Peter L. Jackson
School of Operations Research and Industrial Engineering, Cornell University
Richard Warkentin
Sibley School of Mechanical and Aerospace Engineering, Cornell University
Abstract: An experiential learning module (OPTLINE) has been developed to allow students, through simulation, to modify the design and operational parameters of a manufacturing line with the objective of achieving maximum economic efficiency. OPTLINE features a graphical interface with a high-level modeling language, a detailed model of casting, drilling, and turning operations, and an integrated Design of Experiments module. The module runs from a networked database so it is possible to illustrate concurrent engineering by assigning teams of students to design different parts of the manufacturing line and coordinate their designs through the database.
Introduction: Typical exercises in a course on manufacturing processes focus on process parameters and illustrate only limited process relationships. For example, students may be required to compute the size of the riser required to ensure adequate filling of a casting. Economic issues typically are not addressed. On the other hand, a typical course in engineering economics will avoid engineering design details and will instead focus on cash flow analysis. If an exercise in engineering economics used casting as an example, the volume of material required by the casting would be stated in the problem. In reality, manufacturing engineers make a host of design and operational decisions that have important economic consequences as well as complex interactions. Manufacturing competition is based on optimizing these systems. Students in both courses need to develop a systems view of these interactions and an appreciation for the analysis that is required to conduct global optimization.
Acknowledgments: This work was supported by a grant from the National Science Foundation Product Realization Consortium.
References:
Flinn. Fundamentals of Metal Casting, 1963.
G.E, Turning Handbook of High-Efficiency Metal Cutting, Carbology Systems 1980
MDC, Machining Data Handbook, Vol.2 1980.
OPTLINE v2.0
Lorace L. Massay
Richard Warkentin, Cornell, rw19@cornell.edu
Peter Jackson, Cornell, pj16@cornell.edu
To help students understand the connection between the physical and economic design of manufacturing processes linked in a manufacturing system. Also to provide them with a demonstration that in the systems analysis that is required to design a 'good' manufacturing system, local optimization is inferior to global optimization.
Seniors and M.Eng students in Mechanical Engineering and Industrial Engineering. Could be used by seniors and M.Eng. in all engineering disciplines with interest in manufacturing processes and their economics.
MAE 511, Survey of Manufacturing Processes (Spring 10 Students)
ORIE 451, Economic Analysis of Engineering Systems (Spring 100 Students)
MAE 464, Design for Manufacture (Fall, 85 Students)
Typical exercises in a course on manufacturing processes focus on process parameters and illustrate only limited process relationships. For example, students may be required to compute the size of the riser to ensure adequate filling of a casting without giving due consideration to the economic impact of their selection. On the other hand, a typical course in engineering economics will avoid engineering design details and will instead focus on cash flow analysis. If an exercise in engineering economics used casting as an example, the volume of material required by the casting would be stated in the problem. In reality, manufacturing engineers make a host of design and operational decisions that have important economic consequences as well as complex interactions. Manufacturing competition is based on optimizing these systems. Students in both courses need to develop a systems view of these interactions and an appreciation for the analysis that is required to conduct global optimization.
An experiential learning module (OPTLINE) has been developed to allow students, through simulation, to modify the design and operational parameter of a simple (three step) manufacturing line with the objective of achieving maximum economic efficiency. The processes have been modeled in considerable detail, for example in the turning operation the effect of surface cutting speed, feedrate , and insert geometry on surface finish is calculated. In addition, physical and economic relationships between the processes has been modeled so that local optimization of the individual processes is inferior to a global optimization approach.
The processing steps involved in manufacturing the shafts are sand casting (casting of molten metal in a mold made of sand), turning (machining of the cast piece on a lathe), and drilling. For each of these processes a graphically based training module has been developed which provides the user with information and guidance about the operation. The user is then required to enter information normally requested of the process engineer during the stages of process design. As will be experienced by the student, the selection of the process design parameters can have significant impact on the processing rate and quality of the part and that this impact may not be detected until subsequent processing is underway.
The processes have been modeled in considerable detail, for example in the turning operation the effect of surface cutting speed, feedrate , and insert geometry on surface finish is calculated. In addition, physical and economic relationships between the processes has been modeled so that local optimization of the individual processes is inferior to a global optimization approach.
i. Game (OPTLINE v2.0)
ii. Tutorial (notes and worked problems on casting and machining)
A minimum of 1 hour of instruction will be required if supported/supplemented with self-study/lecture notes to be developed as part of this module.
i. OPTLINE v2.0, PC based manufacturing simulation game.
ii. Casting and Machining lecture/self-study material in electronic format.
Feedback from faculty users and student questionnaire.
IBM compatible with 486 or Pentium chip preferred and 8M of memory running Windows for OPTLINE v2.0.
Lecture notes will be created in Microsoft Word for Macintosh v5.1a. (Compatible with Microsoft for Windows v5.0).
Presentation at annual Cornell Workshop in Experiential Learning for Manufacturing Systems Design; free distribution of materials to workshop participants
