Institute for Advanced Manufacturing

Seminar 2: Automation Principles and Techniques:

For Manufacturing: Managers; Engineers; Supervisors and Maintenance Technical personnel.

Duration: 2 Days

Pre-requisite Knowledge: Some Manufacturing and/or Technical knowledge and background

Overview:

1. Fanuc Robotics: Includes brief understanding of the Fanuc Robotics Fundamentals to operate a Fanuc Mechatronics Arm for performing a programmed functions including: (Welding, Polishing, Pic and Place, Drilling, etc.)

2. Pneumatic Circuits: A pneumatic circuit is an interconnected set of components that convert compressed gas (usually air) into mechanical work. In the normal sense of the term, the circuit must include a compressor or compressor-fed tank.

   The circuit comprises the following components:

   • Active components
   • Compressors
   • Transmission lines
   
   
   • Air Tanks
   • Pneumatic hoses
   • Open atmosphere (for returning the spent gas to the compressor)
   • Passive components
   • Pneumatic Cylinders
   • Valves
   • Service Unit
   • FRL - Filter Regulator and Lubricator

   Pneumatic Cylinder

   In general, based on the application, a pneumatic cylinder is usually a single acting cylinder, where there is a single port in the cylinder and were cylinder extension is done by compressed air and retraction by means of open coiled spring. In double acting cylinders two ports both extend and retract by means of compressed air.

   Direction control valve (DCV)

   The direction control valve is used to control the direction of flow of compressed air. Usually classified into normally open (NO) and normally closed (NC) valves. The normally open valves will permit flow from inlet port of valve to outlet port normally the flow will be cut by changing the position of the valve. The normally closed valves will not permit flow from inlet port of valve to outlet port normally the flow will be permitted only by changing the position of the valve. In general valves are designated as 2/2 DCV, 3/2DCV, 5/2 DCV, 5/3 DCV etc. In which the first numerical indicates number of ports and second numerical indicates number of position to change the position, the valves are generally actuated by:

3. Programmable Logic Controls:  PLC training focuses on understanding PLCs; how they work, terminology, and the hardware and software elements that make up a programmable logic controller.  We will begin to examine the primary causes of faults associated with PLC based control systems: Input/output devices and field wiring.  You will learn to use both hardware and software to find these faults quickly.  Students will learn a systematic approach to troubleshooting; how to set-up and configure local, remote, hierarchical and distributive control systems; how to configure input/output modules using various slot addressing techniques; how to understand program and data table file organization, number systems and processor information flow; and how basic relay type instructions, timers and counters, & data manipulation instructions can be used to achieve the PLC solution you want.  This focus during the PLC training will stretch into day two.

4. Sensors: In the broadest definition, a sensor is an object whose purpose is to detect events or changes in its environment, and then provide a corresponding output. A sensor is a type of transducer; sensors may provide various types of output, but typically use electrical or optical signals. For example, a thermocouple generates a known voltage (the output) in response to its temperature (the environment).

Benefits:

• Have a comprehensible knowledge of Robotics applications and fundamentals.
• Be more familiar with Electro Pneumatic Systems and Design Principles.
• Have better understanding about the applications of Pneumatic Components.
• Become familiar with Programmable Logic Controls (PLC’s) and applications.
• Be introduced to the application and functionality of Sensor’s Engineering.

Seminar 3: HVAC Technology:

For: A/C Technical Servicemen; HVAC Equipment Installers; Contractors.

Duration: 2 Days

Pre-requisite Knowledge: Basic Knowledge of Refrigeration Systems.

Overview:

Basic understanding to operate, maintain, and troubleshoot air conditioning systems is what this seminar is all about. It was created to bring participants up to speed in their skills and knowledge as quickly and safely as possible. Taught by instructors who have been in the technicians’ shoes, the practical, commonsense approach we take in presenting this course, makes it perfect for novice technicians as well as multi-craft tradespeople, or even more experienced HVAC technicians who need a well-rounded refresher or who are looking for new ideas and solutions.

Created to have high impact in a short amount of time, the information being presented is designed to extend equipment life, improve HVAC/R efficiency, save energy costs, and enhance comfort control, while establishing a culture of environmentally safe and technically sound work practices among employees. 

Key Topics:

Fundamentals of heat transfer

• The basic refrigeration cycle
• Identification of components & what they do
• Measuring system pressures & temperatures
• Distinguishing a “component” problem from a “system” problem
• Identifying electrical problems
• Refrigerants & oils, types and classifications
• Necessity of maintaining system oil quality
• HVAC & refrigerant hazards and safety
• EPA 608 technician certification for handling refrigerants
• R-410A high pressure refrigerants
• Handling blended and other special refrigerants
• Applications for commercial and industrial chillers
• AC&R system operation
• Basic AC&R electrical circuits
• Maintenance and service of your AC&R systems
• AC&R system diagnostics & troubleshooting
• Air properties and how it affects your AC system
• Energy conservation
• Maximizing system operating efficiency and equipment longevity
• Regulatory considerations & EPA requirements

Benefits:

• Able to understand, operate, maintain, and troubleshoot your own air conditioning system.
• It was created to bring students up to speed in their skills and knowledge as quickly and safely as possible.
• Taught by instructors who have been in the technicians’ shoes, the practical, commonsense approach we take in presenting this course makes it perfect for novice technicians as well as multi-craft tradespeople, or even more experienced HVAC technicians who need a well-rounded refresher or who are looking for new ideas and solutions.
• Created to have high impact in a short amount of time, this program is designed to extend equipment life, improve HVAC/R efficiency, save energy costs, and enhance comfort control, while establishing a culture of environmentally safe and technically sound work practices among employees.

Seminar 4: Effective Management and Leadership:

For: Business Managers; Supervisors; Leads

Duration: 1 Day

Pre-Requisite Knowledge: None

Overview:

Clear cut distinction of:  Leadership Skills vs. Management Skills; Effective Management Practices; Character for Leadership; Sustainability/Effective Communication.

Benefits:

• Be prepared to apply the Management Skills depicted during the Seminar the next day and going forward
• Acquire the Basic Know-how to Improve People Management and Expectations day to day.
• Have the ability to measure Performance and Lead direct reports to Achieve Expected Results.
• Differentiate between Informal and Organized Management Practices.

Seminar 5: Lean Six Sigma Applied to your Business:

Duration: 2 Days 

Day 1: Deploying Lean Six Sigma for Executive Leaders.

Pre-requisite Knowledge: None

Overview:

A solid executive led drive is the key to a successful Lean Sigma deployment. This workshop introduces the Concepts and Philosophy of Lean, Six Sigma and Lean Sigma and teaches how to lay the groundwork for success. The curriculum focuses on developing the understanding, skills and role definition of the CEO and Executive Team in a change initiative, allowing them to lead the program and achieve business results. Learn from a seasoned deployment professional the mechanisms to link to strategy and to bring the results quickly and effectively.

Key Topics:   

• Methodology Overview
• Deployment Structure
• Deployment Case Studies
• Roles and Responsibilities
• Project Selection, Prioritization and Definition
• Managing and Sustaining
• Deployment Action Planning

Benefits:

• Be prepared as Executives to lead their program
• Have the background and content to establish the required program infrastructure

Day 2: Introduction to Performance Excellence (Lean Sigma & Transformational Change)

Pre-requisite Knowledge: None

Overview:

Process Excellence is a key part of every organization’s approach to meeting strategic goals. The Lean Sigma and Process Standardization approaches can underpin the ability to bring transformational change and deliver the performance required, whether it is financial, quality or service.

This introduction for leaders gives the grounding needed to set the right environment for change and standardization. The session includes insight into key concepts and methods, supported by real-world case examples and experiences.

Key Topics:

• Overview of Performance Excellence
  • Change methods (TQM, Lean, Six Sigma, Lean Sigma)
  • Standardization
• Roadmaps and tools for success
  • DMAIC
  • DMASC
  • Kaizen
• Structuring for change (roles and infrastructure)
• Performance Excellence in real life
  • Experiences / examples of the practical application
  • How to meld Performance Excellence with other operational priorities

Benefits:

• Be conversant in the core language and key tools
• Have a working knowledge of the process and methods utilized
• Have a view of how to successfully link performance excellence to their strategic and operational needs
• Be able to identify and define meaningful projects

Seminar 6: Tool & Die Manufacturing/Mold Making Techniques:

For Tool & Die Apprentices; Tool and Mold Makers and Repairmen; Maintenance Supervisors and Service Shops.

Duration: 1 Day

Pre-requisite Knowledge: Basic Tool & Die Experience and/or Desire to pursue a Technical Career in Tool & Die/Mold Making field.

Overview:

Basically, working from engineering drawings developed by engineers and technologists, tool makers lay out (mark out) the design on the raw material (usually metal), then cut it to size and shape using manually controlled machine tools (such as lathes, milling machines, grinding machines, and jig grinders), power tools (such as die grinders and rotary tools), and hand tools (such as files and honing stones).

Since the advent of computing in the manufacturing fields (including CNC, CAD, CAM, and other computer-aided technologies), tool and die makers have increasingly added IT skills to their daily work. Today's tool and die makers are generally required to have all of the traditional skills plus substantial digital skills; these formidable requirements make the field challenging to master.

Tool making

Tool making typically means making tooling used to produce products. Common tooling includes metal forming rolls, cutting tools (such as tool bits and milling cutters), fixtures, or even whole machine tools used to manufacture, hold, or test products during their fabrication. Due to the unique nature of a tool maker's work, it is often necessary to fabricate custom tools or modify standard tools.

Die making

Die making is a subgenre of tool making that focuses on making and maintaining dies. This often includes making punches, dies, steel rule dies, and die sets. Precision is key in die making; punches and dies must maintain proper clearance to produce parts accurately, and it is often necessary to have die sets machined with tolerances of less than one thousandth of an inch.

Benefits:

Participants will:

• Have a comprehensible knowledge of Tool & Die/Mold Making Techniques.
• Be more familiar with Quality Practices to Improve Reliability of Tools and Molds.
• Have a better understanding of applicable Machine Tools Equipment.
• Be introduced to CNC/CAD Programming (To be covered in a separate seminar).

Seminar 7: Materials Planning and Inventory Control:

For Materials and Production Planners; Inventory Control Managers and Supervisors; Warehouse Managers and Supervisors.

Duration: 1 Day

Pre-requisite: None

Overview:

Basic introduction to APICS which is the premier professional association for supply chain and operations management and the leading provider of research, education and certification programs that elevate supply chain excellence, innovation and resilience. APICS Certified in Production and Inventory Management (CPIM), APICS Certified Supply Chain Professional (CSCP) and APICS Supply Chain Operations Reference Professional (SCOR-P) designations set the industry standard. With over 43,000 members and more than 300 channel partners, APICS is transforming the way people do business, drive growth and reach global customers. For more information, visit apics.org.

Mission

Fostering the advancement of end-to-end supply chain management through a body of knowledge, innovative research, systems, and methods to create value for customers, members and organizations.

Designations

APICS offers several professional designations including, APICS Certified in Production and Inventory Management (CPIM), APICS Certified Supply Chain Professional (CSCP) and Supply Chain Operation Reference Professional (SCOR-P).

Benefits:

Participant will:

• Have a comprehensible knowledge of materials and production planning techniques.
• Be more familiar with tools to control inventory accuracy.
• Have a better understanding of MRP logic and applicable management.

Seminar 8: Preventive Maintenance and Safety:

For Maintenance Managers and Supervisors; Maintenance Engineers; Tool Room Personnel.

Duration: 1 Day

Overview:

• The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects.
• Preventive maintenance tends to follow planned guidelines from time-to-time to prevent equipment and machineries breakdown (Olakotan, 2015).
• According to Bamiro, Nzediegwu, Oladejo, Rahaman and Adebayo (2011), preventive maintenance is the work carried out on equipment in order to avoid its breakdown or malfunction. It is a regular and routine action taken on equipment in order to prevent its breakdown
• Maintenance, including tests, measurements, adjustments, parts replacement, and cleaning, performed specifically to prevent faults from occurring.

The primary goal of maintenance is to avoid or mitigate the consequences of failure of equipment. This may be by preventing the failure before it actually occurs which Planned Maintenance and Condition Based Maintenance help to achieve. It is designed to preserve and restore equipment reliability by replacing worn components before they actually fail. Preventive maintenance activities include partial or complete overhauls at specified periods, oil changes, lubrication, minor adjustments, and so on. In addition, workers can record equipment deterioration so they know to replace or repair worn parts before they cause system failure. The ideal preventive maintenance program would prevent all equipment failure before it occurs.

Benefits:

Participants will:

• Have a comprehensible knowledge of Safe Maintenance Practices and Techniques.
  • Be more familiar with the use of Adequate Equipment and Tools to service the machines.
  • Be introduced to available Preventive Maintenance Programs (PMP) to improve the planning and management of the service of machines in an organized manner.

Seminar 9: Intelligent Manufacturing/Rapid Response:

For Plant and Manufacturing Managers; Manufacturing Engineers; Technical Personnel; Supervisors and Leads.

Duration: 1 Day

Pre-requisite Knowledge: None

Overview:

Intelligent Manufacturing a synonymous to Smart Manufacturing, it’s an engineering tool that uses production process technology that can automatically adapt to changing environments and varying process requirements, with the capability of manufacturing various products with minimal supervision and assistance from operators.

The development and implementation of artificial intelligence in manufacturing to simplify work in process operations either on the assembly line or as a standalone work station. 

Benefits:

Participants will:

• Have a comprehensible knowledge of solid initiatives to improve assembly or piece work processes.
• Acquire the ability to think outside the box, to simplify the manufacturing processes at their place of work.
• Acquire the Basic Knowhow about Intelligent Manufacturing/Smart Manufacturing fundamentals and applications.

Seminar 10: Plastics and Finish Coating Engineering:

For Plant and Operations Managers; Engineers; Supervisors; Leads

Duration: 1 Day

Pre-requisite Knowledge: None

Overview:

Plastics engineering encompasses the processing, design, development, and manufacture of plastics products. A plastic is a polymeric material that is in a semi-liquid state, having the property of plasticity and exhibiting flow. Plastics engineering encompasses plastics material and plastic machinery. Plastic Machinery is the general term for all types of machinery and devices used in the plastics processing industry.^[1] The nature of plastic materials poses unique challenges to an engineer. Mechanical properties of plastics are often difficult to quantify, and the plastics engineer has to design a product that meets certain specifications while keeping costs to a minimum. Other properties that the plastics engineer has to address include: outdoor weather ability, thermal properties such as upper use temperature, electrical properties, barrier properties, and resistance to chemical attack.

In plastics engineering, as in most engineering disciplines, the economics of a product plays an important role. The cost of plastic materials ranges from the cheapest commodity plastics used in mass-produced consumer products to the very expensive, specialty plastics. The cost of a plastic product is measured in different ways, and the absolute cost of a plastic material is difficult to ascertain. Cost is often measured in price per pound of material, or price per unit volume of material. In many cases however, it is important for a product to meet certain specifications, and cost could then be measured in price per unit of a property. Price with respect to process ability is often important, as some materials need to be processed at very high temperatures, increasing the amount of cooling time a part needs. In a large production run cooling time is very expensive.

Some plastics are manufactured from re-cycled materials but their use in engineering tends to be limited because the consistency of formulation and their physical properties tend to be less consistent. Electrical and electronic equipment and motor vehicle markets together accounted for 58 percent of engineered plastics demand in 2003. Engineered plastics demand in the US was estimated at $9,702 million in 2007.

A big challenge for plastics engineers is the reduction of the ecological footprints of their products. First attempts like the Vinyloop process can guarantee that a product's primary energy demand is 46 percent lower than conventional produced PVC. The global warming potential is 39 percent lower. ^[2]

Powder coating is a type of coating that is applied as a free-flowing, dry powder. The main difference between a conventional liquid paint and a powder coating is that the powder coating does not require a solvent to keep the binder and filler parts in a liquid suspension form. The coating is typically applied electrostatically and is then cured under heat to allow it to flow and form a "skin". The powder may be a thermoplastic or a thermoset polymer. It is usually used to create a hard finish that is tougher than conventional paint. Powder coating is mainly used for coating of metals, such as household appliances, aluminum extrusions, drum hardware, and automobile and bicycle parts. Newer technologies allow other materials, such as MDF (medium-density fiberboard), to be powder coated using different methods. 

Benefits:

Participant will:

• Be familiar with the different plastics materials and applications.
• Have a working knowledge about the different plastics resins and matching equipment.
• Be able to have a comprehensible knowledge about the use and precautions of using recycled material.
• Have the basic knowledge about powder coating and acrylic paint applications in plastic components.