Walla Walla University
School of Engineering

ENGR480 Manufacturing Systems Engineering

Spring 2010

Facts:

• Instructor: Ralph Stirling
• Office: CSP262, 527-2071, ralph.stirling@wallawalla.edu
• Class: 10:00 - 10:50AM MWF CSP165, Lab 2-5PM T KRH105
• Webpage: http://engr.wallawalla.edu/engr480
• Text: Machinery's Handbook, Industrial Press

Important Background:

• Basic circuit analysis - if you have forgotten all your Circuits, you may have trouble in this class - review will be in order.
• Instrumentation - if you were completely baffled by sensors and signal conditioning, you may have trouble in this class.
• Machine Design and Advanced CAD - you will need to design a lot of fixtures and parts for the lab project.
• Materials & Processes - if you slept through M&P, you missed important information about machining, which you will need to put into practise in this class.

What you will learn in this course:

• What manufacturing is all about.
• How to automate the handling and creation of parts.
• How to make nifty mechanical widgets that actually do things.
• How to use pneumatics.
• How to do manual and CNC machining.
• How to wire electrical controls.
• How to program a PLC to make your machine "think".

What your grade will be based on:

1. Project - The majority of credit in the class will be based on a large, quarter-long, team lab project. This project will involve the design, fabrication, assembly, programming, wiring, testing, and documenting of an automated production machine. Each team will consist of four students, chosen by me. Each team will be given a grade on their project quality and on their documentation quality, and an individual weighting factor will be applied based on the value of the contribution of each team member.
2. Memos and Reports - Most of your work will be documented in memo and report format. Grading will be on content, writing quality, and persuasiveness.
3. Quizzes, homework, and tests - I will use some more traditional forms of evaluation from time to time as needed.
4. Reading - you will receive 2% extra credit for reading an article each week from a trade magazine or journal, such as Manufacturing Engineering, Design News, Machine Design, Industrial Automation, Modern Machine Shop, or ASME or SME publications. Either print or online editions are acceptable. The CNC Forum on http://www.practicalmachinist.com is also very useful. Just send me an email each week telling me what article you read.
5. Attendance - Marginal grades may be decided by attendance record. Attendance means full engagement in classroom activities, not just physical presence. Surfing the web, texting on your phone, reading email, or playing solitare does not constitute attendance.
6. Shop safety - Your grade may be penalized if you cause an accident in the shop or lab that results in injury to anyone or damage to equipment, through negligence, ignorance, or carelessness.
7. Grade thresholds will be approximately: A: 95%, A-: 90%, B+: 85%, B: 80%, B-: 75%, C+: 70%, C: 65%, C-: 60%, D:55%

Useful Supplemental References:

• Automation Direct DL06 PLC manual
• Designing Technical Reports by J.C.Mathes and Dwight W. Stevenson
• Pneumatic Systems - Principles and Maintenance by S.J.Majumdar
• Metal Cutting Principles by Milton Shaw
• A Study of the Toyota Production System by Shigeo Shingo
• Industrial Automation and Process Control by Jon Stenerson
• Computer Numerical Control: Operation and Programming by Jon Stenerson
• Getting Started Manual - FeatureCAM

Special Considerations:

If you have a learning disability or otherwise need special consideration, please contact the appropriate campus office and have them discuss your needs with me. Since you are all seniors, I assume you will know this process by now if you have such a problem.

Notes on Laboratory and Shop Usage:

• CLEAN UP after yourself as soon as you have finished an operation. Put aluminum chips in the barrel marked ALUMINUM, and steel chips in the barrel marked STEEL. Mixed scrap goes in the trash. There are brooms and brushes in both lab and shop, and a shop vacuum available. There may also be a webcam in the shop for me to monitor the condition of the room before and after use.
• PUT TOOLS AWAY. Learn where tools are kept and return them when you are done using them each day. Keep materials you are working on under your lab station, but don't hoard.
• USE SAFETY EQUIPMENT. Eye shields and ear protectors are provided to help protect you when using machinery. Please use them! Don't wear long sleeves or long hair when working on machines. Clamp work down, remove chuck keys, and use proper feeds and speeds.
• ONLY USE MACHINES YOU ARE FAMILIAR WITH. No power tool is to be used until you have been checked out on it first by Tim Rasmussen (lab assistant), Wes Brown, or myself. The shop courses taught by the Department of Technology are highly recommended as preparation. You may also have parts fabricated by Technical Support Services.
• KEEP E-STOPS PRESSED except when machine or robot is actually in use. This is especially important with Ethernet controlled devices.

Approximate Schedule

Week	Date	Time	Topic	Reading
1	Mar 29	10:00	Machining - basic CNC	Machinery's Handbook - Numerical Control Programming
	Mar 30	2:00	Lab - CNC Turning
	Mar 31	10:00	Machining - CNC boring and threading	Machinery's Handbook - Numerical Control Programming
	Apr 2	10:00	Machining - CNC turning cycles	Machinery's Handbook - Numerical Control Programming
2	Apr 5	10:00	Machining - CNC boring/threading exercise
	Apr 6	2:00	Lab - Flashlight machining
	Apr 7	10:00	Part Feeding
	Apr 9	10:00	Generating Motion - pneumatics
3	Apr 12	10:00	Generating Motion - servo actuators
	Apr 13	2:00	Lab - Nelson Irrigation Tour
	Apr 14	10:00	Sensors
	Apr 16	10:00	CNC Milling - Pro/E
4	Apr 19	10:00	Relay Logic	Machinery's Handbook - Numerical Control
	Apr 20	2:00	Lab - Assembly Machine Design
	Apr 21	10:00	Relay Logic
	Apr 23	10:00	PLC - wiring and I/O
5	Apr 26	10:00	PLC - state machines
	Apr 27	2:00	Lab - Machine Fab & Assembly
	Apr 28	10:00	PLC - state machines
	Apr 30	10:00	PLC - program editing
6	May 3	10:00	PLC - programming
	May 4	2:00	Lab - Machine Assembly
	May 5	10:00	Animatics/Robohand motion controller
	May 7	10:00	Animatics/Robohand motion controller
7	May 10	10:00	Motoman robot controller
	May 11	2:00	Lab - Machine Wiring
	May 12	10:00	Motoman robot controller
	May 14	10:00	PLC/motion controller coordination
8	May 17	10:00	PLC/motion controller coordination
	May 18	2:00	Lab - Machine Wiring & Programming
	May 19	10:00	Flexible manufacturing - stock feeding
	May 21	10:00	Flexible manufacturing - parts unloading
9	May 24	10:00	Toyota Production System
	May 25	2:00	Lab - Machine Programming
	May 26	10:00	Writing memos and reports
	May 28	10:00	Additional Topic
10	May 31		Memorial Day
	June 1	2:00	Lab - Final testing
	June 2	10:00	Additional topic
	June 4	10:00	Lab Cleanup (attendance taken)
11	June 7 (Monday)	10:00	Final project demos/Final Quiz