Application Of Engineering Fundamentals In Manufacture A Case Study

A case study is presented that was developed during a Senior Capstone design course and based on an actual industrial problem. In a manufacturing operation, a materials handling cell did not reliably pick-up single sheets of aluminum. Due to parasitic adhesion, two sheets would be fed into the downstream machines initiating jamming or tool breakage. The system had performed satisfactorily for steel, for which the system had apparently been set-up. Initial discussion with the plant managers and engineers revealed a tolerance of the interruptions and a reluctance to attempt correctives. Analysis of the problem and further discussion revealed a lack of understanding of the basic factors, due to a lack of systematic, fundamental approach. The candidate ideas proposed by the plant personnel were, based on elementary analysis, incorrect, and would have exacerbated the problem. This case study discusses both the technical aspects and the reasons for the failure by the personnel to engage the problem. The problems and circumstances were presented to the students, who then wrote a paper on it detailing their analysis and approach to the problem. Following this, the instructor’s solution was presented and a discussion evolved. This discussion resulted in advocating for and illustrating the advantages of a fundamental approach to engineering in a manufacturing-design setting.