running to each feeder. The robot can run with a cycle time
of 1.2s. Each worker can place individual parts on the conveyor in NegExp 4s; it needs to keep the
number of workers to a minimum. The operating time of this conveyor must also be kept to a
minimum since it involves the additional cost of overtime and/or part-time workers.
3. Fully assembled loudspeakers are passed through an automated test machine (ATM) where 1%
of inspected units do not comply with specifications and are removed for rework – rework is not
part of the study.
4. An eco-friendly and safe shop floor/workshop design is encouraged.
Equipment Reliability
The following information is known about the breakdown and repair of equipment:
Item
MTBF [hr]
MTTR [hr]
Feeders
40
0.5
Robots
180
2.0
Stacker/Wrapper
300
1.5
Conveyors
4000
3.0
Fork-Lifts
300
2.0
Magnetiser
3000
4.0
ATM
2000
4.0
Others


TASK
You should attempt to complete the following tasks:
1. Provide a background/knowledge of the loudspeaker-related product and production through a
literature study.
2. Create a process plan for assembly of a loudspeaker using ‘pre-manufactured components’. Suggest
suitable assembly sequences that would benefit from automated and/or manual operational
processes.
3. Produce a drawing incorporating your proposed facility layout design based on the logic sequences
of assembly within a boundary (with assumptions in Note) and justify your design by considering such
as space utilisation; ease of operations and services; reduction of temporary storage areas or buffer
zones, transport/human operator motions; safety; costs etc.
4. Build a full system model using Enterprise Dynamics (ED) software by incorporating 3D objects (if
applicable) and all the necessary statistical values; test and verify the functionality of the developed
ED models.
5. Design and run suitable experiments with the developed ED models; collect, analyse and interpret
the generated simulation data including graphical simulation results to be presented in the report.
Manufacturing System Design
2020-2021 Page | 5
6. Evaluate system performance making any improvement that would be most beneficial to the system
design and explain why you consider these changes, which may be advantageous.
Note: Make your own assumptions due to any necessary data which may not be given or should not be
included in your particular case study. This may refer to such as the availability of factory space, location
of stores and so on. You may also consider how your system design may be able to cope with an increase
in demands as well as product variances in future.
Your work must be presented and illustrated in a written report. The report should be structured as
indicated at page 1 and it should include your own work with the relevant context, drawings and screencaptures and other materials. Please keep your report concisely below 4000 words.
Your work will be assessed according to the “marking criteria” as attached with this assignment.
Submission
A final report in writing must be submitted via Moodle by 22th January 2021 BEFORE 17:00. The report
must be submitted in the MS Word format. A late submission of the report and its assessment will apply
in accordance with Academic Regulations, University of Portsmouth, Academic Registry, 2012.
Assessor’s Evaluation Form – Manufacturing System Design
Mark Range
>70%
1st Class
60-69%
Upper 2nd
50-59%
Lower 2nd
40-49%
3rd Class
<40%
Fail
Weight
Mark
%
Weighted
%
Self-planning,
commitment &
management
Student has shown a
professional attitude
requiring little supervision
and working effectively.
Required minimal
assistance to
tackle problems and
managed
time well in progress
Worked well with
guidance
and direction but did not
show much initiative
Minimal efforts with
considerable
assistance
Poor self-planning;
limited attendance
0.20 x
Research
Reference to, and
thorough
assimilation of some
published research –based
papers in the field of study
Evidence of usage of
background knowledge in
this field through reading
published materials
Evidence of investigation
of
published materials in
the
relevance to this work
limited investigation of
sources
Inadequate or no
investigation;
unacknowledged
reliance on one
source
0.10 x
Analytical
work,
engineering
analysis
High standard with
professional analytical
work
Good amount of
structured
analytical work and
engineering
analysis
Some analytical work has
been done, but not
always
properly carried out or
interpreted.
Very limited analytical
work
and analysis
Inadequate or no
analytical work
0.10 x
Innovative
Ideas & Design
creativity, synthesis,
innovative thinking,
predictive judgement and
diagnosis
Confidence in use of ideas
and processes within the
field of study
Use of ideas and
processes
from the field of study
Evidence of some
assimilation of basic
concepts in the field of
study
Theory wrongly
applied to the work in
hand with little or no
analysis
0.10 x
Structure and
quality of
Report
Evidence of a professional
attainment in terms of the
coherent presentation of
the work; written report
concisely with the key
elements included
Written material fluent
and
soundly structured
Adequate structure,
average
quality
Material poorly
organised
and largely descriptive
Long on description,
with structure
inappropriate to
content
0.20 x
Evidence of
completeness,
evaluation and
understanding
of the delivered
work
A proper academic and
professional presentation
of the report in
completeness, evaluation
and reflection of outcomes
and engineering analysis
integrated with technical
aspects of the established
work.
Quality completeness and
critical evaluation of
outcomes and engineering
analysis; good
understanding of
computer
modelling simulation
techniques and the
developed computer
models
Evidence in
completeness
and evaluation of
outcomes/alternative
solutions; understanding
of
the major issues of the
developed computer
models
Limited evidence in
completeness and
evaluation
of the reported
outcomes;
and understanding of
the
developed computer
models
No real evidence of
completeness,
evaluation and
understanding of the
work
0.30 x
The mark is given ONLY to the student who has completed the simulation model on her/his computer,
and has submitted simulation files on the moodle.
SUM OF WEIGHTS
1
This marking is based on: Coursework/Report including attached models [√ ].
WEIGHTED OVERALL MARK
%

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