Walla Walla University
School of Engineering

ENGR480 Manufacturing Systems Engineering

Spring 2009

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: Mechanical Assemblies by Daniel Whitney

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:

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 base on the value of the contribution of each team member.
Memos and Reports - Most of your work will be documented in memo and report format. Grading will be on content, writing quality, and persuasiveness.
Quizzes, homework, and tests - I will use some more traditional forms of evaluation from time to time as needed.
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.
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.
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.
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:

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
Automation Direct DL06 PLC manual
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. 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) 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.

Approximate Schedule

Week	Date	Time	Topic	Reading
1	Mar 30	10:00	Analyzing Product and Process	Mech Assm Ch.1
	Mar 31	2:00	Lab - machine inspection & disassembly
	Apr 1	10:00	Machining - basic ops
	Apr 3	10:00	Machining - setup
2	Apr 6	10:00	Machining - feeds & speeds
	Apr 7	2:00	Lab - Nelson Irrigation Tour
	Apr 8	10:00	Machining - turning
	Apr 10	10:00	Machining - milling
3	Apr 13	10:00	FeatureCAM	FC Getting Started
	Apr 14	2:00	Lab - CNC Turning
	Apr 15	10:00	FeatureCAM	FC Getting Started
	Apr 17	10:00	FeatureCAM	FC Getting Started
4	Apr 20	10:00	Part Feeding	Mech Assm Ch.17
	Apr 21	2:00	Lab - Assembly Machine Design
	Apr 22	10:00	Key Characteristics	Mech Assm Ch.2
	Apr 24	10:00	Mathematical Modelling of Assm	Mech Assm Ch.3
5	Apr 27	10:00	Mathematical Modelling of Assm	Mech Assm Ch.10,11
	Apr 28	2:00	Lab - Machine fab & Assembly
	Apr 29	10:00	Generating Motion
	May 1	10:00	Sensors
6	May 4	10:00	Relay Logic
	May 5	2:00	Lab - Machine Assembly
	May 6	10:00	Relay Logic
	May 8	10:00	PLC - state machines	DL06 UM Ch.5
7	May 11	10:00	PLC - Wiring and I/O	DL06 UM Ch.1,2
	May 12	2:00	Lab - Machine Wiring
	May 13	10:00	PLC - state machines	DL06 UM Ch.7
	May 15	10:00	PLC - program editing	DL06 UM Ch.1,2
8	May 18	10:00	PLC - programming
	May 19	2:00	Lab - Machine Wiring & Programming
	May 20	10:00	Animatics/Robohand motion controller	SmartMotor Manual
	May 22	10:00	Animatics/Robohand motion controller	SmartMotor Manual
9	May 25		Memorial Day
	May 26	2:00	Lab - Machine Programming
	May 27	10:00	PLC/Motion controller coordination
	May 29	10:00	Writing memos and reports
10	June 1	10:00	Assembly sequencies
	June 2	2:00	Lab - Final testing
	June 3	10:00	Additional topic
	June 5	10:00	Additional topic
11	June 8	2:00	Final project demos/Final Quiz

Walla Walla University School of Engineering