manufacturing simulation design

industrial design question and need an explanation and answer to help me learn.

i have a word file containing the results, i just need the simulation file from enterprise dynamics software (full version required) based on that file, figures and results
Requirements:
School of Mechanical and Design Engineering
Coursework
Unit Title: Manufacturing System Design
Unit Code: M32064
Student ID: UP2113096
Unit Lecturer: Dr Luka Celent
Date: 14/01/2023
Overview
The term “loudspeaker” refers to an electroacoustic transducer, whose function is to convert an electrical audio stream into audible sound. A loudspeaker has a sturdy basket frame that contains the numerous components, a flexible membrane like a cone or dome that is driven by a magnetism, a magnets and coil arrangement that creates the magnetic field, and a transportation system that supports and moves the diaphragm. Design, prototyping, testing, and finally mass production are just a few of the numerous stages that go into making a pair of loudspeakers. The specifications, such as frequency response, sensitivity, and power handling capabilities, that must be satisfied throughout production will be established during the design process. For the purpose of testing and evaluating the design, a prototype must be built, but only in small numbers. Testing the loudspeaker’s functionality helps determine how effective it is and where issues lie. At this point, the loudspeakers are ready for the last phase of manufacture, known as mass production. There are many various sorts of speakers available, and each one may serve a unique purpose. These speakers are differentiated from one another by their own unique sets of characteristics. One of the most common types of speakers is the dynamic speaker, which uses a coil and magnet to move the diaphragm. One of the most common types is the electrodynamic speaker, which uses an electric current passing through a coil to generate a magnetic field. Ribbon speakers, which use a thin metal ribbon to make sound, and electrostatic speakers, which use an electrostatic charge to drive a diaphragm, are two more types of speakers. One additional kind is the ribbon speaker.
There are a wide range of materials and techniques at one’s disposal for bettering the sound quality of loudspeakers. Lightweight, robust materials like carbon fiber or beryllium may be used for the diaphragm, and sophisticated suspension systems like rubber surrounds or spiders can help the diaphragm move more linearly. These are two practices that may be used to make diaphragmatic movement more linear. The trend in recent years has been toward making more compact and portable loudspeakers. Audio systems in mobile phones and portable music players are prime examples of this development. While these speakers may not pack the same punch as your average loudspeaker, they are designed to maximize output with little loss of quality. Even though they don’t give out a lot of power, these speakers are lightweight and easy to carry about.
System parameters
This project was based on a case that has to be researched about the assembly of loudspeakers while they are being manufactured on a manufacturing line. A company has recently updated the design of its loudspeakers by including certain forged pieces that have enhanced magnetic properties. The redesigned design of the loudspeaker offers other advantages, such as a decreased component count and features on those parts, which will allow automated feeding and simplify the human assembly process. The fundamental components of a loudspeaker are shown in Figure 1. Figure 2 depicts the motor unit and the voice coil in their combined assembled state for your viewing pleasure. A cross-section through a typical loudspeaker is shown in Figure 3, which may be found here. Figures 4 and 5 each provided an illustration of the assembling of a full loudspeaker. While the ideal manufacturing facilities would automate most of the production chain as is humanly possible, it is anticipated that a portion of the so-called “soft” pieces will still be assembled by hand. The target is to manufacture 960 speakers per day and 4,800 speakers per week, which comes out to one speaker every 30 seconds during an 8-hour workday and a 5-day workweek. The speakers have the potential to generate a weekly revenue of £33,600 if they are priced at £7 a unit and sold.
Summary of the parameters
Following an initial inquiry into the system, as well as the gathering and examination of relevant data, the following system parameters have been found and determined:
There were conveyors employed, and the length might be 5, 10, 15, or 20 meters.
Each frame will come at an arbitrary time, and then it will be put into place in the NegExp 28s (by hand).
It was fed and assemble each pole plate in LogNormal 27 seconds, with a standard deviation of 10%.
It takes LogNormal 29 seconds, with a standard deviation of 10%, to feed or assemble the magnet.
The top plate was fed or built in a homogenous distribution between 25 and 28 seconds at a time.
The manual construction of the spiders and coil by a worker takes between forty-five and fifty seconds, with a time distribution that is consistent.
The assembly of the diaphragm takes about 28 seconds on average.
The dust cover may be manually assembled in an average of 26 seconds’ worth of time.
At the station for magnetization, waitedthirty seconds.
Twenty seconds at the automated teller machine (ATM).
Fork-lift trucks are allowed to drive at a speed of 2 meters per second and may be utilized at the very end of the manufacturing line.
Final product
Figure .2.3
Project execution
Using Enterprise Dynamic software for simulation and various assumption methodologies, the report has compiled terms referring to methods of increasing efficiency in production while reducing costs. Lean manufacturing is a method that helps in getting rid of waste and shortening production cycles by getting rid of superfluous stages. Continuous improvement is at the heart of lean manufacturing, and lean production is a process that aids get rid of waste. When it comes to manufacturing, the bottleneck issue is like a barrel effect, where the manufacturing capacity does not rely on the most efficient component but on the least reliable part of the process.
The plan for the assembly of a loudspeaker using pre-manufactured components includes a number of steps, including the sorting and inspection of components, the preparation of components, the assembly of the main structure, the installation of electronic components, testing and quality assurance, and the packaging and shipping of the finished product. At various points along the assembly process, both automated and human operating methods are used to assure both efficiency and precision in the final product. Here, we’ll break things down into three distinct phases: brainstorming, prototyping, and simulation
The loudspeaker production technique employs tractor trailer manufacturing line designs for all manufacturing systems, and the block design range from two hundred to six thousand. Based on the available data, it seems that 8 stations are required at a minimum (total job duration/cycle time). If things are to be done in a prototypical way, an In-line machine setup must be used, and Figure 2 shows that. Idle time and spreading obstructed circumstances lead to insufficient output, and the operational cycle of all terminals cannot remain constant for 20 seconds, that is closer to the real state. After modeling the circumstances, overtime or production system cycle time improvements may accomplish the production objective. The prototype shows that the 8-hour production capability is 731 units, significantly below the target after initial set-up time. Under optimum conditions, the cycle time of the production system is at least 20 seconds. Except for spider coil installation, the entire operation takes around 21 seconds. The status panel demonstrate that the first three builders have failed to provide expected results, while the fourth assembler is busier than expected. The model phase will assume a 20-second rise in spider coil assembler manufacturing speed.
Figure 4. Engineering drawing of the assembly of the loudspeaker
The element of motion is introduced after the queue point. Figure 4 shows how realistic and efficient line balancing may be by assuming the cycle durations of all modeling workstations to be between 19 and 22 seconds and the speeds of wheel truck to be 2 meters per second. From the assembly site to the warehouses, a forklift brings a container containing 36 loudspeakers. Varying the simulation’s cycle time may improve its realism.
If data is eligible for a refund, cost mobility may reduce lean waste from portended. DS simulation must restrict the cross time or container input amount to reduce system congestion and returnable container use. The Figure below displays the cycle time set. The 3D simulation below shows how to put up more returnable containers while keeping the system fluid. Figure 8 shows that facility capacity must be far higher than output to provide necessary storage and support. Pull and just-in-time.
Production layout
Figure 6
Figure 7
Figure 8
Conclusion
Two factors generate a summary report image 11 of loudspeakers that is too imprecise for a fully simulated reality production process: Workstation ATM requires that 1% of examined units fail and be discarded, and rework for defective parts cannot be simulated. The simulation does not take into account the Mean Time Before Failures (MTBF) or the Mean Time to Repair (METR). Instead, the automation system is dependent on the manufacturing machine’s level of dependability. The purpose of this component is to conduct an experiment. The following seem to be some eco-friendly renovation initiatives that have been planned out: Utilize one robot to execute two to three different transport duties while increasing its speed in order to reduce the number of robots used in the input area. If more work needs to be done in the same amount of time, the operation needs to try to cut down on the amount of time each workstation takes to complete its cycle. The adoption of these six lean criteria will contribute to the enhancement of both the work setting and the production methods, which will ultimately result in an increase in indirect output
Figure 9
Academic Year 2022/23 Module: MANUFACTURING SYSTEM DESIGN – M32064 – FHEQ_7 Coursework Deadline For Submission: 9th January 2023, 12:00 PM Submission Instructions Submit the work in a written report via Moodle together with Enterprise Dynamics simulation file. Instructions for completing the assessment: The work involves a design of a complex production system in a virtual environment with solutions developed and submitted in a report via Moodle. The length of the report is suggested no more than 2000 words. Coursework is carried out in groups, ranging from 3 to 6 students. Group will submit just one report. Examiners: Dr Luka Celent
Manufacturing System Design 2022-2023 Page | 1 Aims of this work 1. To develop a systematic understanding and critical awareness of sustainable manufacturing systems, system design approaches and planning techniques applied to industry. 2. To enhance the acquisition of analytical knowledge and practical skills gained for analysing a complex manufacturing process or system and their integration using advanced computer design and modelling simulation tools. 3. To explore modelling simulation techniques to help create rapidly and turn innovative ideas timely into systems design, analysis and improvement particularly for a constraint-based production system in a virtual environment. 4. To become an expert in coping with the system uncertainty, examining the system random behaviour, refining the system design, and developing alternative operational management strategies based on the developed virtual prototyping system to a real industrial case study. Unit learning outcomes 1. Critically appraise a systematic approach with lean thinking and apply it into analysis, planning, design and performance evaluation of a complex production system. 2. Examine modelling techniques and mathematical approaches for capturing the deterministic and stochastic behaviours of manufacturing and prototyping systems Assessment strategies & instructions The overall assessment strategy is designed to test problem solving capabilities through a case study in a virtual environment using computer-aided design and modelling simulation tools to satisfy LO1 and LO2, with solutions developed and submitted in a report. Coursework is carried out in groups, ranging from 3 to 6 students. Every group is expected to develop their own computer models, which will be checked and questioned by the supervisor as part of the overall assessment. No matter the number of students in group (3, 4 or 5), group will submit just one written report. The report should include the following information: Unit Title – Manufacturing System Design Unit Code – M32064 Your Student ID Number Unit Lecturer: – Dr Luka Celent Date/Month/Year 1) Introduction/Background (refers to page 2-3 and your own research work) 2) Main work (refers to page 3-4) 3) Discussions and conclusions References (if applicable) Appendix (if applicable)
Manufacturing System Design 2022-2023 Page | 2 Assignment Background In order to be competitive, modern products must be designed with production methods. Production system should be designed in a cost-effective way and the system is able to operate at optimal or near-optimal conditions. Nevertheless, design of a production system can be a complex process and any small change often makes a significant impact on the overall system performance. Implementation of the entire production system is very expensive and the cost of ‘getting it wrong’ can be very high. For these reasons, both system and product designers need to work together to ensure a ‘right first time’ scenario. Simulation techniques offer a potential solution to the major difficulties involved in design, analysis and performance evaluation of a product and a production system providing a fast delivery of alternative solutions at a minimum of cost. Nowadays, virtual prototyping techniques are commonly used in manufacturing sectors involving some form of computer-aided design and modelling simulation activities. Assignment & Tasks This assignment is based on a case study of assembling loudspeakers on a production line that needs to be investigated. A manufacturer has just upgraded its loudspeaker design by incorporating some forged parts with improved magnetic characteristics. The new loudspeaker design has additional benefits of reduced part count and part features to facilitate automatic feeding as well as simplifying the manual assembly. Figure 1 shows the basic structure of a loudspeaker. How the motor unit and the voice coil are assembled together is illustrated in Figure 2. Figure 3 shows a cross-section through a typical loudspeaker. The assembly of an entire loudspeaker is illustrated in Figure 4 and 5, respectively. The parts in the whole assembly can be grouped into two different types namely: 1. “Soft” parts: • dust cap, the diaphragm, the spider and the coil 2. “Hards” parts (These are all in the ‘motor unit’ sub-assembly) • pole piece, the magnet and the top plate together with the frame The proposed manufacturing facilities should as far as possible incorporate automation, however, it is still anticipated that some of the ‘soft’ parts may be assembled manually. The aim is to produce one loudspeaker every 30s over an 8hr working day and a 5-day week (960 units/day, 4,800 units/week). The speakers can be sold at £7/unit, giving a potential turnover of £33,600/week). After an initial investigation of the system, data collection and analysis, the following system parameters have been identified and determined: • Conveyors will be used and it may be 5, 10, 15 or 20 m long. • Each frame arrives randomly and is loaded in position (manually) in NegExp 28s. • Each pole plate can be fed/assembled in LogNormal 27s, STD: 10%. • The magnet can be fed/assembled in LogNormal 29s, STD: 10%. • The top plate can be fed/assembled between 25-28s in a uniform distribution. • Manual assembly of the spider and coil by a worker takes a time of 45-50s in a uniform distribution. • Assembly of the diaphragm takes an average time of 28s. • Manual assembly of the dust cap takes an average time of 26s. • At the magnetisation station: 30s. • At the automated test machine (ATM): 20s. • Fork-lift trucks may be used at the end of the production line and it may travel at 2m/s.
Manufacturing System Design 2022-2023 Page | 3 Figure 1. Loudspeaker construction Figure 2. Motor unit assembly Figure 3. Cross-section through a typical loudspeaker Figure 4. Engineering drawing of the assembly of the loudspeaker together with a 3D computer design assembly Figure 5. 3D model of assembled loudspeaker
Manufacturing System Design 2022-2023 Page | 4 In addition, the following system elements, operational activities and relevant information are suggested below: 1. Each finished loudspeaker will be individually bagged by a worker (s) after the ATM (automated test machine). A robot might be used to pack the finish products into a container. Each container should hold 36 loudspeakers and filled containers should be stacked and wrapped together in groups of 4 before being taken away by a fork-lift truck (s) to the warehouse. 2. Fully assembled loudspeakers are passed through an automated test machine (ATM) where 1% of inspected units do not comply with specifications and are removed for rework – rework is not part of the study. 3. An eco-friendly and safe shop floor/workshop design is encouraged. 4. Suggesting or using different Lean Manufacturing tools while planning the facility layout and assigning the tasks to the workstation is preferable. Equipment Reliability The following information is known about the breakdown and repair of equipment: Item MTBF [hr] MTTR [hr] Feeders 44 0.55 Robots 180 2.0 Stacker/Wrapper 300 1.5 Conveyors 4000 3.0 Fork-Lifts 300 2.0 Magnetiser 3500 4.5 ATM 2000 4.0 Others – – TASK You should attempt to complete the following tasks: 1. Provide a background/knowledge of the loudspeaker-related product and production through a literature study. 2. Create a process plan for assembly of a loudspeaker using ‘pre-manufactured components’. Suggest suitable assembly sequences that would benefit from automated and/or manual operational processes. 3. Produce a drawing incorporating your proposed facility layout design based on the logic sequences of assembly within a boundary (with assumptions in Note) and justify your design by considering such as space utilisation; ease of operations and services; reduction of temporary storage areas or buffer zones, transport/human operator motions; safety; costs etc. 4. Build a full system model using Enterprise Dynamics (ED) software by incorporating 3D objects (if applicable) and all the necessary statistical values; test and verify the functionality of the developed ED models. 5. Design and run suitable experiments with the developed ED models; collect, analyse and interpret the generated simulation data including graphical simulation results to be presented in the report. 6. Evaluate system performance making any improvement that would be most beneficial to the system design and explain why you consider these changes, which may be advantageous.
Manufacturing System Design 2022-2023 Page | 5 Note: Make your own assumptions due to any necessary data which may not be given or should not be included in your particular case study. This may refer to such as the availability of factory space, location of stores and so on. You may also consider how your system design may be able to cope with an increase in demands as well as product variances in future. Your work must be presented and illustrated in a written report. The report should be structured as indicated at page 1 and it should include your own work with the relevant context, drawings and screen-captures and other materials. Please keep your report concisely within 2000 words. Your work will be assessed according to the “marking criteria” as attached with this assignment. Submission A final report in writing must be submitted via Moodle by 9th January 2023 before 12:00 PM. The report must be submitted in the MS Word format. A late submission of the report and its assessment will apply in accordance with Academic Regulations, University of Portsmouth, Academic Registry, 2012.
Assessor’s Evaluation Form – Manufacturing System Design Mark Range >70% 1st Class 60-69% Upper 2nd 50-59% Lower 2nd 40-49% 3rd Class <40% Fail Weight Mark % Weighted % Self-planning, commitment & management Student has shown a professional attitude requiring little supervision and working effectively. Required minimal assistance to tackle problems and managed time well in progress Worked well with guidance and direction but did not show much initiative Minimal efforts with considerable assistance Poor self-planning; limited attendance 0.20 x Research Reference to, and thorough assimilation of some published research –based papers in the field of study Evidence of usage of background knowledge in this field through reading published materials Evidence of investigation of published materials in the relevance to this work limited investigation of sources Inadequate or no investigation; unacknowledged reliance on one source 0.10 x Analytical work, engineering analysis High standard with professional analytical work Good amount of structured analytical work and engineering analysis Some analytical work has been done, but not always properly carried out or interpreted. Very limited analytical work and analysis Inadequate or no analytical work 0.10 x Innovative Ideas & Design when modelling with ED software Creativity, synthesis, innovative thinking, predictive judgement and diagnosis while modelling and simulating using ED Confidence in use of ideas and processes within the field of manufacturing system modelling and simulation Use of ideas and processes from the field of manufacturing system modelling and simulation Evidence of some assimilation of basic concepts in the field of manufacturing system modelling and simulation Theory wrongly applied to the work in hand with little or no analysis 0.10 x Structure and quality of Report Evidence of a professional attainment in terms of the coherent presentation of the work; written report concisely with the key elements included Written material fluent and soundly structured Adequate structure, average quality Material poorly organised and largely descriptive Long on description, with structure inappropriate to content 0.20 x Evidence of completeness, evaluation and understanding of the system modelling when using ED software A proper academic and professional presentation of the report in completeness, evaluation and reflection of outcomes and engineering analysis integrated with technical aspects of the established work. Quality completeness and critical evaluation of outcomes and engineering analysis; good understanding of computer modelling simulation techniques and the developed computer models Evidence in completeness and evaluation of outcomes/alternative solutions; understanding of the major issues of the developed computer models Limited evidence in completeness and evaluation of the reported outcomes; and understanding of the developed computer models No real evidence of completeness, evaluation and understanding of the work 0.30 x The mark is given ONLY to the student who has completed the simulation model on her/his computer, and has submitted simulation files on the Moodle. SUM OF WEIGHTS 1 This marking is based on: Coursework/Report including attached models [√ ]. WEIGHTED OVERALL MARK %