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| Course Description |
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| Course Name |
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Flexible Manufacturing Cells and Design Methodologies |
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| Course Code |
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MK-517 |
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| Course Type |
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Optional |
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| Level of Course |
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Second Cycle |
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| Year of Study |
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1 |
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| Course Semester |
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Fall (16 Weeks) |
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| ECTS |
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6 |
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| Name of Lecturer(s) |
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Prof.Dr. NECDET GEREN
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| Learning Outcomes of the Course |
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Knows the importance of flexible manufacturing systems (FMS) in production
Knows the principal components of flexible production systems
Knows the design process of flezible manufacturing cells (FMC)
Applies IDEF and similar techniques for functional decompositioning of a system
Determines the best solution for sub-functions of a manufacturing cell/system
Knows the techniques and methods for easing the design of FMC
Knows and applies creative thinking methods in FMC design
Selects the best configuration for overall design
Integrates hardware and software components of FMCs
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| Mode of Delivery |
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Face-to-Face |
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| Prerequisites and Co-Prerequisites |
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None |
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| Recommended Optional Programme Components |
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None |
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| Aim(s) of Course |
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Diferantiates flexible manufacturing cells (FMCs) from conventional manufacturing cells and provide techniques and methods to ease the design of FMCs |
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| Course Contents |
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INTRODUCTION
INTRODUCTION TO FLEXIBLE MANUFACTURING IN CIM
FLEXIBLE MACHINING SYSTEMS (FMS), ASSEMBLY AND INSPECTION SYSTEM
MATERIAL HANDLING AND STORAGE SYSTEMS;
AUXILIARY DEVICES IN FMS
SYSTEMS MODELING (STRUCTURED ANALYSIS AND DESIGN (SAD)
FM CELL AND SYSTEM OPERATION CONTROL STRATEGIES,
FMS and FMC DEVELOPMENT PROCESS
FMC DESIGN PROCESS
CASE STUDY |
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| Language of Instruction |
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English |
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| Work Place |
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Classroom |
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Course Outline /Schedule (Weekly) Planned Learning Activities |
| Week | Subject | Student's Preliminary Work | Learning Activities and Teaching Methods |
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1 |
INTRODUCTION, What do we mean by FMS- FMC- CIM, system modelling, generic CIM design model using IDEF |
Study chapter 1 and search into reference books and other sources. Learn machine/product design process and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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2 |
INTRODUCTION TO FLEXIBLE MANUFACTURING IN CIM; Overview, FMS design examples, |
Study chapter 1 and search into reference books and other sources. Prepare literature survey for FMC design process and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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3 |
FLEXIBLE MACHINING SYSTEMS (FMS), ASSEMBLY AND INSPECTION SYSTEMS; conventional product design, Design requirements of FMS design, summary of Concept |
Study chapter 2 and search into reference books and other sources. Prepare literature survey for Concept generation techniques and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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4 |
Summary of cell and system programming tasks, cell tooling and tool transportation, cell buffering, part transfer and storage, dynamic, real-time operational control. |
Study chapter 2 and search into reference books and other sources. Prepare literature survey for Desicion making and concept selection and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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5 |
MATERIAL HANDLING AND STORAGE SYSTEMS; Overview of general design concepts, AGV concept examples, automated storage and retrieval systems, |
Study chapter 3 and search into reference books and other sources. Prepare literature survey for "Requirement list" and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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6 |
AUXILIARY DEVICES IN FMS; Buffer stores, work mounting and modular fixturing design, and robotic assembly of modular fixtures for FMS, |
Study chapter 4 and search into reference books and other sources. Prepare literature survey for "FMS design domains"and "Machine selection techniques in FMS" , and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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7 |
SYSTEMS MODELLING (STRUCTURED ANALYSIS AND DESIGN (SAD), , a generic FMS design method based on the SAD technique (SADT/IDEF), DATA FLOW DIAGRAMS (DFD), introduction to DFD, |
Study chapter 5 and search into reference books and other sources. Prepare literature survey for "PROJECT PLANNING" techniques in FMS" , and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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8 |
FMS CELL AND SYSTEM OPERATION CONTROL STRATEGIES, FMS dynamic scheduling, FMS production control and scheduling, FMS scheduling rules, etc. |
Study chapter 6 and search into reference books and other sources. Prepare literature survey for "QFD in design" , and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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9 |
Midterm Exam |
STUDY all chapters and homework well |
Questions (vocational and/or problems) are asked to measure the knowledge on the subject |
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10 |
FMS and FMC DEVELOPMENT PROCESS, The FMC design environment, Design tools and techniques for mechanical design and integration. Design of methods and procedures for mechanical part. |
Study chapter 7 and search into reference books and other sources. Prepare literature survey for "DF(X) in machine design" , and prepare a short presentation |
Lecture presentations, discussions, listening-discussing short student presentations |
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11 |
FMC DESIGN PROCESS FOR MECHANICAL PART; Design and selection of mechanical parts, machine selection techniques |
Study Given articles and 2nd reference book, and other sources. Prepare literature survey for "decompositioningin machine design" , and prepare a homework for "Bike decomposition" |
Lecture presentations, discussions, listening-discussing short student presentations |
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12 |
Design of cell controller architecture, Integration and interfacing. |
Study Given articles and 2nd reference book, and other sources. Prepare literature survey for "decompositioningin machine design" , and prepare a homework for "Bike decomposition" |
Lecture presentations, discussions, listening-discussing short student presentations |
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13 |
CASE STUDY; Design of a Flexible Robotic Printed Circuit Board Assembly (PCBA) Rework (remanufacturing) Cell; problem definition, intoduction to PCBA manufacturing |
Study Given articles and 2nd reference book, and other sources |
Lecture presentations, discussions, listening-discussing |
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14 |
PCBA rework, rework technology and rework tools, requirements of rework, generating flexible PCBA rework cell concepts, concept selection, tools and devices for concept, design and manufacturing of the concept, results. |
Study Given articles and 2nd reference book, and other sources |
Lecture presentations, discussions, listening-discussing |
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15 |
FINAL Exam |
STUDY all chapters and homework well |
Questions (vocational and/or problems) are asked to measure the knowledge on the subject |
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16/17 |
RE-FINAL Exam |
STUDY all chapters and homework well |
Questions (vocational and/or problems) are asked to measure the knowledge on the subject |
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Required Course Resources |
| Resource Type | Resource Name |
| Recommended Course Material(s) |
 Flexible manufacturing cells and systems ın CIM, P. G. Ranky, CIMware
Structured Analysis and System Specification, Tom DeMarco
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| Required Course Material(s) |
Leondes C (2001) Computer-aided design, and manufacturing systems techniques and applications, in: Geren N (ed) The Design of Manufacturing Systems, Model-based flexible PCBA rework cell design Chapter 6 vol. V. CRC press Boca raton FL, pp 1-44
Engineering Design G. E. Dieter, L.C. Schmidt, 5th Edit. McGraw-Hill
Manufacturing system design and analysis B.WU, Chapman and Hall
R.V. Rao, Decision Making in the Manufacturing Environment, Using graph theory and fuzzy multiple attribute decision making methods, Springer-Verlag London Limited, 2007
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Assessment Methods and Assessment Criteria |
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Semester/Year Assessments |
Number |
Contribution Percentage |
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Mid-term Exams (Written, Oral, etc.) |
1 |
60 |
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Homeworks/Projects/Others |
7 |
40 |
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Total |
100 |
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Rate of Semester/Year Assessments to Success |
40 |
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Final Assessments
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100 |
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Rate of Final Assessments to Success
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60 |
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Total |
100 |
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| Contribution of the Course to Key Learning Outcomes |
| # | Key Learning Outcome | Contribution* |
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1 |
Is equipped with the basic knowledge of math, science and engineering |
4 |
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2 |
Is dominated with basic concepts, theories and principles in mechanical engineering |
5 |
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3 |
Plans and does experiments in advanced level, interpretes and analizes the results and the data |
1 |
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4 |
Is equipped with a variety of skills and advanced engineering techniques |
5 |
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5 |
To design a system, component or process in order to meet the needs of various engineering problems within the limitations of technical, economic, environmental, manufacturability, sustainability |
5 |
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6 |
Independently reviews and learns the applications in an enterprise, makes a critical assessment of the problems faced with, has the ability of selecting the proper technique to formulate problems and propose solutions |
5 |
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7 |
Identifies a product or its production process, design, development, and prioritise its use |
5 |
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8 |
Becomes aware of the necessity of lifelong learning and continuously self-renew |
4 |
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9 |
Is capable of effective oral and written English for technical or non-technical use |
5 |
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10 |
Uses computers effectively, has the ability of computer-aided drafting, design, analysis, and presentation |
2 |
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11 |
Has teamwork skills, good communication skills and works efficiently as a member of versatile and an interdisciplinary team |
1 |
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12 |
Is aware of the technical and ethical responsibilities, inquisitive and innovative |
2 |
| * Contribution levels are between 0 (not) and 5 (maximum). |
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| Student Workload - ECTS |
| Works | Number | Time (Hour) | Total Workload (Hour) |
| Course Related Works |
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Class Time (Exam weeks are excluded) |
14 |
3 |
42 |
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Out of Class Study (Preliminary Work, Practice) |
14 |
5 |
70 |
| Assesment Related Works |
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Homeworks, Projects, Others |
7 |
5 |
35 |
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Mid-term Exams (Written, Oral, etc.) |
1 |
2 |
2 |
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Final Exam |
1 |
2 |
2 |
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Total Workload: | 151 |
| Total Workload / 25 (h): | 6.04 |
| ECTS Credit: | 6 |
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