Advanced Production Engineering

1
Advanced Production Engineering

• Heini Käyhty
• heini.kayhty_at_lut.fi
• http//www.lut.fi/kayhty

2
Acme Ltd.

• Subcontracting machine shop
• Production machinery
• stand alone NC-lathe (Okuma LC20)
• stand alone vertical machining center (VMC) with
  automatic pallet changer (APC) and two pallets
  (Leadwell FMC1)
• hydraulic press for reamers
• sawing-machine
• different manual tools for deburring etc
• EdgeCAM CAD/CAM software
• Two work shifts. Both employing 2 employees.

3
Background

• Acme Ltd has been asked to make an offer to
  produce a new part. See attached drawing!
• Need for the new part is 1500 pieces per month.
• Need is expected to grow up to 2500 pieces per
  month in near future.
• 5 years contract (minor product modifications are
  possible)
• Material for the new part is Imatra 520 (SFS-EN
  100251994-S355J2G3)

4
Project Work

• Work groups every group includes 2 persons
• Your task is to prepare an offer!
• You have to investigate following matters
• Different manufacturing methods
• Manufacturing costs
• Manufacturing capacity
• Need for new manufacturing machinery
• Need for new employees
• Raw material? Pre cut vs. bar

5
Report

• Dead line for the report is 10.12.2004
• You have to include following topics in your
  report
• Flow chart from manufacturing process and
  production plan (tools, machining data, fixtures
  etc )
• Manufacturing costs based on real manufacturing
  time and actions (EdgeCAM or manual calculation)
• Availability of manufacturing capacity and
  employees
• Need for new manufacturing equipments and
  employees
• Discussion how to make manufacturing more
  profitable (level of automation, different
  manufacturing methods, lay-out etc )
• If you use any references they have to be given
  in the end of your report

6
Tools to Use

• Drawing from offered part
• EdgeCAM software
• Tool manuals Seco, Sandvik,
• AB Sandvik Coromant Modern metal cutting a
  practical handbook
• Books, magazines and internet