Serdar Yüksel 030070129 3rd week answers

1) Benefits measurement (new-better) (benefit measurement method)

The various hypotheses imply that improved product

quality and increased flexibility in the use of capital are beneficial to users of

CIM. However, the argument thus far is only qualitative. To carry it a step

further, one must define quality and flexibility more precisely and formulate

them in terms of conventional economic variables and models. This is the

next task to be undertaken, and it is a vital one.

To organize the discussion, it is helpful to consider five possible kinds of

economic benefit:

(1) Labor saving. Some CIM technologies (most notably robots) can be

regarded as direct substitutes for semiskilled human labor. This means 

that robots (sometimes called “steel-collar workers”) can also be regarded

as additions to the labor force, although their “wages” are partly operating costs 

and partly costs of capital.

(2) Capacity augmenting/capital saving. Some CIM technologies, such as
scheduling systems and programmable controllers (PCs) with sensory
feedback, can be regarded as capital savers or capacity augmenters. This
is the case to the extent that they increase the effective utilization of
existing machine tools and other capital equipment (e.g., by permitting
unmanned operation at night) or permit shorter delivery times, faster
turnarounds and reductions in the inventory of work in progress. The
productivity of capital is thus increased.
(3) Capital sharing/saving. The major benefit of flexibility, as discussed in
Chapter 3, is that it permits faster response to changing market condi-
tions, or superior ability to differentiate products. The major reason for
slow response is the widespread use of dedicated, specialized (“Detroit”)
automation in mass production. Here, the lowest possible marginal unit
cost is achieved at the expense of very high fixed capital investment and
large write-ofl's in case the product becomes obsolete and cannot be sold.

Flexibility in this context is the ability to adapt (or switch) capital equip-
ment from one generation of a product to the next. The term flexibility
is also widely used in a rather different context - to describe a futuris-
tic concept analogous to an automated job shop, capable of producing
“parts on demand.” In either case, capital is shared among several prod-
ucts rather than dedicated to a single one. Evidently capital sharing is
practically indistinguishable from capacity augmentation. However, it is
perhaps slightly preferable to model it as an extension of the lifetime of
existing capital or (in some cases) as credit for capital recovery.
(4) Product quality improvement. The term “quality” is not very precise,
since it comprises at least two aspects: (1) product reliability (defect
reduction) and (2) product performance. The latter can be disregarded,
here, as being an aspect of product change (discussed in Section 5.4). It
is postulated that several CIM technologies, especially the use of “smart
sensors” in conjunction with programmable controllers, will eventually
reduce the in-process error/ defect rate. Moreover, these technologies will
also permit more complete and more accurate testing and inspection of
workpieces and final products.
(5) Acceleration of product performance improvement. As noted above in
connection with quality, improved product performance can be distin-
guished, in principle, from improved product reliability though reduced
error/defect rates. The latter is a function of the manufacturing process

in time may be due to superior brand-name recognition, cheaper labor or
energy source, better location vis-a-via markets, more eflicient production
technology, or better product design. But unless these advantages are pro-
tected, e.g., by brand-name copyright (e.g., “Coke”), a monopoly franchise
(such as CBS), an impenetrable secret, or a set of interlocking patents, prof-
itability will last just as long as it takes for a competitor to imitate or improve
on the product or build a larger or newer plant or both.
It follows, therefore, that continuous long-term profitability for a firm
can only be assured by a continuous process of creating and exploiting new
advantages (of some kind) to replace the older, dissipating ones. Opening
new markets, advertising, product improvement, process improvement — all
are means of creating competitive advantages. Forward motion is essential:
to be inactive is to sink and be overwhelmed. A moving bicycle, a circling
“hula-hoop,” a spinning top, or a gliding water ski are dynamically stable;
but when the motion stops the system collapses. The same thing holds true
for species in an ecosystem or a firm in a competitive market. There is

no safe place to hide indefinitely from hungry predators seeking a meal or
hungry competitors seeking a. market.
In short, only a dynamic model of firm behavior has any value in as-
sessing the benefits of CIM technologies (or, indeed, any other technologies
provided exogenously). Furthermore, it is essential to view the firm in the
context of its dynamic competitive environment. Most simple models of the
behavior of the firm assume a static environment (e.g., an exogenous demand
schedule or market price) and neglect the realities of competitive response.
If all competing firms adopted a more eflicient production technology si-
multaneously, none would gain any special advantage over the others but
all would bear the cost of the necessary investment. To the extent that the
adoption of more eflicient product processes (CIM) results in lower costs and
these are subsequently passed on to consumers as lower prices, the market
for each product might (or might not) grow enough to result in increased
profitability for the producer, ceteris paribus.

(Computer integrated manufacturing: 

Revolution in progress, Robert U. Ayres, 1991, page: 134-136-140)


Benefits measurement (old)
The main idea is to show how the performance of the supply chain can be improved with the integration of various tiers in the chain. Integration is prerequisite for effective sharing and utilization of information between different companies in the chain. Simulation-based methodology for measuring the benefits combines the simulation of business processes with the simulation of supply and demand. 
Benefits measurement is realized by measuring improvements resulting from benefits realisation. The ‘before’ or 'as is' state needs to be measured and baselined in the benefits profile. Benefits realisation, which happens towards the end of the benefits management process, is reinforced by the implementation of relevant measurement processes.
To provide realistic and usable measures for benefit realisation is not straightforward.Benefits may be owned by different parts of the organisation. Some benefits can be tracked using financial measures, others will need more complex measures, or indicators, to demonstrate their realisation. Benefits profile provides the baseline before measurement and details of the measurement of improvements. Measuring benefit achievement should focus on the improvements in performance achieved by the business operations and changed working practices.

Measurement of Supply Chain Integration Benefits, Peter Trkman and Aleš Groznik, University of Ljubljana, Faculty of Economics, Slovenia, Interdisciplinary Journal of Information, Knowledge, and Management Volume 1, 2006 



2) Belt Sanding (new-better) (manufacturing method)

Belt Sander
In my opinion, belt sanders really dont
belong in a woodworking shop. They're
a very rough tool and can cause more
damage than good if you're not familiar
with their operation. But. I own one
and have used them for decades. There
are just some jobs that require the
quick removal or leveling oi a surface
that calls lor at belt sander.
The most common belt sanders take
3'-wide (76mm) or 4'-wide (lO2mm)
belts. A 4‘ (l02mm) sander will give
you more surface area on the material.
making it easier to level a panel. but
the extra size also makes them a little
harder to control. And it only takes a
second to remove too much material
with a belt sander. Belt sanders‘ motors
range in size from 5 amps to 120 amps.
Again. more power means more to con-
tml. and I find the middle of the pack
adequate lor most woodworking tasks.
Pricing will range between $ 120 to


$200. so its not a tool that you should
buy just in case.
Let's look at maintenance on a belt
sander first. These machines are built
tough to take abuse. Maintenance on
them is fairly simple and centers on the
belt itself. Because of the way the belt
rides on two cylindrical rollers. the roll-
ers need to be in perfect parallel with
one another to keep the belt tracking in
the center of the rollers. Its much like
a band saw — you adjust the tracking
each time you put on a new belt.
Removing a belt is the easy part.
Simply noll the sander onto its side
with the open side of the belt exposed.
The llick of a handle releases the spring
mechanism and lets the belt slide oll
the rollers. Once you‘ve got the belt
oll. it's time to do a little maintenance
inspection.
On a belt sander is a part called
the platen. The platen is a thin sheet
of metal backed most commonly by a
sheet of cork. This platen ts attached at
one end to the underside of the sander
and fits between the inside of the sanding
belt and the shoe ofthe sander. Its purpose
in life is to providea flat but

slightly springy support, to the belt.
lt's also the place where the back ol the
belt rubs. so the platen will wear over
time and need replacing.
With the belt removed you can take
a look at the platen and inspect it for
damage. lt should be obvious without
removing the platen if the cork is badly
damaged. but you may want to take it
oll' every so often to double-check. The
platen is also prone to thinning at the
unattached end and should be checked
periodiatlly. If it's time to replace the
platen, it's a quick job and well worth
the time.
Putting the belt back on is the
tricky part. “ell, actually putting the
belt on is easy — getting the belt to
track correctly takes some finesse. Mth
the tension lever open. check the direc-
tion of the belt (yes, there is a correct
direction) and just slip the belt over
the rollers. With the handle closed you
should be able to go right to work.
right? Not so. Every belt is slightly
dlllerent from another. Whether it's
slightly longer or shorter. or the seam is
at a dillerent angle. all these things add
up to make it necessary to readjust the
tracking almost every time you put on
a new belt.

(

David Thiel's Power Tool Maintenance: 

Peak Performance and Safety for Life, David Thiel, 2006, page: 114,115)

Belt Sandling (old)
By far the best method for achieving professional quality shaft tip abrasion is to use a belt-sandling machine. The most popular belt sandling machines used by clubmakers are the 1’’ x 30’’, 1’’ x 42’’ or 2’’ x 48’’ size machines. By using a coarse or medium grid sandling belt (medium grit is acceptable because of the speed of the belt sanding machine), clubmakers can abrade steel shaft tips to the proper roughness and do so faster than with any other method. To avoid notching or cutting a potentionally damaging groove in the shaft. Tip abrasion should always be performed on the flexible portion of the belt where there is no hard metal backing (known as the platen) behind the abrasive belt.
(Jackson J., The Modern Guide to Golf Clubmaking: The Principles and Techniques, 2001, p.56))

3) Powder spraying (coating) (old):

A painting process in which electrostatic and compressed air transfer mechanisms are used to apply finely ground dry plastic to a part. The applied powder is heated to its melting point and flows out, forming a smooth film. It cures by means of a chemical reaction.
(Computer-Based Design and Manufacturing An Information-Based Approach, Emad Abouel Nasr,. Ali K. Kamrani ,p 383)


Powder Spraying (new-better):(manufacturing method)



Powder Coatings: In powder coatings the coating material is applied to the workpiece in the form of
dry (i.e._ solvent-free) thermoplastic or thermosetting powder. The powder particles
are heated and melt to form a film. The thermoplastic powders melt and fuse on
heating whereas the thermosetting powders also become chemically cross-linked.
Two main application processes are used: electrostatic spraying and fluidized-bed
coating.
Electrostatic Spraying:{definiton of powder spraying}
The principle of electrostatic spraying is simple. A coating
powder is a dust with a particle size in the range 10- 80pm. When dispersed (flu-
idized) in air the powder flows in the same way as a liquid and is applied in spray
cabins using special spray guns onto the cold or hot workpiece. The coating powder
adheres to cold workpieces electrostatically, whereas on hot workpieces it adheres by
fusion. The workpiece generally passes through a dryer. The coating powder over-
spray is suctioned off. separated from the air, screened, and reused.
Care should be taken to minimize the length of pipes for powder transport and to
maximize the deposition efficiency in order to avoid problems caused by a shift in
the particle size distribution. A sufficiently large number of guns, a coating powder
cloud size matching the size of the workpiece, adjustment of the oscillating move-
ment of the gun supports, gun triggering, and a continuous powder metering system
with maximum accuracy are advantageous. Minimizing the powder content of a
plant facilitates cleaning.

Coating powders are mainly sprayed with guns with negative corona charging.
Guns with friction charging (positive charging by charge separation on polytetraflu-
oroethylene) also used in addition. A new generation of corona-charged guns are
producing less free ions by inplementing special earthing devices and therefore better
penetration into corners and cavities (Faraday cages). Higher deposition efficiencies
are obtained by using slit-shaped nozzles and a triggered powder output that may be
related to the shape of the object. Increasing the number of guns or reducing the gun
output often improves coating application. Parts with complicated shapes. particu-
larly those with Faraday cages. are extremely difficult to coat. at least with a con-
stant layer thickness.
Good grounding (earthing) is necessary for satisfactory results. For safety rea-
sons, earth leakage resistances of less than I MR (at 5 kV) are required. Good
grounding can also be obtained via contactless, electrostatic processes.

(Paints, Coatings and Solvents, Werner Freitag, Dieter Stoye, 2008, page: 214)






CANCELED       Electropolishing (new-better) (manufacturing method)
The electropolishing process was first described by lacquer in I936. He
observed polishing of metallographic copper specimens when an anodic current
was applied in onhophosphoric acid. In I936 to 1937, Faust discovered mixtures
of orthophosphoric and sulfuric acids produced a superior polishing effect on
stainless steel. He described the metal surface to be highly lusterous and
free from scratches and the “piled'' layers characteristic of mechanically polished
surfaces. These solutions patented in 1943 form the basis for contemporary
electrolytes used to electropolish AISI Type 3l6L stainless steel implants.
The amount of basic research aimed at understanding electropolishing, the
techniques involved, and the possible benefits of the process seem less than
warranted, considering the wide-spread use in research and industry. Surveying
the literature available on electropolishing, one finds only brief references to the
increase in corrosion resistance of electropolished surfaces. Only recently has
the influence of electropolishing on the corrosion resistance of AISI Type 3l6L
stainless steel been presented. The object of this discussion is to present a
brief electrochemical description of the process. industrial techniques used. and
data on the corrosion resistance of electropolished stainless steel.
(Corrosion and degradation of implant materials: second symposium : a symposium, Charles D. Griffin, 1985, page: 136)


There is no older definition!

4) Adequate clamping force (new-better)  (fixing principles)
Non-monolithic systems, such as the clamped leaf-spring flexure used here,
require additional design considerations to attain desired accuracy and repeatability. In
general, beam elements are asembled with a series of clamping bars and bolts to provide
the necessary preload force. The following desigt rules, adapted fi'om [71], aim to
provide adequate clamping force between the members (preventing slippage and fretting)
without overstressing the material or adding stress concentrations:
* Frictional force (product of the clamping pressure and coeflicient of
friction) between the clamping bar and leaf spring should be at least 3x
greater than the tensile stress on the surface of the beam at the clamping
contact point; a thin film of high shear-strength adhesive can be applied if
necessary.
* Clamping pressure should be less than 30-50% of the yield strength of the
leaf-spring material.
* Bolts used in assembly should be preloaded to ensure adequate clamping
pressure, even as the bolts stretch during use.
* Mating surfaces of all eomponents should be clean, flat (preferably
ground), and burr-free. Contamination or uneven surfaces can create stress
concentrations during assembly and use.

(Kinematic alignment system for the creation of integrated microfluidic devices, Christine Ann Trinkle,University of California, Berkeley, 2008, page: 60)

Adequate clamping force (old)

The workholder must hold the workpiece immobile against the forces of gravity,centrifugal forces,inertial forces, and cutting forces.Milling and broaching operations, in particular ,tend to pull the workpiece out of the fixture, and the designer must calculate these machining forces against the fixture's holding capacity. The device must be rigid. (DeGarmo's materials and processes in manufacturing J. Temple Black, Ernest Paul DeGarmo, Ronald A. Kohser
p.342)

5) Tool-post grinders (new-better) (Grinding Attachment)
Grinding Attachment

*It is also known as 'tool post grinder'.
*a typical form of this attachement (for external grinding) consists of a bracket, which is mounted on the cross-slide, a grinding wheel and a seperate motor. Thus, the grinding wheel is driven seperately by this motor.
*The job is held as usual in a chuck between centres and the rotating grinding wheel is fed against the job.
*Some tool post grinders carry provisions such that the same attachment with a littlechange can be employed for internal as well external grinding. 
(A textbook of manufacturing technology: (manufacturing processes), R. K. Rajput, 2007, page: 441)

Tool-post grinders: Tool-post grinders are self-contained units and usually are attached to the tool post of a lathe. The workpiece is mounted on the headstock and is ground by moving the tool post. These grinders are versatile, but the lathe components should be protected from abrasive debris.

(Kalpakjian S. , Schmid S.R. ,Manufacturing Engineering and Technology, 5th Edition, p. 816)