Student Comments on ME 474 Topics

Fall 2011 - Taught by Dr. Uma Jayaram

1. DFMPro: I really enjoyed using the DFMPro software in conjunction with the CAD system. It allows me to see the manufacturing flaws of my designs and the "hidden" flaws of other CAD models. This would be very effective in the work place. I learned that the design may look legitimate with the naked eye, but can be flawed still.

2. Communication between Design Engineers and Workers: The link between designers and the people making the part is paramount to the success of the part/assembly, and it was good to learn/reinforce the idea that talking to an experienced machinist or operator can help you become a better designer.

3. Production Volume: I learned the Importance of production volume. It can be extremely expenive to create a mold for an injection-molded part, so you have to be producing a lot of parts for it to be cost affective. For lower production volumes, sometimes the more complicated process can be cheaper.

4. Lab Exercises: I really enjoyed the last two labs (Mold design and Sheetmetal) and feel they were extremely beneficial. If I do choose to pursue a career in manufacture, I think these are important skills to have and I thought it was really great to learn the tools that can really be applied in the outside world.

5. Boothroyd-Dewhurst DFMA: The module was actually quite fun to work with and I am pleased to be using for our ME 316 project. I feel that this will be a good tool to have waiting in my bag-o-engineering tricks.

6. Lean Manufacturing: I was happy to learn that there is much being done in this industry. This topic has two points that stand out to me. Part of this topic is all about achieving maximum efficiency in manufacturing with as little resources as possible. The other is the fact that many aspects of this support "sustanability" and being environmentally friendly, which is very important with the current global problem of climate change.

7. Spokane Industry trip: Dr. Jayaram, thanks again for putting together such a wonderful trip to Spokane Industries! It was really and eye opening experience. I know that I personally learned alot in the short time that we were at each of the facilities. I really appreciate your willingness to invest in us young engineers. T.M.


Fall 2009 - Taught by Dr. Uma Jayaram

1. Poka Yoke Method: Very interesting to detect problems quickly and stop the process until problem is fixed.

SMEO: A concept to have it a lot of extra machining or different processes are required to manufacture a product. Faster and cheaper to exchange bits and tools rather than lots of machines.

2. Six Sigma: It appealed to me because it allows for changes to be calculated into the statistical controls from the beginning concerning the number of deficits a product being produces should have, it helps to lower the number of these defects.

Lean Manufacturing: also appealed me because it is a much more efficient way to manufacture and produce things. I particularly was interested in the “just intuitive” process so manufacturers can save space and not have piles of extra parts around.

3. The section of the class on quality was the most informative to me seeing ways that it is measured in particular.

4. I liked the DFMS software even though it has some limitations on the shapes. I liked seeing how the different affected the price per part. I also liked the class project because we were able to apply what we have learned.

5.  I thought it was interesting how manufacturing has shifted to more than production to make things cheaper and more effective; it was surprising to me how long it took to do this.

Learning about DFMS guidelines was also appealing. Most of the things in the guidelines seem so obvious but it is easy to see how they could be forgotten or looked over. It is a useful tool for designing for the manufacturing process.

6. Sheetmetal bending can be complex and has many guidelines for how it is designed. The limitations and required complexity of the tooling machinery must be taken into account at all stages in the design process.

The ability to recycle a product after its intended lifetime is an important concept used in modern manufacturing.

7. 5S related to my internship and had over the summer and was interesting to learn about what it actually means.

I enjoyed learning about quality too because my dad is a quality engineer. I enjoyed learning more of what my dad does.

8. Sheetmetal: I learned that punched or drilled holes should be completed prior to bending.

Kazen: The idea of constant incremental improvements. This system is easy to implement and required very little resource.

9. Assembly: Reduce parts, orientation, alpha symmetry and beta symmetry. This simple concept can make the assembly easier and reduce assembly time and avoid mistake.

Die casting, use: uniform wall thickness, add draft, add fillet to make the metal easily flow over.

10. Injection molding wall thickness: Fluid dynamics and heat transfer being what it is, the cooling time required for an injection molded part follows a quadratic pattern. Do not make thick rolled parts.

Costing: costing is very versatile, but requires two things: draft for part extraction and post processing to remove flashing and runner system.

11. Machining: I thought the DFM guidelines for machining help me better understand the machining process and therefore improved my design skills.

Lean manufacturing: I thought the idea of Lean manufacturing versus traditional were interesting. I will be able to use the ideas later in my career.

12. Lean manufacturing: During this part of the class, I learned a lot about modern philosophy of manufacturing. This will help me as a manufacturing engineer to create a more efficient workplace by applying concepts like Kaizen and Sidoka.

Quality control: In this topic, I learned about mathematical process control and what modern quality control consists of. I feel this will also be helpful as it will allow me to understand shop-level problems that may affect final product quality.

13. The concept of machining, I found very insightful as I do a lot of it. Several key problems I have come across during the machining of a part have been addressed, giving a much better understanding of what I am actually doing.

Also the DFMA software has proven itself to be a vital aspect of my senior project. We have used it to show increased cost savings and as justification for part redesigns. Along with this topic, the cost analysis has been used in nearly every aspect of my senior design as well. These were 3 things that previously never used or heard of.

14. I enjoyed first learning about DFA, mostly the software but also the different rules that we in place to help easily decrease cost.

The second topic I enjoyed was GD&T because I do some drafting for work .It is applicable to be able to provide the shop with proper tolerances.

15. The sheet metal stamping process was interesting to me. I was not aware of the large number of stations required to make seemingly simple parts.

I also found the machining concepts to be interesting as well. The limitations involved with these processes, such as allowable drilling depth, were higher than I imagined.

16. I liked the design for manufacturing portion of this class. It was interesting learning about the tools available to evaluate a part’s manufacturability.

I also enjoyed learning, how to design molds in Pro/E.

17. 5S pillars were interesting in how sweeping those changes can be. They reduce cost and increase capacity just by organizing everything.

Injection molding- It was interesting to learn just how expensive an internal undercut is.

18. Poka-yoke method was interesting to both eliminate defects and incorporate DFA principles. Shows that as little thought beforehand can go a long way.

Jidoka is an excellent concept to empower and involve the employees while at the same time reducing the need for rework/inspection areas and times.

19. Process election: I learned how to make decisions on which types of materials and processes to use when designing parts. Specifically I can apply the process to future designs.

The lecture on Kaizen were my favorites, I have notices how the concept of continual improvement can be applied to all aspects of my work life.

20. Poka yoke: Another class discusses a set of HazMat containers which were improperly sealed and put on an airplane, where they consequently failed and brought the plane down. If using poka yoke they were designed so they could not be improperly sealed, lives could have been spared.

Jidoka: I also thought allowing the manufacturer to know when a process fell out of tolerance was interesting too. By letting an operator know as soon as things go south, apart can either be immediately scrapped with extra time wasted on it, or might be salvaged. This could realize huge improvements in cost depending on what is being manufactured.

21. Toyota production system: I learned about the greater product variety and fast response to meet demand that the TPS can do. I also learned how they were able to have good relations with suppliers and how that relationship should work.

I enjoyed learning the seven deadly wastes.

22. I found the concurrent costing appealing because it put a direct relation between product variations and the cost of the part. I also liked the lean manufacturing section because the Kaizen, kanban and jidoka gave a real life view from TPS on how production can be improved.

23. The comparisons between injection molding and die casting process were fairly interesting to me. It had occurred to me previously that they were much the same things but the differences in thickness of parts made really served to differentiate the processes besides the obvious material differences.

The poka yoke method was really interesting especially given the GM manufacturing examples. I had never given thought to the fact that obvious malfunction indicators needed to be engineered into products and processes.

24. I thought that the concurrent costing software was interesting because it really helps demonstrate how high production volumes really drive down cost individual parts most of the time.

I also learned a lot from the Pro/Sheet metal labs that we did. These helped me understand how the sheetmetal parts were made much better.

25. I enjoyed learning about lean manufacturing as it seems very useful to stop mistake before they happen or get moved down the line. Also, the idea of continuous improvement is good as nothing can be perfect.

I enjoyed learning to use the DFMA program as it seems extremely useful in determining which manufacturing processes work best in a situation.

26.DFMA- Design for manufacturing and assembly, is a widely used process for calculating many important aspects of manufacturing. A very useful tool that makes things easier to calculate and help with the design process.

Lean Manufacturing: I learned how it is important and if it is used efficiently the production process is done in half the time, in half the space using half the tools but still be able to compete with companies not using it. Ex: Toyota and GM where Toyota was way more efficient of lean manufacturing.




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