E-portfolio LM - Muhammad Taqiyuddin Anuar

▪ Alat dimasukkan secara tegak ke 31/7/2021
dalam kerja berputar di beberapa
lokasi untuk memotong bahagian ▪ Alat bentuk runcing diberi makan secara
tersebut linier di permukaan bahagian kerja
berputar selari dengan paksi putaran pada
kadar suapan yang besar, sehingga
membuat thread. (ulir)

▪ Holding the work between centers
▪ Chuck
▪ Collet
▪ Face plate

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▪ Perbezaan antara Boring dan Turning ▪ Membuat lubang bulat di ruang kerja
▪ Boring dijalankan pada diameter dalam ▪ Berbeza dengan operasi boring yang hanya dapat
sesebuah lubang.
▪ Turning dijalankan pada diameter luar membesarkan lubang yang ada
sesebuah silinder. ▪ Alat pemotong yang disebut mata gerudi atau drill

▪ Erti kata lain, boring ialah operasi bit.
internal turning ▪ Operasi dilakukan menggunakan mesin gerudi

▪ Upright drill – mesin gerudi yang besar dan berdiri. ▪ Through-holes - gerudi keluar dari bahagian kerja yang bertentangan. (gerudi
▪ Bench drill – sama seperti upright drill tetapi kecil dan dipasang pada meja kerja. tembus)
▪ Radial drill - Mesin gerudi besar direka untuk bahagian besar
▪ Blind-holes – gerudi tidak keluar kerja di bahagian bertentangan.

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▪ Digunakan untuk sedikit membesarkan 31/7/2021
lubang, memberikan toleransi yang
lebih baik pada diameter, dan ▪ Digunakan untuk menyediakan
memperbaiki kemasan permukaan benang skru dalaman pada lubang
yang ada

▪ Alat yang dipanggil Tap

▪ Menyediakan lubang bertingkat, di mana ▪ Bahan kerja boleh dikepit dengan menggunakan vise, fixture atau Jig
diameter yang lebih besar mengikuti ▪ Vise - pemegang kerja am dengan dua rahang
diameter yang lebih kecil sebahagiannya ▪ fixture - peranti pegangan kerja yang biasanya direka khas untuk bahagian kerja
ke dalam lubang
tertentu
▪ Jig –sama dengan perlengkapan tetapi juga menyediakan alat untuk membimbing

alat semasa pengerudian.

▪ Operasi pemesinan di mana kerja digerakkan kearah alat pemotongan yang
berputar dengan pelbagai sudut.

▪ Paksi putaran alat adalah tegak lurus ke arah mata pemotongan.

▪ Membuat permukaan satah; bentuk geometri lain mungkin sama ada melalui sudut
pemotong atau bentuk.

▪ Faktor dan syarat lain:
▪ Milling adalah interrupted cutting operation
▪ Alat pemotong yang disebut milling cutter,bahagian tepi mata alat disebut “teeth“
▪ Mesin digunakan dipanggil mesin milling/kisar.

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▪ Peripheral milling ▪ Bentuk asas peripheral milling di mana lebar alat pemotong melebihi bahan kerja
▪ Paksi pemotong selari dengan permukaan yang dimesin di kedua-dua belah bahagian.
▪ Keratan tepi di pinggir luar pemotong

▪ Face milling
▪ Paksi pemotong berserenjang dengan permukaan yang digiling
▪ Keratan tepi di hujung dan luar pemotong

▪ Lebar mata alat pemotong kurang dari lebar benda kerja, mehasilkan slot dalam ▪ Mata alat pemotong berfungsi di kedua-dua bahagian.
bahan kerja

▪ Diameter alat pemotong kurang dari ▪ Proses end mill di mana bahagian tepi yang
lebar kerja, jadi setiap slot dipotong rata dipotong
menjadi bahagian tertentu.

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31/7/2021

▪ Satu lagi proses end mill yang digunakan untuk ▪ Ball-nose mill dijalankan berulang-alik di
menggisar poket cetek pada bahagian sepanjang permukaan bagi menghasilkan
permukaan rata. lengkung pada time interval tertentu
untuk membuat bentuk permukaan tiga
dimensi.

▪ Mesin automatik yang mampu melakukan pelbagai operasi pemesinan di bawah
kawalan CNC dalam satu setup dengan perhatian dan kawalan manusia yang
minimum.
▪ Operasi kebiasaan yang dijalankan ialah milling dan turning.
▪ Mampu merangkumi 3, 4 & 5 paksi.

▪ Ciri-ciri lain;
▪ Penukaran mata alat automatik
▪ Pergerakan ulang-alik.
▪ Penukaran kedudukan bahan kerja secara automatik.

▪ Alat pemesinan yang sangat automatik yang dapat melakukan operasi turning,
milling, dan penggerudian di bahagian benda kerja.

▪ Boleh meletakkan benda kerja silinder pada sudut yang ditentukan sehingga alat
pemotong berputar (milling cutter) dapat menjalankan proses pemesinan.
▪ Conventional turning machine tidak dapat menghentikan bahagian kerja pada
kedudukan sudut yang tertentu dan tidak mempunyai spindle penukar mata alat.

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▪ Menggunakan alat pemotong satu titik 31/7/2021
yang bergerak secara linear terhadap
bahagian benda kerja. ▪ Menggerakkan alat pemotong bergigi
yang berperingkat secara linear dengan
▪ Hasil kerja berupa permukaan rata. arah paksi alat pada bahagian benda
▪ Kelajuan yang perlahan kerana kerja.

pergerakan mula-henti (start-and-stop ▪ Kelebihan:
motion) ▪ Kemasan permukaan yang baik
▪ Toleransi yang baik

▪ Alat pemotong yang disebut broach
▪ Oleh kerana rumit dan mata alat sering

custom, perkakasnya mahal.

▪ Memotong dalam bahan kerja menggunakan alat yang terdiri ▪ Kelajuan pemotongan lebih tinggi dari penggunaan operasi alat pemesinan
daripada rangkaian gigi yang tajam dengan jaraknya sempit. konvensional.

▪ Dikenali dengan nama saw blade. ▪ Trend berterusan sepanjang sejarah pemesinan adalah kelajuan pemotongan yang
lebih tinggi dari semasa ke semasa.
▪ Fungsi kebiasaannya untuk;
▪ Memisahkan bahan kerja kepada dua atau lebih bahagian. ▪ Pada masa ini terdapat minat baru dalam HSM karena berpotensi untuk kadar
▪ Memotong bahagian bahan kerja yang tidak diperlukan. pengeluaran yang lebih cepat, lead time yang lebih pendek, dan pengurangan
kos.

▪ DN ratio = bearing bore diameter (mm) multiplied by maximum spindle speed
(rev/min)

▪ For high speed machining, typical DN ratio is between 500,000 and 1,000,000
▪ Allows larger diameter bearings to fall within HSM range, even though they

operate at lower rotational speeds than smaller bearings

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31/7/2021

▪ hp/rpm ratio = ratio of horsepower to maximum spindle speed ▪ Bearing khas yang dirancang untuk rpm tinggi
▪ Conventional machine tools usually have a higher hp/rpm ratio than those ▪ Keupayaan kadar suapan tinggi (mis., 50 m / min)
▪ Kawalan gerakan CNC dengan ciri “look ahead" untuk mengelakkan jalan mata
equipped for HSM
▪ Dividing line between conventional machining and HSM is around 0.005 hp/rpm alat "undershooting" atau "overshooting"
▪ Thus, HSM includes 15 hp spindles that can rotate at 30,000 rpm (0.0005 hp/rpm) ▪ Alat pemotong, pemegang alat, dan spindle yang seimbang untuk mengurangkan

getaran.
▪ Sistem penghantaran coolant yang dapat memberikan tekanan yang lebih tinggi

daripada sistem pemesinan konvensional
▪ Sistem cip kawalan untuk mengatasi kadar penyingkiran logam yang jauh lebih

besar.

▪ Industri kapal terbang, pemesinan komponen kerangka besar dari blok aluminium ▪ ©2002 John Wiley & Sons, Inc. M. P. Groover, “Fundamentals of Modern
besar. Manufacturing 2/e”
▪ Banyak penyingkiran logam, kebanyakannya dengan milling.

▪ Banyak operasi pemesinan pada aluminium untuk menghasilkan komponen
automotif, komputer, dan perubatan
▪ Penukaran mata alat dan kawalan mata alat yang laju dan penting.

▪ Industri die-and-mold
▪ Membuat bentuk geometri kompleks dari bahan keras

DETERMINE CUTTING
PARAMETERS

DMA1082

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Explaination Video

• Determine cutting parameter for Lathe – drill – milling
• Speed – rate at which the metal is removed by tool
• Feed – distance travelled by the tool on the workpiece
• Depth of cut – thickness of metal removed in one cut of the tool
• Machining time – time taken for one machining process

BASIC FORMULAE MACHINING PARAMETERS FOR LATHE
OPERATIONS

• Cutting speed
1. Cutting speed of a tool is the speed at which the metal is removed by the tool from the
workpiece
2. In a lathe it is the peripheral speed of the work past the cutting tool expressed in meter per
minute.

• Feed
1. The longitudinal feed of a cutting tool in lathe work is the distance that a tool advances for
each revolution of the work.
2. It is expressed in mm/rev

MACHINING PARAMETERS FOR LATHE
OPERATIONS

• Depth of Cut
1. The depth of cut is the perpendicular distance measured from the machined surface to
the unmachined surface of the workpiece

• Machining time
1. If rotational speed, feed and length of the workpiece known then machining time for
turning can be calculated.

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MACHINING PARAMETERS FOR LATHE MACHINING PARAMETERS FOR MILLING
OPERATIONS OPERATIONS

• Video
https://www.youtube.com/watch?v=WwAzeGQzmeY&t=206s

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MACHINING PARAMETERS FOR MILLING MACHINING PARAMETERS FOR DRILL
OPERATIONS OPERATIONS

• Video
https://www.youtube.com/watch?v=70yT7_qizt8

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MACHINING PARAMETERS FOR DRILL
OPERATIONS

• Video
https://www.youtube.com/watch?v=3uMiYQCFoTY&t=72s

THANK YOU!

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CHAPTER 3: EQUIPMENT 31/7/2021
AND TOOLS PLANNING
Pengenalan Jigs & Fixtures
DMA1082
 Kejayaan menjalankan operasi pengeluaran secara besar-besaran bergantung kepada
pertukaran yang boleh ditukar untuk memudahkan pemasangan dan pengurangan kos
unit.

 Kaedah pengeluaran besar-besaran memerlukan kaedah kerja penentuan kedudukan
yang cepat dan mudah untuk operasi yang tepat di atasnya.

 Jigs dan fixtures adalah production tools yang digunakan untuk menghasilkan komponen
pendua (duplicate) dan yang boleh ditukar(interchangeable) dengan tepat.

 Jigs dan fixtures direka khas supaya sebilangan besar komponen dapat dimesin atau
dipasang secara serupa, dan untuk memastikan pertukaran komponen yang selaras
(interchangeability).

Jigs

 Ia adalah alat penahan kerja yang memegang, menyokong dan mencari benda kerja dan
memandu alat pemotong untuk operasi tertentu.

 Jig biasanya dilengkapi dengan bushings besi yang dikeraskan untuk memandu atau alat
pemotong lain. jig adalah sejenis alat yang digunakan untuk mengawal lokasi dan / atau
pergerakan alat lain.

 Tujuan utama jig adalah untuk memberikan kebolehulangan (repeatability), ketepatan
(accuracy), dan keupayaan pertukaran (interchangeability) dalam pembuatan produk.

 Peranti yang melakukan kedua fungsi (memegang kerja dan membimbing tools) dipanggil jig.

BORING JIG

 Contoh jig adalah apabila kunci diduplikasi, yang asli digunakan sebagai jig sehingga kunci baru
dapat memiliki jalan yang sama dengan yang lama.

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FIXTURES A VISE-JAW FIXTURE

 Ia adalah alat pemegang kerja yang memegang, menyokong dan mencari benda kerja untuk
operasi tertentu tetapi tidak membimbing alat pemotong. Ia hanya menyediakan permukaan
rujukan atau peralatan sokongan.

 Apa yang menjadikan sesebuah fixtures unik adalah bahawa setiap satu dibina untuk
memenuhi bahagian atau bentuk tertentu.

 Tujuan utama fixtures adalah untuk mencari dan dalam beberapa kes memegang benda kerja
semasa operasi pemesinan atau proses pembuatan yang lain.

 jig berbeza dari fixtures kerana ia mengarahkan alat ke kedudukannya yang betul di samping
mencari dan menyokong benda kerja.

 Contoh fixtures – vise & chucks

Perbezaan Jigs & Fixtures Kelebihan Jigs & Fixtures

Jigs fixture

Ia adalah alat pemegang kerja yang memegang, Ia adalah alat pemegang kerja yang memegang,

menyokong dan mengesan benda kerja dan memandu menyokong dan mengesan benda kerja untuk operasi

alat pemotong untuk operasi tertentu. tertentu tetapi tidak membimbing alat pemotong Interchangeability
& Kualiti
Produktiviti

Jig tidak disepit ke meja tekan gerudi kecuali diameter fixtures dipasang dengan kemas ke meja mesin walaupun
besar untuk digerudi dan ada keperluan untuk kerja sudah selesai.
menggerakkan jig untuk membawa setiap bush tepat di
bawah gerudi.

Jig adalah alat khas terutamanya dalam operasi fixtures adalah alat khusus yang digunakan terutama

penggerudian, reaming, tapping & boring. dalam mesin milling, shapping dan slotting. SKILL Yang Mudah Pengurangan Kos

Gauge blocks tidak diperlukan. Gauge blocks mungkin diperlukan untuk pengendalian
operasi yang lebih berkesan.

Prinsip asas pembangunan Jig & Fixtures Faktor yang perlu dipertimbangkan untuk
reka bentuk jigs & fixtures

Locating Fool proof Berat Jigs komponen Kapasiti mesin Keperluan Lokasi jig &
points dilengkapi pengeluaran fixtures

kaki

Alatan Bahan Pengurangan Pengaturan Urusan Clearance Ejectors
pengapit Waktu Idle pengapit memuat dan antara Jig dan
memunggah
Komponen

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Faktor yang perlu dipertimbangkan untuk
reka bentuk jigs & fixtures

Base and Tool guiding Rigidity and Gauges and measuring
Body & cutter vibration instrument
setting
construction

Keselamatan Kos

Pengenalan Gauges

 Gauge adalah alat yang digunakan oleh jurutera untuk memperbaiki  Plain Gauge didefinisikan sebagai alat pengukuran atau pemeriksaan dimensi, tanpa skala
kesalahan dari segi pengukuran linear. Pengukuran linear berkaitan untuk mengukur mana-mana bahagian pembuatan alat.
dengan panjang, ketinggian, diameter, dll
 Untuk memeriksa shaft & holes, Plain Gauge digunakan.
 Alat ukur digunakan untuk mengukur kuantiti fizikal. Terdapat pelbagai  Plain Gauge dikelaskan kepada empat jenis;
jenis dan bentuk instrumen untuk melakukan pengukuran.
 Bergantung pada prinsip dan jenis pembuatan.
 Bergantung pada tujuan
 Bergantung pada fungsinya
 Bergantung pada Reka Bentuk

Bergantung pada prinsip dan jenis pembuatan Bergantung pada prinsip dan jenis pembuatan

 Standard Gauge - didefinisikan sebagai alat pengukur yang memeriksa salinan bahagian  Limit Gauge didefinisikan sebagai gauges yang digunakan
mating bahan. Alat pengukur ini tidak dapat digunakan oleh jurutera kerana adanya toleransi untuk mengukur komponen dengan dua had, satu tinggi
pada benda kerja. dan satu lagi rendah. Jadi, ada dua alat pengukur untuk
mengukur dimensi bahan.

 Dua alat pengukur adalah Go-Gauge dan Not-Go-Gauge.
Bahagian komponen harus melalui Go-Gauge dan untuk
Not-Go-Gauge, ia tidak boleh melepasi. gauges ini banyak
digunakan dalam industri.

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Bergantung pada prinsip dan jenis pembuatan Bergantung pada prinsip dan jenis pembuatan

 Indicating Gauge didefinisikan sebagai gauges yang  Combination Gauge didefinisikan sebagai tolok yang boleh mengambil lebih dari satu dimensi
digunakan untuk mengukur bahagian bahan dan bahagian-bahagian bahan secara berturut-turut. Ia sangat berguna kerana pada satu masa
menunjukkan pengukuran pada paparan. gauges ini lebih daripada satu pengukuran bahagian dapat diambil. Ia memakan masa yang lebih sedikit
menampilkan pengukuran pada indikator atau paparan. dan menghasilkan hasil yang lebih cekap.
gauge ini kompleks daripada alat pengukur lain.

 Contoh terbaik dari Indicating Gauge ialah Dial Gauge.
Pada masa ini alat penunjuk seperti ini mempunyai
sistem paparan visual.

Bergantung pada tujuan Bergantung pada tujuan

 Workshop Gauge didefinisikan sebagai alat pengukur yang  Inspection Gauge didefinisikan sebagai alat  Master Gauge didefinisikan sebagai alat
digunakan untuk mengukur bahagian-bahagian bahan pada pengukur yang digunakan oleh pemeriksa pengukur untuk memeriksa alat pengukur
masa pengeluaran. Tolok ini digunakan dalam masa di kilang setelah pembuatan produk selesai yang lain. Ia sangat berguna kerana
pengeluaran di bengkel. sebelum menerimanya. Oleh kerana kecekapan alat pengukur yang lain
penerimaan atau penolakan bergantung bergantung pada master gauge.
 Workshop Gauge direka seperti itu, di mana toleransi berada pada pengukuran tolok supaya toleransi
di garis tengah. Supaya Workshop Gauge sangat berguna di Inspection Gauge ini sedikit lebih daripada  Sekiranya master gauge tidak dapat
kilang atau bengkel berbanding yang lain. workshop gauge. memeriksa alat pengukur atau instrumen
lain dengan betul maka alat pengukur dan
 Sekiranya tolerance komponen tinggi maka instrumen tersebut tidak dapat memberikan
ia diterima sebaliknya komponen tersebut hasil yang tepat
harus ditolak

Bergantung pada fungsinya Inside Dimension Plug Gauge
Measuring Gauge Pin Gauge
 Dimension Measuring Gauge didefinisikan sebagai tolok yang mengukur parameter bahagian-
bahagian bahan yang sangat kecil dengan ketepatan yang sangat tinggi. Dimensi ini adalah Outside Dimension Snap Gauge Geom etric
kedalaman, tinggi, diameter, dan lain-lain. Measuring Gauge Ring Gauge Measuring Gauge

 Tolok ini digunakan untuk mendapatkan dimensi yang sangat spesifik dan tepat. Ianya dikelaskan Dimension Calliper Gauge
dalam tiga jenis seperti berikut: Measuring Gauge
 Inside Dimension Measuring Gauge Gauge of Taper
 Outside Dimension Measuring Gauge Both sides
 Both sides Dimension Measuring Gauge Dimension Gauge of Profile
Measuring Gauge

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Bergantung pada Reka Bentuk Measurement instruments

 Single limit and Double limit - single limit gauge mempunyai rahang yang tetap yang  Dibahagikan kepada 3 jenis –
menjadikan tolok terhad, Tetapi dalam hal double limit gauge, ia mempunyai rahang bergerak  Semi precision measurement
yang dapat digandakan dengan bantuan rahang yang boleh disesuaikan.  Precision measurement
 High precision measurement
 Single-ended and Double-ended - single-end gauge mempunyai hujung tunggal yang boleh
menjadi ‘Go end’ atau ‘No-go end’ Tetapi di Double-end gauge mempunyai kedua
hujungnya, satu hujungnya adalah 'Go end' yang satu lagi adalah 'No-go end'.

 Fixed and Fastened Gauges - Pada fixed end gauge, kedua rahang dipasang pada masa yang
sama, tetapi di Fastened end gauge hanya satu rahang yang boleh bergerak atau boleh
disesuaikan

Semi precision measurement

 Pembaris  Instrument pengukuran sudut
 Adjustable Square  Protektor
 Angkup  Bevels
 Die makers square
 Angkup luar
 Angkup dalam
 Tolok tetap
 Tolok radius
 Tolok fillet
 Tolok sudut

Precision measuring instrument

 Surface Plate  Dial and Digital Calipers
 Vernier Measuring tools  Surface finish Measurement

 Vernier Calipers  Surface Roughness Comparator
 Vernier Height Gage
 Vernier Protractor
 Micrometers
 Outside Micrometer
 inside Micrometer
 Depth Micrometer

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High precision measurement Evolution of Measuring Instruments

 coordinate Measuring Machine (CMM) CM M
 Mesin moden yang digunakan untuk pengukuran yang sangat tepat.
 CMM berfungsi berdasarkan prinsip Pengukuran Koordinat iaitu Visual Universal
Inspection M easuring
pengukuran berdasarkan pengumpulan titik data yang diambil dalam machines M achines
Sistem Koordinat Cartesian
Length Gauges and
Comparator Dial
Indicators

Gauge
Blocks

M icrometer

Cubit

CHAPTER 3: EQUIPMENT
AND TOOLS PLANNING –

CUTTING TOOLS

DMA 1082

INTRODUCTION

• Satu proses di mana bahan mentah (raw material) dipotong menjadi bentuk dan
ukuran yang diinginkan dengan alat pemotong tajam dikenali sebagai Proses
Pemesinan.

• Proses pemesinan:
• Drilling
• Turning
• Milling

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APA ITU CUTTING TOOLS • Single-Point Cutting Tool
• Cutting tool dalam bentuk paling ringkas
• Cutting tools / mata alat digunakan untuk mengasingkan bahan dari permukaan • Hanya mempunyai satu sudut pemotongan untuk memotong bahan.
benda kerja. Ia mesti lebih keras daripada bahan kerja untuk menjalankan operasi • Arah pergerakan cutting tools boleh dari kanan/kiri.
pemesinan tertentu. • Contoh; cutting tools untuk operasi turning,shaping dan boring.

• 2 jenis kategori cutting tools • Multi-Point Cutting Tool
• Single-Point Cutting Tool • Mempunyai lebih dari satu alat pemotong untuk membuang lebihan bahan.
• Multi-Point Cutting Tool • Ia dianggap sebagai satu siri titik pemotong tunggal di penjuru
• Operasi setiap bahagian memotong secara bebas memotong benda kerja.
• Contoh; cutting tools untuk milling, drill.

MILLING CUTTING TOOLS

• Mata alat bergerak tegak lurus ke • Roughing end mill • Wood ruff cutter
paksinya, membenarkan ia
mengeluarkan bahan dari benda kerja • Slab mill • Thread mill cutter
dalam perimeter mata alat.
• End mill cutter • Fly cutter
• Mesin milling adalah mesin serba boleh
di mana kita dapat melakukan pelbagai • Hollow mill • Slide and face
operasi pemesinan. cutter
• Ball mill cutter
• Hobbing cutter
• Involute gear
cutter • Dovetail cutter

• Face mill cutter

FLAT END MILL BALL ENDMILL

• Mempunyai bentuk rata di permukaan. • Mempunyai permukaan yang bulat.
• Diperbuat daripada HSS, Cobalt dan Solid Carbide. • Untuk kerja-kerja pemotongan 3D.
• Mempunyai 4 sudut kritikal yang mempengaruhi keberkesanan • Mempunya geometri yang hampir sama dengan Flat Endmill.

pemotongan iaitu cutting edge angle, axial relief angle, radial 7
relief angle dan radial rake angle.
• Terdapat beberapa “flutes” dan “teeth” seperti 2,3,4,6 dan 8
Flutes.
• Digunakan untuk proses pemotongan Slot, Contour, Pocket dan
sebagainya.

BULL NOSE END MILL 31/7/2021

• Mempunyai radius yang kecil pada bucu dan membolehkan FACE MILL
ianya membuat pemotongan yang memerlukan chamfer atau
radius. • Digunakan untuk pemotongan permukaan yang luas
secara rata.
• geometri hampir sama dengan Flat Endmill.
• Juga mempunyai “flutes” dan Teeth” • Menggunakan Carbide Insert sebagai mata pemotong.
• Mempunyai bilangan teeth sepert 4,5,6 teeth.
CHAMFER TOOL
CENTRE DRILL
• Digunakan untuk membuang lebihan bucu yang tajam pada
benda kerja yang siap di mesin. • Digunakan untuk membuat lubang kecil untuk membolehkan
Twist Drill membuat penebukan yang tepat di koordinat yang
• Mempunyai flutes untuk memastikan keberkesanan mata alat diinginkan.
dalam operasi Chamfer.
• Menjadi sebagai “pemandu arah” untuk Twist Drill menebuk
tanpa tergelincir.

TURNING CUTTING TOOLS

• Mesin larik adalah mesin yang memutar benda • Turning tool. • Boring tool.
kerja mengenai paksi putaran untuk melakukan
pelbagai operasi seperti menampang, • Chamfering tool. • Parting-off tool.
menggerudi,threading,boring dll.
• Thread cutting tool. • Counterboring tool
• Mata alat yang digunakan ialah jenis single point
tool. • Internal thread • Undercutting tool
cutting tool. • Knurling tool
• Kaedah untuk mengaplikasikan Feed
• Right-hand tool • Facing tool.
• Left-hand tool
• Round Nose • Grooving tool.

• Forming tool.

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TURNING TOOL TURNING TOOL

• 2 jenis turning tools • Rough turning tool • Finish turning tool
• Rough turning tool
• Finish turning tool • Digunakan untuk membuang logam pada • Digunakan untuk membuang sejumlah kecil
kadar maksimum dalam masa minimum yang logam.
dibenarkan oleh alat, kerja, dan mesin.
• Sudut mata alat sangat rata sehingga dapat
• Sudut pemotongan sangat rata sehingga dapat menghasilkan permukaan yang sangat halus
menahan tekanan pemotongan yang dan tepat.
maksimum

CHAMFERING TOOL THREAD CUTTING TOOL

• Mata alat ini digunakan untuk memotong sudut di sudut • Alat pemotong benang (Thread cutting tool)
silinder dan digerakkan secara serong. digunakan untuk memotong benang pada
bahagian pelarik. Dalam pemotongan benang
• Chamfer boleh digunakan untuk melicinkan tepi tajam atau luaran, bahagian itu dapat dipegang pada chuck
berbahaya pada benda kerja. atau dipasang di antara dua pusat.

• bagi pemotongan benang dalaman, bahagian itu
dipegang pada chuck, alat bergerak melintasi
bahagian secara linier, membuang cip dari
benda kerja dengan setiap pergerakan

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• External thread cutting tool

FACING TOOL

• Facing tool membuang logam dengan mata pemotong disudut tepi sebelahnya.

• Internal thread cutting tool

KNURLING TOOL PARTING TOOL

• Operasi membentuk logam digunakan untuk menghasilkan corak • Mata alat berbentuk mata pisau yang digunakan untuk melarik atau mengetam atau
silang biasa di permukaan kerja. untuk memotong bahan menjadi dua bahagian.

• Fungsinya sebagai pegangan untuk pemegang, juga biasanya • Lebar mata alat antara 3 hingga 12 mm sahaja. Panjang mata alat yang dimasukkan
dibuat pada pengikat seperti nut. ke dalam bahan kerja mestilah lebih panjang sedikit daripada jejari bahan yang
dimesin.
• Knurling tool direka dengan corak tertentu

KAEDAH UNTUK MENGAPLIKASIKAN FEED DRILLING CUTTING TOOL

Right-hand tool Left-hand tool Round Nose

Pergerakan dari tailstock ke Pergerakan dari headstock ke Biasanya digunakan untuk finishing
headstock ketika operasi dijalankan tailstock ketika operasi dijalankan operasi turning.

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REAMING TAPPING

• Ialah satu operasi untuk menjadikan dimensi lubang sedia ada lebih tepat daripada • Benang dalaman pada benda kerja dapat dihasilkan dengan tapping.
yang telah dicapai semasa menggerudi sebelumnya & meningkatkan surface finish • Tap ialah mata alat yang menghasilkan cip benang dengan gigi pemotong yang banyak.
lubang tersebut.

• the dreamer – mata alat yang menggabungkan reaming & drilling. Hujung mata alat
menjalankan operasi drilling, dan seterusnya operasi reaming dijalankan dalam
masa yang sama.

CUTTING TOOL COATING KELEBIHAN FUNGSI LAPISAN COATING

• Apabila mata alat dilapisi dengan betul dan berfungsi seperti yang dirancang, Menambah Life Menurunkan Meningkatkan
hasilnya bagi pengguna adalah kadar pemotongan yang lebih tinggi, jangka hayat Time (waktu koefisien kekerasan
alat yang lebih lama dan dry machining yang selamat. pakai). gesekan. permukaan.

Meningkatkan Meningkatkan
stabilitas suhu oksidasi dan
ketahanan kimia
tools

KELEBIHAN FUNGSI LAPISAN COATING KAEDAH UNTUK COATING CUTTING TOOLS

Memungkinkan Mengurangi Mengurangi CVD (Chemical • kaedah melibatkan pemanasan substrat dalam reaktor
peningkatan gaya potong adanya chip Vapor Deposition) kimia dan mendedahkan substrat ke aliran gas. Gas
Feeding dan yang menempel pecah di permukaan substrat panas, membentuk
RPM lapisan pelapis.

Meminimalkan Pengerjaan PVD (Physical • kaedah memerlukan suhu sekitar 1,000 darjah celcius
jumlah coolant tanpa coolant – Vapor Deposition) • Lapisan biasa menggunakan ketiga-tiga gas TiCL4
yang digunakan, dry machining
(titanium tetrachloride), H2 (hydrogen), & N2 (nitrogen)
= TiN (titanium nitride) + HCl (Hydrogen Chloride).

• kaedah melibatkan pengangkutan bahan laminasi
dalam vakum dari sumber melalui ruang pengangkutan
ke substrat.

• Bahan lamina diuapkan menggunakan tenaga haba atau
elektrik dari sumber kuasa, yang kemudian
membolehkan bahan yang diuapkan melekat pada
substrat.

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PVD (PHYSICAL VAPOR DEPOSITION) KELEBIHAN & KEKURANGAN CVD & PVD

• Dua teknologi utama dalam PVD yang digunakan untuk melapisi substrat yang CVD PVD
berbeza: arc method dan sputtering method
• Kelebihan - lekatan lapisan • Kelebihan - suhu operasi
Arc method Sputtering method yang optimum, serta yang agak rendah, sekitar
• melibatkan sumber kuasa • melibatkan sumber tenaga pengagihan lapisan yang 450 ° C
konsisten.
elektrik menghentam bahan termal, yang mengubah • Kekurangan - lapisan
lamina dan mengubah bahan lamina pepejal dengan segera • Kekurangan - suhu tinggi permukaan dalaman sukar
ini dari pepejal ke cecair ke menjadi keadaan gas. Tidak mempengaruhi kualiti (lapisan memerlukan garis
fasa gas. ada titisan berlaku kerana substrat. penglihatan dari bahan
bahan melepasi fasa cecair. lamina ke substrat) dan
keperluan permukaan
substrat jauh lebih tinggi.

CUTTING TOOL LIMITATION • Tiga bentuk Kegagalan mata alat

• Faktor yang mempengaruhi cutting tool life • Fracture failure
• Keadaan pemotongan. • Daya pemotongan menjadi berlebihan menyebabkan patah rapuh.
• Geometri alat.
• Bahan alat. • Temperature failure
• Bahan kerja. • Suhu pemotongan terlalu tinggi untuk mata alat & bahan.
• Cecair pemotongan.
• Getaran sistem kerja alat mesin • Gradual wear
• Mata alat semakin haus setelah digunakan.

• Fracture dan suhu adalah kegagalan pramatang.

• Gradual wear menunjukkan kepada penggunaan mata alat yang paling lama

• Gradual wear berlaku pada dua bahagian mata alat;
• Crater wear – occurs on top rake face
• Flank wear – occurs on flank (side of tool)

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Chap 4 – PLANNING  4.1 Work standards document
 4.1.1 Standard Operation procedures (SOP)
DMA1082 – PROCESS PLANNING  4.1.2 Work instruction
 4.1.3 Instruction Charts
 4.1.4 Control Plan
 4.1.5 Process planning sheet

 4.2 Methods
 4.2.1 Manual method
 4.2.2 Computer Aided Process Planning (CAPP)

An overview def: standard work

The new employee steps onto the production line, eager to get to  Standard work is a detailed representation and documentation of
work, when the old veteran says, “Just watch what I do. You will figure the most efficient method to produce a product or service.
it out in no time.”
The new employee watches the veteran work, quietly noting that  It breaks down current state work into the elements and
others working in the area seem to be doing the same work in all sorts characteristics needed to understand and perform a process
of different ways. repeatedly.
What’s going on, here? What is the right way to do the job? What is
the standard work?  Standard work provides a method to document the process
information in a written format.

 It is also considered a very useful learning tool. It provides enough
information so that new comers and workers on the job can use
them to do their work more efficiently.

Takt time = production rate to meet Takt Benefits of standard work
customer demand time

Reduces Faster training
variability ramp-up
periods
Standard
work Information for
element process

Standard Work time improvement
inventory & projects

sequence

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Standard 31/7/2021
Operation
procedures Standard Operating Procedures
(SOP)
(SOP)
 a document that describes the best way to execute a process and
Process Work its activities to maintain consistent working practices.
planning instruction
 It represents the what will be done, how it will be done, and who will
sheet Standard be responsible for making sure it gets done
Work
 Standard work and SOP documents may contain written
Document instructions, drawings, flowcharts, photographs, checklists, or any
other information needed to clearly communicate the standard.

Control Instruction
Plan Charts

What is in SOP? SOP
Manufacturing
 The description and scope of the work.
 Why things are done in a certain way. Process
 The exact work sequence involved in which activities are
SOP Services
completed. Process
 The optimal amount of time needed for each activity.
 The rate at which products must be produced to meet customer

demand.
 Responsibilities and work distribution.
 Key points related to safety, quality and performance.
 The materials, equipment and tools needed to complete the work.
 A revision control system

Work instruction (WIs) Work instruction (WIs)

 Wis are elaborated and linked to the SOP. In addition to describing  Based on a user manual, work instructions should use simple
the activities and those responsible for them, these documents language and be written using an uncomplicated step-by-step
provide more details on the tasks, including aspects such as the process with information that is essential to perform the task.
mode and time of execution.
 Images, photos and tables can be used to further facilitate
 In other words, WIs show “how” activities are carried out. employee understanding

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•Standard Operating Procedures are
the top layer. They describe which
actions to take under a variety of
circumstance
•Work instructions are the lowest
layer. They describe the work to be
performed. These provide the lowest
possible level of detail. As the name
implies they are instructions to
perform a specific piece of work.
Some are less than one page. Just a
list of bullet points

Main differences between Process, Procedure, & WIs

Cont.. Instruction Charts

 A chart may be a diagram, a picture or a graph which gives an
overall view of the situation, say a process. It helps visualizing various
possibilities of alteration or improvement.

 A chart records graphically or diagrammatically, in sequence, the
operations connected with a process.

 The chart portrays the process with the help of a set of (process
chart) symbols and aids in better understanding and examining the
process with a purpose to improve the same.

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 An outline instruction chart:

 Surveys and records an overall picture of the process and states only
main events or steps sequence-wise,

 It helps visualising and comprehending the full process so that necessary
improvements may be made if required,

 It shows relationship between the different activities.

 It considers only (main) operations and inspections, and thus it makes
use of only two symbols,

 Each operation and inspection is numbered from the beginning to the
end of the chart,

 Description of operations and inspections are written on the right-hand
side of the symbols

Control Plan

 A method for documenting the functional elements of quality
control that are to be implemented in order to assure that quality
standards are met for a particular product or service.

 The intent of the control plan is to formalize and document the
system of control that will be utilized.

Why is a Process Control Plan How to Fill Out A Process Control
important? Plan

 Each process area knows what they need to do quality-wise, and they know how  The left side
their work is evaluated.  The columns on the left list the process steps or the products (usually purchased from external
suppliers) to be controlled.
 It shows whether there is a quality system in place, and it gives the information
needed to evaluate whether there are holes in that system.  Here are typical code letters for special characteristics:
 A = Critical to Quality (CTQ), need to have very specific actions taken
 The quality manager can draw a process improvement plan based on the holes he  B = Functional dimensions and therefore tolerances need to be monitored
detects.  C = Need monitoring but calls for fewer resources

 Top management can set up an audit schedule that verifies that the plan is
respected.

 It gives customers much confidence about the organization’s capability to deliver
good quality.

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How to Fill Out A Process Control Process planning sheet
Plan
 A set of manufacturing instructions for a specific batch, lot, or runs. It
 The right side describes the operating parameters and settings for the equipment
 The columns on the right include the standard and the tolerance, the control method and and facilities used. And also associated tooling or supplies.
sampling, and reaction plan.
 It contains part information, routing information, and operation
detail information.

The components outlined in a Structure of a typical process sheet
process sheet for manufacturing

 A process sheet for machining comprises of two units,  Outlining the sequence of work.
 A route sheet.
 A process sheet.  Figuring out the assemblies and sub-assemblies involved and drawing a map to figure
out where each one fits.
 A route sheet is like a map that mentions the path to be followed,
and exactly how the production and management activities were  Determining the number of units to be produced.
to proceed.
 Machines, tools, and details of other instruments required, along with other details like
 A process sheet not only mentions the step-by-step programs to be their efficiency, capacity and run times to be mentioned.
followed but also one which outlines all the materials required for
each task, maintains a logbook of items that arrived or yet to arrive  The sequence of these operations, drawn in detail on a map which develops a clear
conception of how the raw material is converted into the finished product.

 A certain quality is required throughout the process; hence quality controlling
instructions are also important.

 Instructions during packing and handling of the products, or movement during the
processing are also mentioned.

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Process Planning Method

• Manual method
• Computer Aided Process Planning (CAPP)

recap The development of process plans

 Process planning acts as a bridge between design and manufacturing by  Analysis of part requirements
translating design specifications into manufacturing process details.  Selection of raw work piece
 Selection of manufacturing operations and their sequences
 Process planning answers the questions regarding required information and  Selection of machine tools
activities involved in transforming raw materials into a finished product. The  Selection of tools, tool holding devices, work holding devices and
process starts with the selection of raw material and ends with the completion of
part. inspection equiptments
 Selection of manufacturing conditions i.e. cutting speed, feed and

depth of cut
 Determination of manufacturing times

Manual method Computer Aided Process Planning
(CAPP) method
 The manual method based process planning is most widely used.
 It is mainly based on a manufacturing engineer's experience and knowledge  a system was developed in which design
information is processed by the process
of production facilities, equipment, their capabilities, processes and tooling. planning system to generate manufacturing
 The major problem with this approach is that it is time consuming and process details.

developed plans may not be consistent and optimum.  Computer Aided Process Planning (CAPP)
 The feasibility of developed process plan is dependant on many factors such Systems are designed with two approaches.
These approaches are called:
as availability of machine tools, scheduling and machine allocation etc.
 Modern industry is currently lacking skilled labour force to produce machined  (a) Retrieval CAPP Systems, and (b)
Generative CAPP Systems
parts as was done in the past.
 Computer Aided Process Planning is developed to overcome these problems

to some extent.

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Comparison between manual &
CAPP

 Systematic development of accurate and consistent process plans.
 Reduction of cost and lead time of process planning.
 Reduced skill requirements and Increased productivity of process planners.
 Higher level application programs such as cost and manufacturing lead time

estimation and work standards can be interfaced.

Steps Involved in CAPP Retrieval/variant CAPP Systems

 A complete CAPP system has following steps :  It is based on the principles of Group Technology (GT) and Parts
 (i) Design input Classification & Coding.
 (ii) Material selection
 (iii) Process selection  In this a standard process plan is stored in the computer files for
 (iv) Process sequencing each part code number.
 (v) Machine and tool selection
 (vi) Intermediate surface determination  These standard route sheets are based on current part routings or on
 (vii) Fixture selection an ideal process plan that has been prepared for each part family.
 (viii) Machining parameter selection
 (ix) Cost/time estimation  Development of the data base of these process plans requires
 (x) Plan preparation substantial effort.
 (xi) Mc tape image generation.
 Before the system can be used for process planning a significant
amount of information must be compiled and entered into the CAPP
data files. This is referred to as the “Preparatory Stage”.

 Preparatory Stage consists of following steps:
 a) Selecting appropriate classification and coding scheme for company.
 b) Forming part families for the parts produced by the company.
 c) Preparing standard process plans for the part families.

 Step ‘b’ & ‘c’ are repeated as new parts are designed and added to
the company’s design database.

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 After the preparatory phase is completed, the system is ready for use.  This ability to edit the standard plan is what gives the retrieval system its
alternative name: Variant CAPP System.
 Now assume a new component for which the process plan is to be
determined, the first step is to derive the GT Code number for the part.  If the file does not contain a standard process plan for the given code
number, the user may search the computer file for a similar or related
 With this code no., a search is made in the part family file to determine if code number for which a standard route sheet does exist and edit that
a standard route sheet exists for the given part code, if a standard route process plan according to his requirements.
sheet exists for the part, it is retrieved from the database. Hence the
word “Retrieval” for this CAPP System.  Even if the user does not find any related file than he may start from
scratch, thus the user prepares the route sheet for the new part and this
 The standard process plan is examined to determine whether any route sheet becomes the standard for the new part code number.
modifications are necessary. Modifications to be made may be minor or
major. The user edits the standard plan accordingly.  The process planning session concludes with the Process Plan Formatter,
which prints out the sheet in the proper format.

Advantages and limitations of
Variant CAPP

 Investment in hardware and software is not much.

 The system offers a shorter development time and lower manpower
consumption to develop process plan.

 The system is very reliable and reasonable in real production
environments for small and medium size companies.

 Quality of process plan depends on knowledge and background of
process planner

Generative Process Planning Elements Required In A Fully
Generative CAPP System
 It is an alternative approach to automated process planning.
 Instead of retrieving and editing an existing plan contained in a computer  First element is technical knowledge of manufacturing.

database, a generative system creates the process plan by means of decision  This CAPP system requires an expert system which can convert the
logics, formulas, algorithms and geometry based data that are built or fed as input logic used by successful process planners into a computer program
to the system. by using certain codes. Such an expert system generates a
 Format of input may be: knowledge base.
 a) Text input (interactive)
 b) Graphical input (from CAD models)  This knowledge base is used by Generative CAPP System to solve
 A fully Generative CAPP System would produce a route sheet without any human process planning problems (i.e.- to create route sheets)
assistance and without a set of predefined standard plans.

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 Second element is a computer compatible description of the part  The third element is the capability to apply the process knowledge
to be produced. This description contains all of the data and and planning logic contained in the knowledge base to a given
information needed to plan the process sequence. part description.

 Two ways of providing this description are:  In brief we can say that, Generative CAPP system uses its
knowledge base to solve a specific problem, i.e.- planning the
 a) Geometric model of the part that is developed on a CAD system process. This system synthesizes a new process plan from scratch for
during product design. each new part that has been presented to it.

 b) A GT code number of the part that defines the part features in
significant detail.

Advantages and limitations of Benefits of CAPP
Generative CAPP System
1. Process rationalization and standardization: Automated process planning leads to
 The generative CAPP has all the advantages of Variant CAPP more logical and consistent process plans than when process planning is done
however it has an additional advantage that it is fully automatic completely manually.
and a up-to-date process plan is generated at each time.
2. CAPP helps in arriving at standard and consistent process plans : Standard plans
 It requires major revisions if a new equipment or processing tend to result in lower manufacturing costs and higher product quality.
capabilities became available.
3. Increased productivity of process planners : The systematic approach and the
availability of standard process plans in the data files permit more work to be
accomplished by the process planners.

4. Reduced lead time for process planning : Process planners working with the CAPP
system can provide route sheets in a shorter lead time compared to manual
preparation.

5. Improved legibility and readability : Computer prepared route sheets are legible
and easier to read than manually prepared route sheets.

6. Incorporation of other application programmes : The CAPP programme can be
integrated with other application programmes, such as estimation of standard
time, cost estimating and formulation of work standards.

Question?

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CHAP 5 - PRODUCTION PLANNING ➢ Job design and enrichment
➢ Job enrichment
DMA1082 - PROCESS PLANNING ➢ Job enlargement
➢ Job rotation

➢ Job assignment and work schedule
➢ Job assignments category
➢ Work Schedule
➢ Real time monitoring

➢ Master production schedule (MPS)
➢ Manufacturing resource planning
➢ Material requirement planning (MRP)

INTRODUCTION INTRODUCTION TO JOB DESIGN

• A job consists of a related set of tasks that are carried out by a person to • Job design is the efforts to organize tasks, duties and responsibilities
fulfil a purpose. It can be regarded as a unit in an organization structure into a unit of work so as to achieve organizational objectives.
that remains unchanged whoever is in the job.
• It deals with the allocation and arrangement or organizational work
• A job in this sense is a fixed entity, part of a machine that can be activities and tasks into sets where a singular set of activities constitutes
‘designed’ like any other part of a machine. Routine or machine- a “job” and which is subsequently performed by a job incumbent.
controlled jobs do indeed exist in most organizations but, increasingly,
the work carried out by people is not mechanistic.

• What is done, how it is done and the results achieved depend more and
more on the capabilities and motivation of individuals and their
interactions with one another and their customers or suppliers.

DEFINITION OF JOB DESIGN WHAT IS JOB DESIGN

• “the specification of the content, methods and relationships of • Goals - Job designing has vital impact on the employees as well as the
jobs in order to satisfy technological and organizational organization.
requirements as well as the social and personal requirements of
the job holder” • Target -

• Employee productivity and satisfaction are the two important • Facilitating the interest of employees towards the job and enhancing their
concerns of a human resource manager. The structure of work, satisfaction
the activities to be performed and the responsibilities attached
to a position are the determinants of employee productivity and • Increasing employee motivation and productivity
satisfaction.
• Enhancing employees’ skills by identifying their training needs

• Ensuring safer working environment

• Making the communication process clear and effective in the organization

• Improving the quality of working life of employees

• Minimizing cost by reducing wastage.

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GUIDELINE FOR JOB DESIGN FACTOR AFFECTING JOB DESIGN
organizational environmental behavioural
• Identifying the tasks clearly and forming natural work units
• Fixing the responsibility associated with a job clearly
• Allowing an appropriate provision for the autonomy of doing a work in the job design
• Equipping the employees to participate in decision-making
• Including the details about working environment of a job
• Developing interest of employees in their jobs
• Presenting the timely feedback to employees on their performance
• Providing timely recognition and sufficient support to employees
• Establishing good relationship and open feedback channels to get effective feedback

from the employees.

Work
Nature

Environmental

Culture organizational Ergonomics

Workflow Employee Socio economic
availability and and cultural
expectations
abilities

Autonomy METHOD FOR JOB DESIGN

Use of skills Behavioural Feedback Job Job
and abilities enlargement enrichment

Job rotation

Diversity

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JOB ROTATION Avoid Frequent
Monopoly Interruption
• Job rotation involves shifting a person from one job to another, so that he is able to
understand and learn what each job involves. The company tracks his performance advantages disadvantages
on every job and decides whether he can perform the job in an ideal manner. Based
on this he is finally given a particular posting. Opportunity Misunderstanding
to Broaden with the Union
• Job rotation is done to decide the final posting for the employee, e.g., Mr. A is Member
assigned to the marketing department whole he learns all the jobs to be performed One’s
for marketing at his level in the organization. After this, he is shifted to the sales Knowledge
department and to the finance department and so on. He is finally placed in the
department in which he shows the best performance. Avoiding Reduces
Fraudulent Uniformity in
• Job rotation gives an idea about the jobs to be performed at every level. Once a
person is able to understand this he is in a better understanding of the working of Practice Quality
organization

JOB ENLARGEMENT Variety Increases
of Skills Work
• Job enlargement involves combining various activities at the same level in the Burden
organization and adding them to the existing job. It increases the scope of the job.
advantages Improve disadvantages Increasing
• It is also called the horizontal expansion of job activities. Job enlargement can be Earning Frustration
explained with the help of the following example. If Mr. A is working as an executive Wide Capacity Problem
with a company and is currently performing three activities on his job after job Range of with Union of the
enlargement or through job enlargement we add four more activities to the existing Activities Members Employee
job so now Mr. A performs seven activities on the job.

• The new activities which have been added should belong to the same hierarchy level
in the organization. By job enlargement we provide a greater variety of activities to
the individual so that we are in a position to increase the interest of the job and make
maximum use of employee’s skill

JOB ENRICHMENT • The motivating factors can be:
• Giving more freedom.
• Job enrichment is a term given by Fredrick Herzberg. According to him, a few • Encouraging participation.
motivators are added to a job to make it more rewarding, challenging and • Giving employees the freedom to select the method of working.
interesting. According to Herzberg, the motivating factors to an existing job to • Allowing employees to select the place at which they would like to
make it more interesting. work.
• Allowing workers to select the tools that they require on the job.
• Job enrichment gives lot of freedom to the employee but at the same time • Allowing workers to decide the layout of plant or office.
increases the responsibility. Some workers are power and responsibility
hungry. Job enrichment satisfies the needs of employees

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Interesting negative DIFFERENCE BETWEEN JOB ENLARGEMENT AND JOB
and implications ENRICHMENT

Challenging
Job

Improves lead to ego
problems
Decision-
Making

advantages disadvantages

Identifies Identifies will only work
Higher Order Future in certain
situations
Needs of Managerial
Employees Calibre

Reduces Some people
are internally
Work Load dissatisfied
of Superiors
with the
organization

JOB DESIGN PRINCIPLE WORK ASSIGNMENT

• Job design principles help in tackling and managing the following issues • Managers cannot perform all the tasks in the organization. Part of his job
needs to be given to someone else to perform. Managers need to work
Work overload Work underload Work and people Multiple shifts with employees to ensure that all tasks that need to be performed can be
isolation completed properly.

Managing pending Excessive working Lack of • Definition of assignment
filling-up of hours understanding of • Assignment is a process in which a chief or manager gives rights or delegates
vacancy authority and responsibility to his subordinates to carry out tasks on his behalf.
the whole job
process

PRINCIPLES OF ASSIGNMENT • Responsibility is the obligation of an individual to perform a task that has
been assigned perfectly. Managers need to be aware of the fact of the
Responsibility Accountability Power and responsibilities that have been entrusted to perform.
Authority
• Every manager and employee must be accountable for the results of the
work that has been done. Responsibilities that have been assigned are the
responsibility of the manager or employee to perform. Managers or
employees must be willing to accept praise or ridicule for the success or
failure of the work that has been done. Managers are not only responsible
for themselves but are also accountable for the work done by others.

• Authority is the right or permission of a manager to take a decision and take
action to carry out a task that has been assigned. It is also the power that
allows the manager to direct and delegate authority to his subordinate staff.
Authority and responsibility must go hand in hand. This means that when a
person is given a responsibility, he or she should also be given the power or
authority to perform that task.

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THE ASSIGNMENT PROBLEM THE ASSIGNMENT PROBLEM

• In many business situations, management needs to assign - • This situation is a special case of the Transportation Model And it is known as the assignment problem.
personnel to jobs, - jobs to machines, - machines to job locations, • Here, jobs represent “sources” and machines represent “destinations.”
or - salespersons to territories. • The supply available at each source is 1 unit And demand at each destination is 1 unit.

• Consider the situation of assigning n jobs to n machines.
• When a job i (=1,2,....,n) is assigned to machine j (=1,2, .....n) that

incurs a cost Cij.
• The objective is to assign the jobs to machines at the least possible

total cost.

THE ASSIGNMENT PROBLEM THE ASSIGNMENT PROBLEM

The assignment model can be expressed
mathematically as follows:
Xij= 0, if the job j is not assigned to machine i

1, if the job j is assigned to machine i

THE ASSIGNMENT PROBLEM EXAMPLE THE ASSIGNMENT PROBLEM EXAMPLE

• Ballston Electronics manufactures small electrical devices. Under current arrangement, assignment of inspection
• Products are manufactured on five different assembly lines areas to the assembly lines are 1 to A, 2 to B, 3 to C, 4
to D, and 5 to E.
(1,2,3,4,5). This arrangement requires 10+7+12+17+19 = 65 man
• When manufacturing is finished, products are transported from minutes.

the assembly lines to one of the five different inspection areas
(A,B,C,D,E).
• Transporting products from five assembly lines to five inspection
areas requires different times (in minutes)

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HUNGARIAN METHOD EXAMPLE HUNGARIAN METHOD EXAMPLE

Step 1: Select the smallest value in each row. If not finished, continue
Subtract this value from each value in that row with other columns.
Step 2: Do the same for the columns that do not
have any zero value.

HUNGARIAN METHOD EXAMPLE HUNGARIAN METHOD EXAMPLE 2

Step 3: Assignments are made at zero values.
• Therefore, we assign job 1 to machine 1; job 2 to machine 3, and job 3 to machine 2.
• Total cost is 5+12+13 = 30.
• It is not always possible to obtain a feasible assignment as in here.

HUNGARIAN METHOD EXAMPLE 2 HUNGARIAN METHOD EXAMPLE 2

• A feasible assignment is not possible at this moment. The next step is to select the smallest uncrossed out element. This
• In such a case, The procedure is to draw a minimum number of lines through some of the rows and element is subtracted from every uncrossed out element and added

columns, Such that all zero values are crossed out. to every element at the intersection of two lines.

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HUNGARIAN METHOD EXAMPLE 2 WORK SCHEDULE

• We can now easily assign to the zero values. Solution is to assign (1 to 1), (2 to 3), (3 to 2) and (4 to 4). • What is work schedule?
• If drawing lines do not provide an easy solution, then we should perform the task of drwaing lines one • Work schedules refer to the specified days and times that an employee is
expected to complete the tasks of their employment position.
more time. • The schedule that an employee works can impact their work responsibilities,
• Actually, we should continue drawing lines until a feasible assignment is possible. payment, work benefits and federal and state law requirements.

WHY IS EMPLOYEE WORK SCHEDULING IMPORTANT? • SAVING TIME: Using efficient scheduling procedures can reduce the amount of time
you spend making adjustments and dealing with logistics, allowing you to focus on high-
Saving time Ensuring legal Establishing level leadership tasks.
compliance consistency
• ENSURING LEGAL COMPLIANCE: Good employee scheduling procedures also help you
Determining Increasing comply with legal requirements about full-time vs. hourly employees, ensuring that
labor costs customer each employee gets the appropriate number of hours each week.
satisfaction
• ESTABLISHING CONSISTENCY: Being strategic about schedule-making lets you have a
good idea of who will be working each week, allowing you to manage employees more
effectively. It also allows you to seamlessly delegate scheduling to managers or other
employees.

• DETERMINING LABOR COSTS: Over-scheduling employees results in wasted wage
expenses, while under-scheduling employees could leave your company short-handed.
Good scheduling can also reduce turnover costs associated with replacing an employee.

• INCREASING CUSTOMER SATISFACTION: Scheduling employees based on their skill sets
allows you to improve service to customers and clients

TYPE OF WORK SCHEDULE

Full-time schedules FULL-TIME SCHEDULES

Part-time schedules Fixed schedules • While the Fair Labor Standards Act (FLSA) doesn’t define “full-time,” full-time
typically includes a work schedule that is at least 40 hours per week. Generally, full-
Flexible Rotating On-call Compressed Freelance time employees work for the same days or hours each week.
schedules shift schedules schedules schedules
• Some full-time employees might be paid on an hourly basis, while others receive a
schedules salary. Due to the extensive amount of time on the job, most organizations offer
benefits to full-time employees, such as vacation days, sicks days and health
insurance.

• Example: A full-time schedule is typically Monday-Friday from 8 a.m.–5 p.m. with an
hour lunch break

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PART-TIME SCHEDULES FREELANCE SCHEDULES
Freelance work is a type of work agreement in which a contractor completes work tasks
Part-time schedules are any schedules with less than full-time hours. These schedules but is not considered an official employee of the business. They are often paid at the
often allow for greater flexibility, granting employees the availability for other work or completion of a project rather than for the number of hours they work. Freelance
responsibilities. In most cases, part-time employees don’t earn the same benefits as full- workers can work on a schedule that meets their needs but often do not qualify for work
time employees, and their schedules may change from week to week. benefits

Example: A part-time schedule could be Monday from 10 a.m.–2 p.m., Wednesday from COMPRESSED SCHEDULES
11 a.m.–2 p.m., Friday from 10 a.m.–2 p.m. and Saturday from 9 a.m.–3 p.m. for a total of With a compressed work schedule, employees work a set number of hours over fewer
17 hours in one week days. This type of employee work schedule is often best implemented in office settings,
but can also be implemented across industries with the right planning.
ROTATING SHIFT SCHEDULES Example: A full-time, compressed employee might work four 10-hour days rather than
five eight-hour days
In a rotating shift work schedule, employees work a series of day and night shifts
determined by the employer. Rotating shift schedules are common in industries that
operate 24/7, like health care and hospitality.

Example: A rotating shift schedule could be four shifts during the day, three days off and
then four night shifts.

REAL TIME MONITORING BENEFITS OF REAL TIME MONITORING

• Real-time monitoring is the employment of applications and tools that track and Network Network Incident
record continuous snapshots of your network's overall performance. security
performance response time
• Organizations use real-time monitoring to track network activity, improve network
security, and identify potential problems as soon as they arise. Every business,
regardless of size, can benefit from monitoring their network in real time.

Employee Cost savings
productivity

MATERIAL REQUIREMENT PLANNING (MRP) MRP MRP Processing MRP Outputs

• A dependent demand technique that uses a bill-of-material, inventory, expected MRP Inputs Changes
receipts and a master production schedule to determine material requirements.
Master Order releases
• Dependent inventory models require that the operations manager know the schedule
following: Primary Planned-order
• Master Production Schedule Bill of reports schedules
• Specifications or bill of materials materials
• Inventory availability Exception reports
• Purchase orders standing file
• Lead time MRP computer Secondary Planning reports
Inventory
records programs reports Performance-
control
file reports

Inventory 48
transaction

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PLANNING HORIZON MASTER SCHEDULE

Assembly Master schedule: One of three primary inputs in MRP;
states which end items are to be produced, when these
Subassembly are needed, and in what quantities.

Fabrication Cumulative lead time: The sum of the lead times that
sequential phases of a process require, from ordering of
Procurement parts or raw materials to completion of final assembly.

1 2 3 4 5 6 7 8 9 10 Weeks Time fences: Series of time intervals during which order
changes are allowed or restricted.
49
50

BILL-OF-MATERIALS PRODUCT STRUCTURE TREE

Bill of materials: One of the three primary inputs of Level Chair Back
MRP; a listing of all of the raw materials, 0 Seat Assembly
parts, subassemblies, and assemblies needed
to produce one unit of a product. 1 Leg
Assembly
Product structure tree: Visual depiction of the
requirements in a bill of materials, where all 2 Legs (2) Cross Side Cross Back
components are listed by levels. bar Rails (2) bar Supports (3)

51 52

INVENTORY RECORDS OTHER CONSIDERATIONS

• One of the three primary inputs in MRP • Safety Stock
• Includes information on the status of each item by time period • Lot sizing

• Gross requirements
• Scheduled receipts
• Amount on hand
• Lead times
• Lot sizes
• And more …

53 54

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MRP PROCESSING MPR PROCESSING

• Gross requirements • Gross requirements
• Schedule requirements • Total expected demand
• Projected on hand
• Net requirements • Scheduled receipts
• Planned-order receipts • Open orders scheduled to arrive
• Planned-order releases
• Planned on hand
• Expected inventory on hand at the beginning of each time period

55 56

MPR PROCESSING INVENTORY REQUIREMENTS

• Net requirements • Net requirements: Net Requirements =

• Actual amount needed in each time period Gross Requirements
– Available Inventory
• Planned-order receipts
• Available Inventory: Available Inventory =
• Quantity expected to received at the beginning of the period in which it is shown,
reflecting the lot size Projected on hand
– Safety stock
• Planned-order releases – Inventory allocated to other items

• Planned amount to order in each time period; same as Planned-order receipts
offset by lead time

57 58

T14-1: MRP - Example Clear

Master Schedule Week Number 12345678 A KEY MRP OUTPUT
100 150
for Shutters: Quantity • Planned orders (referring to Planned Order Releases)- schedule indicating
the amount and timing of future orders. It tells us how when to order and
Shutters: Gross requirements 0 0 0 100 0 0 0 150 how much, assuring us a lower level of inventory than if we did not use
Scheduled receipts MRP.
Quantity = 1 Projected on hand 0 0000 000
LT = 1 Net requirements 0 0 0 100 0 0 0 150 60
1 Planned-order receipts 0 0 0 100 0 0 0 150
Lot Size = Planned-order releases 0 0 100 0 0 0 150 0 10

Frames: Gross requirements 0 0 200 0 0 0 300 0

Scheduled receipts

Quantity = 2 Projected on hand 0 0 0 120 120 120 120 140

LT = 2 Net requirements 0 0 200 0 0 0 180 0

Lot Size = 320 Planned-order receipts 0 0 320 0 0 0 320 0

Planned-order releases 320 0 0 0 320 0 0 0

Wood sections: Gross requirements 0 0 400 0 0 0 600 0
70
Scheduled receipts 70 70 70 20 20 20 20 50
0 0 330 0 0 0 580 0
Quantity = 4 Projected on hand 0 0 350 0 0 0 630 0
0 350 0 0 0 630 0 0
LT = 1 Net requirements

Lot Size = 70 Planned-order receipts

Planned-order releases 59

Note: Use Lot Size = 1 for lot-for-lot ordering.

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OTHER MRP OUTPUTS (MRP SECONDARY REPORTS) CAPACITY PLANNING

• Performance-control reports Capacity requirements planning: The process of
• Planning reports determining short-range capacity
• Exception reports requirements.

61 Load reports: Department or work center reports
that compare known and expected future
capacity requirements with projected capacity
availability.

62

CAPACITY REQUIREMENTS IN MRP PLANNING

Develop a tentative Use MRP to BENEFITS OF MRP
master production simulate material
• Low levels of in-process inventories
schedule requirements • Ability to track material requirements
• Ability to evaluate capacity requirements
Convert material Revise tentative • Means of allocating production time
requirements to master production
resource requirements
schedule
Is shop No
capacity No
adequate? Can
capacity be
Yes changed to meet
requirements
Firm up a portion 63 64
of the MPS Yes

Change
capacity

REQUIREMENTS OF MRP MASTER PRODUCTION SCHEDULE (MPS)

• Computer and necessary software • The master production schedule definition is a term used to describe a centralized document telling you
• Accurate and up-to-date what you need to produce, how much you need to produce, and when you need to produce it.

• Master schedules • The purpose of a master production schedule is to save you time by making the hours you spend
• Bills of materials managing your production flow much more efficiently, giving you more space to scale your
• Inventory records manufacturing business.
• Integrity of data
65

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MPS FUNCTION MPS OBJECTIVES

Translating Evaluating Produce • Makes your demand flow smoother;
Production Alternative Capacity • Keeps your lead-time low;
Schedules Requirements • Standardizes communication across your business;
Plans • Helps you to prioritize requirements;
• Helps keep production stable;
Facilitating Utilization of • Generates workable plans for your manufacturing orders; and
Information Capacity • Assists in making accurate purchases and transfer orders
Processing

PROCEDURE TO DEVELOP MPS

• All product models you produce
• order them by popularity, so the items you produce the most are at the top of the list
Product List

Variation • Have a field for each product variation
Sub-Lists • For example, you can split backpacks into S, M, and L for size.

• useful for planning and keeping records, which is necessary for accurate demand forecasting. Split up your schedule into months and weeks.

Year, month, • The aim is to have a solid plan of what you will produce for the next few months. You can reassess your projected demand every few months
and week

Production • This is the number of units you decide to manufacture each week. you decide to manufacture 200 units of product in a week.
quantities • This depends on what you already have in stock, and what the projected demand is.

A MPS EXAMPLE

HOW DO MANUFACTURERS USE A MPS

The master production schedule is compatible with different production workflows:
• — Make-to-Stock (MTS);
• — Make-to-Order (MTO); and
• — Assemble-to-Order (ATO).

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A MPS EXAMPLE MASTER PRODUCTION SCHEDULE VS.
MANUFACTURING RESOURCE PLANNING
• Let’s say you produce wooden furniture such as chairs, dining tables, and coffee tables.
• At the start of the period, you have 40 chairs in stock. Your sales forecast says that you will sell 200 of them. That The master production schedule is one of the jumping-off points for manufacturing
resource planning (MRP II).
means you will need to produce 160 chairs during that period in order to match the demand. Apart from the MPS, however, MRP II uses additional inputs such as inventory statuses,
• As a consequence, the beginning inventory of your next period will be 0. As business is steady, another 200 chair BOMs, routings, material requirements and costs, financial records, staffing and machine
capacity, etc.
sales are forecasted. This means that now you will need to produce 200 chairs within a period in order to match This allows the MRP II system to create a highly detailed plan for all of the different
demand. resources related to production and provide you with a real-time overview of your
business.

MANUFACTURING RESOURCE PLANNING (MRP II) MRP II OR MANUFACTURING RESOURCE PLANNING

• Manufacturing Resource Planning is the operational and financial • Expanded MRP with and emphasis placed on integration
planning of the manufacturing process of an organization. This is an • Financial planning
integrated system and an extension of MRP or Material Requirement • Marketing
Planning. • Engineering
• Purchasing
• The idea here is a single entity for planning and controlling purposes of • Manufacturing
the manufacturing process. MRP II covers all the areas from finances and
general accounting to machine and labour capacity planning and quality,
allowing companies to plan and work with more efficiency

76

MRP II

Finance Market Manufacturing Master MRP I VS. MRP II
Marketing Demand production schedule
• MRP II software is considered a functional replacement of MRP I. It is because the
Production MRP Adjust master schedule MRP II information system includes all the functionality of its predecessor; it offers
plan inventory tracking, bill of materials (BOM), and master production scheduling. In
addition to such characteristics, it also enables the involvement of logistics,
Rough-cut Capacity marketing, and finance.
capacity planning planning
• MRP II is also able to account for the human resources of an organization, thus
Adjust No providing a holistic view of the real operating capacity of a company, unlike MRP I. It
production plan Problems? includes machine capacity and personnel capacity.

Yes Problems? No Requirements Yes • MRP II also enables effective demand forecasting. It also allows its operators to enter
schedules data into the system and see what variables will produce a downstream effect. The
MRP II system enables them to arrive at the optimal level of sales. Moreover, it can
77 also provide feedback based on the variables entered for a given operation, which is
why it is also known as a closed-loop system.

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ISI KANDUNGAN

PENGENALAN OBJEKTIF MENDIMENSI

MELAKAR VIDEO TUJUAN
SOALAN RUMUSAN

 Dapat mengetahui apa itu lukisan  Unjuran isometri ialah satu kaedah yang
isometri. membantu pembentukan objek 3D.

 Paksi yang sesuai di gunakan  Objek isometri ialah simulasi bentuk
untuk membentuk lukisan lukisan 3 dimensi dalam keadaan tidak
isometri. sebenar.

 Mengetahui teknik lukisan  Objek yang dibentuk tiddak boleh
isometri. dipandang dari satu sudut yang berlainan
dalam membentuk pandangan perspektif
seperti objek 3D sebenar.

Paksi A Paksi Isometri

 Lukisan ini mempunyai 3 paksi Paksi B Paksi C

◦ Paksi A bersudut tepat dengan paksi mendatar. 30° 30º
◦ Paksi B dan Paksi C bersudut 30° dengan paksi

mendatar.

Paksi A

Paksi B Paksi C

30° 30º Lukisan Isometri 30º

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31/7/2021

Paksi Isometri juga
boleh dilukis

menghala kebawah
dari paksi mendatar
untuk menunjukan

bahagian bawah
dengan jelas

2