1. 1 Flexible Manufacturing Manufacturing Teams Copyright © Texas Education Agency, 2012. All rights reserved.

2. Manufacturing Teams Manufacturing companies have different types of teams: – Design Team – Safety Team – Production Team 2 Copyright © Texas Education Agency, 2012. All rights reserved.

3. Design Team Manufacturing Companies use teams to develop their production plans. The teams take the customer’s designs or ideas and decide the best methods of production. The schedule of production is charted. 3 Copyright © Texas Education Agency, 2012. All rights reserved.

4. Design Team The customer wants a driving device to force pins and bolts from holes. The end of the device has to be flat and ¼” diameter. 4 1/8 CHAMPER 1 1/4 TAPER TO 1/4 DIA. 1/2 DIA. TOOL STEEL ROD 5 DRIVE PUNCH Copyright © Texas Education Agency, 2012. All rights reserved.

5. Safety Team The member of this team will review the production process for product safety and personal safety. The Occupational Safety & Health Administration (OSHA) and other manufacturing regulations are followed in order to have a safe work place. 5 Copyright © Texas Education Agency, 2012. All rights reserved.

6. Safety Team The safety team has to research the OSHA site and the manufacturing site for up to date safety data. Other sites such as the ones listed below can also be checked for regulations. -Fabricators and Manufacturers Association -American Welding Society -The Machinery's Handbook 6 Copyright © Texas Education Agency, 2012. All rights reserved.

7. Safety Requirements “Will the equipment in the factory safely produce the punch?” should be the first consideration. The heat treating furnace will have to be safely loaded and unloaded and the punches will have to have a cooling time. 7 Copyright © Texas Education Agency, 2012. All rights reserved.

8. Safety Regulations What waste materials will be produced when making the punches? Turning the punch will produce metal shavings. The lathe may use a turning fluid to keep the part cool while being made. 8 Copyright © Texas Education Agency, 2012. All rights reserved.

9. Machining Waste How will the waste materials be safety disposed of without harming the environment? The metal shavings are sharp and need to be recycled. This fluid will have to be treated to remove harmful chemicals and the clean water is fed back into the water system. 9 Copyright © Texas Education Agency, 2012. All rights reserved.

10. Production Team Production costs are figured using the following: equipment operation cost and labor cost. Time management techniques are used to prepare a work schedule. The team has to communicate with the customer and production staff so the product can be manufactured quickly and safely for a comparative price. 10 Copyright © Texas Education Agency, 2012. All rights reserved.

11. Production Team The plans are sent to the production team to review for machine steps. The manufacturing flow chart is established for the parts and machine costs are calculated. 11 Cost of Parts Machine Operating Cost Labor CostOverhead Expense Copyright © Texas Education Agency, 2012. All rights reserved.

12. Production Team The part will have to be turned on a lathe to be produced. The punch will have to be heat treated for hardness after machining is finished. 12 1/8 CHAMPER 5 1 1/4 TAPER TO 1/4 DIA. 1/2 DIA. TOOL STEEL ROD Copyright © Texas Education Agency, 2012. All rights reserved.

13. WHEN DO I HAVE TO WORK? 13 Copyright © Texas Education Agency, 2012. All rights reserved.

14. Work Schedules Manufacturing work schedules are the times workers should be on the job. There are four basic types of work schedules: – Fixed – Flexible – Non fixed – Rotating 14 Copyright © Texas Education Agency, 2012. All rights reserved.

15. Work Schedules Fixed is the same work time each week. This is the 8 to 5 daily time most people work. Flexible is when the employee has the ability to select the time they work their 40 hour work week. 15 Copyright © Texas Education Agency, 2012. All rights reserved.

16. Work Schedules Non fixed is a work schedule that has no required hours per week or required start/end time. Rotating work schedules have a fixed work week for a week or month, then the shift changes to a different time. An example of this is 7 to 4 for a week, then 4 to 12 for the next week. 16 Copyright © Texas Education Agency, 2012. All rights reserved.

17. Understanding a Drawing or Plan 17 3.5 1/4 -20 X 3/4” 1/4” dia. Rod 1/4 -20 X 3.4” Both Ends 4 3 1.37 1.250 0.375.750.250 1/4 - 20 X 3.4” Copyright © Texas Education Agency, 2012. All rights reserved.

18. Understanding a Drawing or Plan Using your handout, answer the questions about the four drawings on the following slides. 18 Copyright © Texas Education Agency, 2012. All rights reserved.

19. Punch 19 1/8 CHAMPER 1 1/4 TAPER TO 1/4 DIA. 1/2 DIA. TOOL STEEL ROD 5 1 1/2 1/8 CHAMPER 1/2 DIA. TOOL STEEL ROD Center Punch Drive Punch 5 Copyright © Texas Education Agency, 2012. All rights reserved.

20. Small Hammer 20 3.5 1/4 -20 X 3/4” 1/4” dia. Rod 1/4 -20 X 3.4” Both Ends 6 3 1.37 1.250 0.375.750.250 1/4 - 20 X 3/4” Handle Shaft Head ½” Dia. Copyright © Texas Education Agency, 2012. All rights reserved.

21. Tablet Computer Stand 21 60 30 60 I PAD STAND 17 15 10 1/2 90 BEND 60 BEND 30 BEND 60 BEND 6 Copyright © Texas Education Agency, 2012. All rights reserved.

22. Welded Angle Shelf 22 44 12 CUT ENDS AT A 45 DERGEE ANGLE ¾” ANGLE IRON IS USED TO MAKE THE SHELF Copyright © Texas Education Agency, 2012. All rights reserved.

23. SHEET METAL MATERIALS 23 Copyright © Texas Education Agency, 2012. All rights reserved.

24. Types of Metal Metal is usually divided into two groups: non- ferrous and ferrous metal. Non-ferrous metals are metals that do not have any iron particles in them. These are also non magnetic. ex: copper, aluminum, brass and bronze Ferrous metals have iron and are magnetic. ex: iron, steel, stainless steel 24 Copyright © Texas Education Agency, 2012. All rights reserved.

25. Non-ferrous Metals KindNatural/AlloyColorUse CopperNaturalReddish orange Plumbing and electrical BrassAlloy of copper and zinc YellowishMusical instruments and hardware BronzeAlloy of copper and tin Medium brown Tools, coins AluminumNaturalSilvery to dull gray Wire, building material 25 Copyright © Texas Education Agency, 2012. All rights reserved.

26. Ferrous Metals KindNatural/AlloyColorUseCarbon % IronNaturalGrayCovers and engine blocks 2% to 4 % Mild steelAlloy iron and carbon SilverSheets, wire, pipe 0% to 0.25% Medium carbon steel Alloy iron and carbon SilverRails, plates, structures 0.25% to 0.45% High carbon steel Alloy iron and carbon SilverTools, springs, instruments 0.45 to 1.50% Stainless steelAlloy iron and chromium, nickel SilverUtensils, cutlery, watch cases 26 Copyright © Texas Education Agency, 2012. All rights reserved.

27. Shapes Round diameter 3/16 – 9 inches Square ¼ by ¼ to 4 ½ by 4 ½ Flats (rectangular shapes) 1/8 by 5/8 to 3 by 4 inches Hexagons (six sided) from ¼ to 4 inches across flat sides Octagon (eight sided) ½ to 1 ¾ inches across flat sides Sheet thickness 0.0060 to 0.2391 inches, 38 to 3 gauges Plate thickness 3/16 to 10 inches 27 Copyright © Texas Education Agency, 2012. All rights reserved.

28. WELDING PROCESSES 28 Copyright © Texas Education Agency, 2012. All rights reserved.

29. Fundamentals of Oxy-fuel Processes The thickness of the metal determines the size of torch used. The American Welding Society does not have a standard tip size. Each manufacturer sizes their own tips. The chart on the next slide uses number drill sizes to size the tips. 29 Copyright © Texas Education Agency, 2012. All rights reserved.

30. Welding Tip Size 30 Metal Thickness Tip Drill SizeDiameter of RodOxygen PsiAcetylene Psi 1/3270-801/1622 60-691/16-3/3233 3/3255-591/16-1/833 1/854-573/32-1/845 3/1652-551/844 1/444-525/32-3/1644 3/840-503/16-1/455 Copyright © Texas Education Agency, 2012. All rights reserved.

31. Different Types of Acetylene Tips Welding tips are used for welding metal together. Cutting torch tips are used to heat the metal, then furnish a blast of oxygen to cut the metal. Rosebud tips are used to heat metal for straightening or bending. 31 Copyright © Texas Education Agency, 2012. All rights reserved.

32. SMAW - Stick Metal Arc Welding Sheet metal welding using an arc rod method is challenging to master. The thin metal burns through easily if too much amperage is used. The metal can overheat and distort ( warp, twist or bend). 32 Copyright © Texas Education Agency, 2012. All rights reserved.

33. Welding Sheet Metal Select the lowest welding amperage the machine has to prevent burn through. Use a 1/8” E6013 electrode because of the ease of welding with that rod. Weld several spots down the joint to help with distortion. 33 Copyright © Texas Education Agency, 2012. All rights reserved.

34. Welding Sheet Metal When the spot welds are in place, chip the flux away from the spots and weld the joint together. Watch for warping and twisting. Weld through the spots making a single bead. 34 Copyright © Texas Education Agency, 2012. All rights reserved.

35. ASSIGNMENTS 35 Copyright © Texas Education Agency, 2012. All rights reserved.

36. Welding Assignments Practice welding beads on sheet metal 1/16” thick with oxygen/fuel torch and an SMAW welder. Assignments to be graded Weld a butt joint in 1/16” thickness using oxygen/fuel welding. Weld a butt joint using 1/16” thickness metal using a SMAW welder. 36 Copyright © Texas Education Agency, 2012. All rights reserved.

37. Welding Assignment Rubrics 37 The rubrics below will be used for the sheet metal welding assignments. The handout has two rubrics for grading both the Oxygen/Fuel and the SMAW assignments. Oxygen/Fuel Welding Joint Assignment Uniformity of beads max 40 points Penetration of weld max 40 points Overall appearance max 15 points Weld splattermax 5 points Grade: Copyright © Texas Education Agency, 2012. All rights reserved. SMAW Welding Joint Assignment Uniformity of beads max 40 points Penetration of weld max 40 points Overall appearancemax 15 points Weld splattermax 5 points Grade:

38. Machining Assignments Use one of the drawings in this lesson and turn a punch or a hammer. 38 Copyright © Texas Education Agency, 2012. All rights reserved.

39. Machining: Punch Rubrics 39 Center Punch MeasurementSectionPoints Total length End taper Taper length Finish Grade Lath Project: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance the section receives 10 points. If the section is not within tolerance the points can be from 0 to 10. Add the points for a grade. Copyright © Texas Education Agency, 2012. All rights reserved. Drive Punch Total length End taper ¼” dia. end Finish Grade

40. Machining: Hammer Rubrics 40 Lath Project: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance the section receives 10 points. If the section is not within tolerance the points can be from 0 to 10. Add the points for a grade. Copyright © Texas Education Agency, 2012. All rights reserved. Hammer MeasurementSectionPoints MeasurementSectionPoints Handle length Head length Handle taper Head taper Handle thread Assemble Shaft length Finish Shaft threads Grade Shaft threads

41. Resources American Welding Society http://www.aws.org Fabricators and Manufacturers Association http://fmanet.org/ Occupational Safety & Health Administration http://www.osha.gov/ 41 Copyright © Texas Education Agency, 2012. All rights reserved.