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Content

Manufacturing Processes


Assembly and Disassembly



MACHINE INTELLIGENT FIXTURELESS ROBOTIC ASSEMBLY & JOINING USING REAL-TIME FEEDBACK CONTROLLED VISION AND FORCE SENSING FANUC ROBOTS

An In-depth Technical Discussion and Practical Demonstrations with Virgil R. Wilson, Senior Engineer, FANUC Robotics America, Inc., Rochester Hills, Michigan, USA. Interviews and Edited by Professor Paul G. Ranky

This publication is a professional quality DVD introducing and demonstrating various fixtureless, machine intelligent robotic assembly and joining solutions (also shown in slow motion video) using robot-integrated vision and force sensing. The in-depth technical interview and demonstrations also illustrate some robot control, cell networking and vision system programming related aspects of lean, flexible, and reconfigurable assembly cells using smart FANUC robots. Due to the many innovative and mind-triggering ideas shown and discussed, this DVD is also excellent for undergraduate / graduate education and research.


DVD / 2007 / () / 19 minutes

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PROCESS KANBAN IN FINAL ASSEMBLY, KAIZEN, QUALITY INSPECTION, HEIJUNKA SYNCHRONIZATION WITH THE CUSTOMER, VISUAL FACTORY MANAGEMENT AND LEAD-TIME REDUCTION EXAMPLES WITH SUPPLIER KANBAN IN DENSO'S MICHIGAN MANUFACTURING PLANT, USA

Edited by Professor Paul G. Ranky, NJIT, New Jersey, USA.

An Engineering Management Educational Program

This publication is a professional quality DVD factory tour, covering Denso lean manufacturing system solutions, with kanban, kaizen, quality inspection, heijunka synchronization methods and actual industrial solutions in a Visual Factory Management & Control (VFM) framework. VFM is an integrated set of methods and technologies for the purpose of reducing waste at all levels, improving profitability, increasing lean production control, product & process quality, productivity, safety, on-demand / just-in-time (JIT) Kanban production / delivery, and employee morale in a factory, or virtually in any business. VFM and factory automation typically begins by following an integrated process, requirements, and risk analysis method, embedded into a statistical analysis and multimedia framework. As a result, the team will have a clear picture about what needs to be done, when, and how. The next step is typically the implementation of a 'Five S', a 'Lean Six-Sigma', and a 'Monozukuri' program.


DVD / 2007 / () / 28 minutes

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ADVANCED ELECTRONIC ASSEMBLY & QUALITY ASSURANCE: AUTOMOTIVE DIAGNOSTIC SYSTEM ASSEMBLY AND TEST

By Professor Paul G. Ranky

USA National Electronics Manufacturing Initiative's (NEMI) Plug & Play Factory Project at GenRad Inc., USA. A Virtual Factory Tour on Video with In-depth Technical Discussions

This electronic publication is a professional quality program presentation of an advanced, lean electronic manufacturing / assembly operation with practical demonstrations. The discussion topics and application examples on the shop floor and in front of simulation and quality control screens include: How do small batch electronic assembly lines operate? íK How do operators get their assembly instructions in a lean, visual factory?... What happens to production control data collected from the line?... How does the quality assurance and product test system work in small batch electronic assembly systems? íK and others.

What you will learn: Having watched the DVD video, you will be able to understand the way a small batch electronic assembly line is operated in a lean, visual electronic manufacturing / assembly factory.


DVD / 2005 / () / 23 minutes

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ADVANCED ELECTRONIC ASSEMBLY & QUALITY ASSURANCE: ELECTRONIC ASSEMBLY MACHINES AND SHOPFLOOR CONTROL SYSTEMS

By Allan Frase. Interviews and Edited by Professor Paul G. Ranky

USA National Electronics Manufacturing Initiative's (NEMI) Plug & Play Factory Project at GenRad Inc., USA. A Virtual Factory Tour on Video with In-depth Technical Discussions

This electronic publication is a professional quality DVD video presentation of an advanced, lean electronic manufacturing / assembly operation with practical demonstrations. The discussion topics and application examples on the shop floor and in front of simulation and quality control screens include: How do electronic assembly machines operate? ... How can they be programmed?... What happens to production control data collected from machines?... How does the quality assurance system work in advanced electronic assembly systems? ... What are the key tasks of shopfloor control systems in electronic assembly?... and others.

What you will learn: Having watched the DVD video, you will be able to understand the key aspects of the shopfloor control tasks of advanced electronic assembly systems in lean factories.


DVD / 2005 / () / 33 minutes

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ADVANCED ELECTRONIC ASSEMBLY & QUALITY ASSURANCE: THE USA NATIONAL ELECTRONICS MANUFACTURING INITIATIVE'S (NEMI) PLUG & PLAY FACTORY PROJECT AT GENRAD INC., USA

By Professor Paul G. Ranky

A Virtual Factory Tour on Video with In-depth Technical Discussions

This electronic publication is a professional quality DVD video presentation of an advanced, lean electronic manufacturing / assembly operation with practical demonstrations. The discussion topics and application examples on the shop floor and in front of simulation screens include: What is the NEMI Plug & Play Factory Project? What are the key components of advanced, reconfigurable electronic assembly systems? ...What are the key system components? ... How does the technology work in simulation mode and on the shop floor?... What are the main application areas of XML (Extended Markup Language) in electronic assembly?... What are the quality, cost and agility issues? ... How can the technology be adopted to other types of cellular manufacturing? ... and others.

What you will learn: Having watched the DVD video, you will be able to understand the key aspects of advanced electronic assembly systems in lean factories.


DVD / 2005 / () / 20 minutes

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FORD ROUGE: ASSEMBLY

By Professor Paul G. Ranky.

Professor Ranky's Video Factory Tour in the Ford Rouge, Dearborn, MI, USA Plant

This electronic publication is a professional quality DVD factory tour focusing on the Assembly Processes at the Ford Rouge Plant, in Dearborn, Michigan, USA. Throughout the program you will feel the excitement of the virtual tour in an advanced, high quality factory. The program is produced in such a way, that you'll have the feeling of actually participating in the tour. You will enjoy the way the trucks are assembled, built and tested by skilled technicians and robots in this environmentally friendly, well organized, clean, lean and flexible factory.

What you will learn: Having watched the DVD video, you will be able to understand the basic principles of how Ford's environmentally friendly and lean factory can build a range of different automobiles.


DVD / 2005 / () / 25 minutes

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MANUFACTURING INSIGHTS: DESIGN FOR MANUFACTURE AND ASSEMBLY

This program features an interview with Nicholas Dewhurst of Boothroyd Dewhurst regarding the concepts and use of DFMA in product analysis to understand the drivers of cost, and the interaction of the individual pieces within the product to optimize design, manufacturability, and assembly.

Two companies successful use of DFMA are also highlighted, including: MDS-SCIEX, a scientific instrumentation manufacturer, where implementation of DFMA philosophies helped reduce the product development design cycle for their API 2000 mass spectrometer from 48 months to 16 months; and Plug Power, a fuel cell manufacturer, where the integral use of DFMA facilitated development of their Proton Exchange membrane fuel cell systems at the lowest cost.


DVD / 2005 / () / 30 minutes

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PROFESSOR RANKY'S FACTORY TOUR IN THE BMW (UK) MANUFACTURING LTD., OXFORD, ENGLAND PLANT: THIS IS WHERE THE MINI IS MADE - ENGINE MARRIAGE ASSEMBLY AND TEAMWORK

By Professor Paul G. Ranky.

This electronic publication is a professional quality DVD factory tour of the BMW MINI plant in Oxford, England, focusing on engine marriage assembly and teamwork, including robotized and manual engine marriage and lean assembly processes, manual and automated assembly processes, smart sensory-feedback tools, robots, and other methods, tools and technologies, team management, team leadership, continuous quality control and training, not missing out all those excellent people who work in this factory.


DVD / 2005 / () / 20 minutes

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PROFESSOR RANKY'S FACTORY TOUR IN THE BMW (UK) MANUFACTURING LTD., OXFORD, ENGLAND PLANT: THIS IS WHERE THE MINI IS MADE - FINAL ASSEMBLY

By Professor Paul G. Ranky.

This electronic publication is a professional quality DVD factory tour of the BMW MINI plant in Oxford, England, focusing on final assembly, including manual and lean automated assembly processes, smart sensory-feedback tools, robots, windshield assembly, final inspection, and other methods, tools and technologies, not missing out all those excellent people who work in this factory.


DVD / 2005 / () / 18 minutes

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PROFESSOR RANKY'S FACTORY TOUR IN THE BMW (UK) MANUFACTURING LTD., OXFORD, ENGLAND PLANT: THIS IS WHERE THE MINI IS MADE - ROBOTIC FRAMING, WELDING AND LEAN ASSEMBLY OF THE BMW MINI

By Professor Paul G. Ranky.

This electronic publication is a professional quality DVD tour of the BMW MINI plant in Oxford, England, focusing on lean manufacturing and assembly, including robotic framing, welding and lean assembly. Furthermore, during the virtual factory tour, we cover novel design and assembly methods, tools and technologies, not missing out all those excellent people who make this all happen.


DVD / 2005 / () / 28 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: FASTENING AND ASSEMBLY

This program focuses on the primary fasteners and assembly processes used, and includes sections on: mechanical fastening, adhesive bonding, and automated assembly. The mechanical fastening segment features in detail the various types and uses of integral fasteners, threaded fasteners, non-threaded fasteners, and stapling. The adhesive bonding section covers the many types and applications of adhesives used in joining similar and dissimilar materials together. The automated assembly segment examines the ways in which parts are sorted, loaded and presented for automated assembly machine types including: the dial, or rotary index machine, the in-line indexing assembly machine, and the carousel assembly machine.

DVD / 2003 / () / 20 minutes

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FUNDAMENTAL MANUFACTURING PROCESSES: PLASTICS MACHINING AND ASSEMBLY

This program focuses on the primary machining and assembly processes used for plastics.

The plastics machining segment highlights the use of sawing, milling, routing, turning, waterjet cutting, laser cutting, drilling and the secondary holemaking operations, such as tapping and reaming. The importance of coolant used while machining plastics is also explored in detail.

The plastics assembly section covers the many fastening and joining methods used to produce plastic parts. Included are segments on snap-fit fasteners, the use of hinges, mechanical fasteners, adhesive and solvent bonding applications, and the various plastic welding processes, including: spin welding, hot-gas welding, ultrasonic welding, vibration welding, heat staking and ultrasonic staking.


DVD / 2002 / () / 27 minutes

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AUTOMOTIVE ENGINE MARRIAGE ASSEMBLY AND TEAMWORK: VIDEO FACTORY TOUR IN THE BMW MINI (UK) MANUFACTURING LTD., OXFORD, ENGLAND PLANT



DVD / / () /

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CNC PROFESSOR, THE - PART 1: AN INTRODUCTION TO CNC (COMPUTER NUMERICAL CONTROL) PRINCIPLES WITH CNC MILLING, TURNING, COMPUTER CONTROLLED ROBOTIC WELDING, ASSEMBLY, AND OTHER ADVANCED MANUFACTURING & ASSEMBLY EXAMPLES



4 DVDs / / () /

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CNC PROFESSOR, THE - PART 2: AN INTRODUCTION TO CNC (COMPUTER NUMERICAL CONTROL) PROGRAMMING PRINCIPLES WITH CNC MILLING, TURNING, COMPUTER CONTROLLED ROBOTIC WELDING, ASSEMBLY, AND OTHER ADVANCED MANUFACTURING & ASSEMBLY EXAMPLES



4 DVDs / / () /

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DFRA: COMPONENT ORIENTED DISASSEMBLY FAILURE RISK ANALYSIS (VOL. 2) AKHTER PC & HUMMER HEADLIGHT DISASSEMBLY

By Professor Paul G. Ranky

This publication, tested on many undergraduate and graduate students and professionals in the USA and in the UK, is an excellent introduction to disassembly (and process) failure risk analysis principles, standards, applications and practical examples. It discusses the basic methods, tools and technologies with several industrial and research case studies discussed and demonstrated by industry experts in 3D. The over 700 interactive screens include 8 major topic areas, and over 40 digital videos and highly interactive 3DVR objects, covering: Introduction to disassembly (and generic process) failure risk analysis; A detailed case study and electronic user manual of the DFRA tool; Case-based learning and marketing methods; Major Review Questions & Problems; A PC and a Fax machine disassembly (process) risk analysis challenge (using 3D objects); References; Case documentation guidelines; Useful spreadsheet templates for educators and students; A Major Glossary of Terms; Customizable, open-source MS-Excel Tools & Templates to perform your own calculations.


CD-ROM (Win) / / () /

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DFRA: COMPONENT ORIENTED DISASSEMBLY FAILURE RISK ANALYSIS (VOL. 3) AKHTER PC & IBM PC FLOPPY DRIVE DISASSEMBLY

By Professor Paul G. Ranky

This publication, tested on many undergraduate and graduate students and professionals in the USA and in the UK, is an excellent introduction to disassembly (and process) failure risk analysis principles, standards, applications and practical examples. It discusses the basic methods, tools and technologies with several industrial and research case studies discussed and demonstrated by industry experts in 3D. The over 700 interactive screens include 8 major topic areas, and over 40 digital videos and highly interactive 3DVR objects, covering: Introduction to disassembly (and generic process) failure risk analysis; A detailed case study and electronic user manual of the DFRA tool; Case-based learning and marketing methods; Major Review Questions & Problems; A PC and a Fax machine disassembly (process) risk analysis challenge (using 3D objects); References; Case documentation guidelines; Useful spreadsheet templates for educators and students; A Major Glossary of Terms; Customizable, open-source MS-Excel Tools & Templates to perform your own calculations.


CD-ROM (Win) / / () /

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DFRA: COMPONENT ORIENTED DISASSEMBLY FAILURE RISK ANALYSIS (VOL. 4) AKHTER PC & HUMMER INDICATOR LIGHTS & SWITCH DISASSEMBLY

By Professor Paul G. Ranky

This publication, tested on many undergraduate and graduate students and professionals in the USA and in the UK, is an excellent introduction to disassembly (and process) failure risk analysis principles, standards, applications and practical examples. It discusses the basic methods, tools and technologies with several industrial and research case studies discussed and demonstrated by industry experts in 3D. The over 700 interactive screens include 8 major topic areas, and over 40 digital videos and highly interactive 3DVR objects, covering: Introduction to disassembly (and generic process) failure risk analysis; A detailed case study and electronic user manual of the DFRA tool; Case-based learning and marketing methods; Major Review Questions & Problems; A PC and a Fax machine disassembly (process) risk analysis challenge (using 3D objects); References; Case documentation guidelines; Useful spreadsheet templates for educators and students; A Major Glossary of Terms; Customizable, open-source MS-Excel Tools & Templates to perform your own calculations.


CD-ROM (Win) / / () /

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DIGITAL PRODUCT DESIGN: CONCURRENT ENGINEERING PRINCIPLES AND SOME TOOLS FOR QUALITY DESIGN FOR MANUFACTURING, ASSEMBLY & DISASSEMBLY, AND A DESKTOP TELEPHONE DISASSEMBLY USE CASE



DVD / / () /

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DIGITAL PRODUCT DESIGN: DESIGN FOR QUALITY, MANUFACTURING, ASSEMBLY & DISASSEMBLY PRINCIPLES, AND AN INKJET PRINTER GREEN ENGINEERING DISASSEMBLY USE CASE

In order to achieve professional quality product/ process and service system design engineering skills, besides a strong analytical, digital design and digital manufacturing / assembly engineering foundation, one needs to learn basic and often very simple design rules. One of the best ways to learn these rules is to disassemble and analyze various products, try to understand the design / manufacturing / assembly processes followed, and also learn from mistakes. In this program Professor Ranky introduces, and to some extent illustrates several basic product design, process design, design for quality, assembly /disassembly, and other design rules with simple and practical examples whilst disassembling an inkjet printer on screen. In particular, the rules and principles discussed with examples include: design for quality, maintenance, assembly, disassembly, green / eco-friendly design issues, cost, risk, the concept of designing components, modules, and systems that can be assembled, as well as disassembled, material selection issues, design for the environment, the principle of 'z' stacking for assembly / disassembly, modular design principles, some part handling, and feeding issues, automated assembly and disassembly challenges, and others.

DVD / / () /

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DIGITAL PRODUCT DESIGN: THE DESIGN PROCESS FOR MANUFACTURING (DFM) AND ASSEMBLY (DFA) PRINCIPLES AND PRACTICAL GREEN PRODUCT DESIGN EXAMPLES



DVD / / () /

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