albert by ROcq7NRA


									     A Virtual Factory Model for
      Learning and Teaching of
     Product and Process Design

                          Albert C K Choi
          Department of Industrial and Systems Engineering

Aim of the Project
    This project aims at
     using virtual manufacturing applications in the subject
      area of product design and manufacture
     It is proposed to develop teaching and learning materials
      with integrated case study using multi-media format for
      illustrating various methods and computer tools in
      product design and process analysis
     Problem based learning activities would be incorporated
      into the various stages of the project

The Digital (Virtual) Factory
    A newly established laboratory with world class software
     and hardware facilities
    To provide an interactive, graphical-based discrete event
     simulation environment for students, researchers to model,
     develop, experiment, analyze and optimize design and
     manufacturing processes in a digital (virtual) environment
     prior to production

New Curriculum Under Development
    Alongside with the development of the Digital
     Factory in the Department, a framework of a new
     9 credit student centered learning activity titled
     "Integrated Product and Process Design (IPPD)"
     has been developed.
    The activity based on the "Virtual Factory"
    This is to be implemented in the final year of the
     BEng/MEng course in Industrial and Systems
    This subject is aimed to integrate the different aspects in
     the area of product and process design through an
     integrated problem base learning approach.
    The learning activities are carried out in the Digital
     Factory laboratory, which provides a self learning
     interactive, flexible and graphic-based digital simulation
     environment for students to model, develop, experiment,
     analyze and optimize product design and manufacturing
     process including plant layout.

Teaching and Learning Approach
   The subject is conducted with problem based approach.
   The student group has to determine the knowledge they
    need to master in order to complete the task requirements.
   The knowledge is arranged as a range of study modules
    which are available to the students for choosing.
   These modules are designed with student-centered nature,
    with coverage of differing virtual design and
    manufacturing tools.
   A mixture of lectures, briefings, seminars, tutorials,
    simulation exercises and case studies will be used to
    deliver the various topics so that students are able to
    complete the task activities.
   At the end each student is required to compile an overall
    portfolio to illustrate the learning outcomes.

                  IPPD Task Activities

      Virtual Manufacturing Learning Modules

             Product      Process       Plant &
             Design      Design and    Workplace
                        Optimization    Design

Typical Student Centered Study Modules
       Computer Aided Design using Pro-E, UG, Solid
        Work and Catia
       Product Data Management SmarTeam
       e-Manufacturing using eM Power and QUEST
       Virtual Machining using IGRIP & VNC
       Virtual Assembly using Dynamo
       Design for Assembly using Boothroyd & Dewhurst
       Mould Flow Analysis using C-mold
       Sheet metal tooling analysis using Pam-stamp
       Computer aided process planning

     Task Activities
1.    Product Design Evaluation

     Based on the product received, each group of student
      will apply different types of design analysis tools to
      evaluate the requirements including functions, quality,
      assembly so as to dictate the detail specification of the
      design. Detailed product engineering specification and
      virtual prototyping of the product are the required task

     Task Activities
2.     Optimization and Design of process, tooling and

      This task consists of the detailed evaluation of
       manufacturing process parameters and tooling design by
       applying virtual manufacturing tools such as virtual
       machining, mould flow analysis and plant simulation.
       Deliverables include detailed process plans and specific
       design of tooling

 Assessment Method

1.    Student-centered study modules   30%
2.    Task reports and presentations
      (including peer assessment)      60%
3.    Individual portfolio             10%

    Case Study - Rapid Product Development
   This case study deals the adoption of concurrent
    engineering can take advantages of information systems
    to synchronize the data and help to provide a virtual
    collaboration among the users.
   The case example illustrates how the isolated islands of
    functional unit can be grouped together through the
    adoption of concurrent engineering concept, thus bringing
    an integrated view of a company's knowledge sources to
    an individual's desktop, enabling better decision making
    by providing immediate access to key business
   The package is available on a CD with instructions for the
    students and guidance notes for the teacher.

    Case Study – Web Integrated Product and
    Process Planning

   This case example is designed to facilitate the real time
    input from potential customers regarding the kind of
    product they want, allowing small quantities with
    dissimilar design of product.
   In addition, the case example prototype is going to
    provide value chain information such as order placement
    and production logistics.
   Such prototype aims at quickly providing the right
    information to the right place at the right time in the right
    format throughout the inter-enterprise concurrent
    engineering processes to facilitate communication,
    coordination, control and integration of multi-enterprise
    concurrent product and process development.
Self Learning Package - Integrated Design
and Planning for Assembly in a Virtual
     This package concentrates on the area of design for
      assembly and virtual analysis.
     It includes a set of study guide and notes to help students
      to get familiarize with the topic.
     A case study using software to illustrate the concept of the
      analysis and typical results obtained including product
      redesign and improvement directions.
     An exercise based on a toy train model has been included
      and assessment of results are to be discussed.
     A number of short multiple choice questions are also
      available for students' self evaluation in the form of a quiz.
     The package has been trial implemented in the last
      semester and was well accepted by the students.
Case study on a computer mouse

                                            The boss of base make shorter.

                                               The ribs of base move forward.

                                 The hole of PCB make larger.

                                 Original                           Modify
Learning Package on Virtual Design and
Analysis of Sheet Metal Forming

   This package concentrates on how computer assists the
    design and analysis of sheet metal forming.
   It includes a slide show and movie to help student to have
    a general idea of the process, the advantage of computer
    aided design, with demonstration of professional software
    used in industry.
   A number of multiple choice questions are available to
    help student familiar with the basic concept of sheet metal


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