Wim k03!04!01 Machining Supervisory

5/27/2018 Wim k03!04!01 Machining Supervisory

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K 3 DIPLOMA TEKNOLOGIPEMBUATANVERSI : 1 / 2009

NO. PINDAAN : 0

K

03-04-01MACHINING

SUPERVIS

ORY

TERHAD

TERHA


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Cetakan Pertama Julai 2009

Institusi Latihan Jabatan Tenaga Manusia

http ://www.jtm.gov.my/kurikulum

Hak Cipta Terpelihara. Dokumen ini diklasifikasikan sebagai TERHAD. Tidak dibenarkan

mengeluar mana-mana bahagian dalam kandungan Bahan Pembelajaran Bertulis (WIM)

dalam apa jua bentuk tanpa keizinan daripada Jabatan Tenaga Manusia (JTM).

MODUL PEMBELAJARAN : K03-04-01 MACHINING SUPERVISORY disediakan dalam

bentuk bahan pengajaran dan pembelajaran bagi kursus sepenuh masa di Institusi LatihanJabatan Tenaga Manusia (ILJTM). Modul pembelajaran ini dibangunkan oleh ahli

jawatankuasa pembangunan WIM dan disemak serta diluluskan oleh Jawatankuasa

Pemandu Kurikulum untuk tujuan gunapakai bagi semua ILJTM yang terlibat.

Kod Pengesahan WIM : WIM/K03/12009/S04

Tarikh Pengesahan WIM : 30 Jun 2009


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PENGESAHAN JAWATANKUASA PEMANDU KURIKULUM

KLUSTER PEMESINAN

Dengan ini adalah dimaklumkan bahawa Bahan Pengajaran Bertulis ( WIM )kluster

PEMESINAN bagi kursus peringkat Diploma Teknologi Pembuatan - Semester

Empat telah DISEMAKdan DISAHKANdalam Mesyuarat Jawatankuasa Pemandu

Kurikulum bil. 1/2009 yang telah diadakan pada 30 Jun 2009 Sehubungan itu, WIM

yang telah disahkan ini hendaklah digunapakai bermula Julai 2009 di seluruh Institut

Latihan Jabatan Tenaga Manusia (ILJTM).

Pengerusi Mesyuarat Pengerusi Kluster

Jawatankuasa Pemandu Kurikulum


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Bil Perkara Mukasurat

1. Senarai Ahli Jawatankuasa WIM i

2. Group Clustering ii

3. Jadual Pengalaman Pembelajaran iii

4. Penggubalan WIM Mengikut Modul iv

5. Bahan Pengajaran Bertulis Bagi LE1

Pelan Mengajar Teori - K03-04-01-LE1-IS1a-LP1a 1

Kertas Penerangan - K03-04-01-LE1-IS1a 9

Kertas Tugasan - K03-04-01-LE1-AS1a 27

Pelan Mengajar Teori - K03-04-06-LE1-IS1b-LP1b 31Kertas Penerangan - K03-04-06-LE1-IS1b 39

Kertas Tugasan - K03-04-06-LE1-AS1b 47

Kertas Penerangan - K03-04-06-LE1-IS1c 51

Kertas Tugasan - K03-04-06-LE1-AS1c 61

Pelan Mengajar Teori - K03-04-06-LE1-IS1-LP1c 65

Kertas Penerangan - K03-04-06-LE1-IS1d 72

Kertas Tugasan - K03-04-06-LE1-AS1d 77

Kertas Penerangan - K03-04-06-LE1-IS1e 81

Kertas Tugasan - K03-04-06-LE1-AS1e 91


Pelan Mengajar Teori - K03-04-06-LE2-IS2-LP2 95

Kertas Penerangan - K03-04-06-LE2-IS2a 102

Kertas Tugasan - K03-04-06-LE2-AS2a 107

Kertas Penerangan - K03-04-01-LE2-IS2b 111



Pelan Mengajar Teori - K03-04-01-LE3-IS3-LP3 123

Kertas Penerangan - K03-04-01-LE3-IS3a 131Kertas Tugasan - K03-04-01-LE3-AS3a 137

Kertas Penerangan - K03-04-01-LE3-IS3b 141



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i

SENARAI AHLI JAWATANKUASA

JAWATANKUASA PEMBANGUNAN WIM KURSUSDIPLOMA TEKNOLOGI PEMBUATAN

Ahli Jawatankuasa:

1. Mustal Bin Makmud - ADTEC Shah Alam(Pengerusi Kluster)

2. Rosmiza Bt Majid - ADTEC Kulim(Pen. Pengerusi)

2. Tuan Mohd Kamal Tuan Aziz - ADTEC Batu Pahat(Ketua Penyelaras)

3. Hasri Bin Abd Hamid - ADTEC Kulim(Penolong Penyelaras)

4. Hemi Azwan Bin Ikhwan - ADTEC Shah Alam

5. Mohd Faizal Bin Arshad - ADTEC Shah Alam

6. Nor Aslinawati Bt Ramli - ADTEC Shah Alam

7. Aslina Bt Anis - ADTEC Shah Alam

8. Mohd Khairil Bin Md Isa - ADTEC Kulim

9. Abdul Jalil Bin Hassan - ADTEC Kulim

10. Fathi Safwan Bin Che - ADTEC Batu Pahat

11. Hairul Hairil Bin Harun - ADTEC Batu Pahat

12. Haizal Bin Ahmad - ADTEC Batu Pahat

Urusetia:

1. Pn. Hafazah binti Jaffar - JTM

2. Pn. Norpisah binti Jumin - JTM

3. En. Norhasni bin Dakie - JTM

4. Cik Norida binti Othman - JTM

5. Pn. Noor Hazlina binti Khalid - JTM

Tarikh dibangunkan : 23 - 26 Februari 2009Tempat : Empress Hotel Sepang


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ii

GROUP CLUSTERING(K03-04-01)

13.01 Prepare job planning & job process

13.02 Prepare time schedule for job in machiningagainst machine and operator available

13.03 Review material & tooling requirement

M01 MACHINING SUPERVISORY13.04 Ensure machines/ equipment are alwaysmaintain

13.05 Recognize workers contribution andachievement

13.06 Maintain good communication betweenmanagement & workers

13.06a Determine job sheet Instruction is workable

13.06b Determine job priority (turn around time)


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JADUAL PENGALAMAN PEMBELAJARAN(LEARNING EXPERIENCE TABLE)

No. & TAJUK MODUL : M01 MACHINING SUPERVISORY

TERMINAL PERFORMANCE OBJECTIVE :Prepare job planning, process, service, status report, manpower plan, determine job priority tooling requirement, ensured machines/equipment are always maintained, Mediate staff/persworkers contribute so that the production will established and complete within time with cost

PENGALAMANPEMBELAJARAN

(LEARNING EXPERIENCE)

NO & TUGASAN BERKAITAN(No. & RELATED TASK)

KOD(CODED BY)

LE 1 : Process Planning 13.01 Prepare job planning & job process13.02 Prepare time schedule for job in

machining against machine andoperator available

13.03 Review material & toolingrequirement

13.04 Ensure machines/equipment arealways maintain

P1

Prepare joestimating sequences machine/eqestablished

job is within

LE 2 : Communication Skill

13.05 Recognize workers contribution andachievement

13.06 Maintain good communicationbetween management & workers

P4

Recognizeassessing so that the recorded agood commworkers

LE 3: Perform Job13.06a Determine job sheet

Instruction is workable13.06b Determine job priority (turn around

time)

P3

Job sheet inthat the job requiremen

iii


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PENGGUBALAN WIM MENGIKUT MODUL

No. & TAJUK MODUL : M06 MACHINING SUPERVISORY


(LEARNING EXPERIENCE)

No. & TUGASAN BERKAITAN( No. & RELATED TASK)

LESSON PLANTHEORY

INFORMATIONSHEET

ASSIGNMSHEE

LE 1 : Process Planning

LE 2 : Communication Skill

LE 3: Perform Job

13.01 Prepare job planning &job process

13.02 Prepare time schedulefor job in machiningagainst machine and

operator available13.03 Review material & toolingrequirement

13.04 Ensure machines/equipment are alwaysmaintain

13.05 Recognize workerscontribution andachievement

13.06 Maintain goodcommunication betweenmanagement & workers

13.06a Determine job sheetInstruction is workable

13.06b Determine job priority(turn around time)

LP1b

LP1c

LP2

LP3

IS1a

IS1b

IS1c

IS 1dIS1e

IS2aIS2b

IS3aIS3b

AS1

AS1

AS1

AS1AS1

AS2AS2

AS3AS3

LP1a

iv


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TAJUK KEMAHIRANDAN TAHAP

DIPLOMA TEKNOLOGI PEMBUATAN TAHAP 3(SEMESTER 4)

No. DAN TAJUKMODUL

M 01 MACHINING SUPERVISORY

No. DAN TAJUK


LE 1 PROCESS PLANNING

LE 2 COMMUNICATION SKILLLE 3 PERFORM JOB

OBJEKTIF PRESTASIAKHIRAN / TERMINALPERFORMANCEOBJECTIVE

PREPARE JOB PLANNING, PROCESS, SERVICE, STATUSREPORT, MANPOWER PLAN, DETERMINE JOB PRIORITYINFORMATION, REVIEW MATERIAL & TOOLINGREQUIREMENT, ENSURED MACHINES/EQUIPMENT ARE

ALWAYS MAINTAINED, MEDIATE STAFF/PERSONNELMATTERS, RECOGNIZED WORKERS CONTRIBUTE SO

THAT THE PRODUCTION WILL ESTABLISHED ANDCOMPLETE WITHIN TIME WITH THE COST BENEFITRANGE

INSTITUT LATIHAN JABATAN TENAGA MANUSIAKEMENTERIAN SUMBER MANUSIA

MALAYSIA

PELAN MENGAJAR - TEORI(K03-04-01-LE1-IS1-LP1)


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ISI KANDUNGAN


TASK 13.01 Prepare job planning & job process


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No. & TAJUKPENGALAMANPEMBELAJARAN


No. & TAJUKTUGASAN

TASK 13.01 Prepare job planning & job process

TEMPAT: Bilik KuliahTEMPOH : 1 jam 30 min Code. : K030401-LE1-IS1-LP1 MUKA: 1 drp 6

TAJUK : PERFORM SUPERVISORY FUNCTION(title)

TUJUAN PENGAJARAN :(instructional aims)Pelajar pelajar mesti boleh :-

1 Nyatakan jenis-jenis garisan lukisan teknik.

2 Mengenali berbagai bagai jenis simbol.

3 Memahami spesifikasi mesin.

ALAT BANTUAN PENGAJARAN:(INSTRUCTIONAL AIDS)

ALAT BANTUAN PENGAJARAN TAJUK KOD No.

BAHAN PENGAJARANBERTULIS(WRITTEN INSTRUCTIONALMATERIALS)

Kertas Tugasan

Kertas Penerangan

K03-04-01-LE1a-AS1K03-04-01-LE1a-IS1

ALAT PANDANG DENGAR(AUDIO VISUAL AIDS)

LCDWHITE BOARD

Perkara Kuantiti

Papan tulis 1unit

Pen marker 1unit

Pemadam papan tulis 1unit

PERALATAN, KELENGKAPANDAN BAHAN-BAHAN(TOOL, EQUIPMENT AND MATERIALS)


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Code No: K030401-LE1-IS1-LP1 MUKA : 2 drpd 6

AKTIVITI PENGAJARAN(INSTRUCTIONAL ACTIVITIES)

ALAT BANTUANPENGAJARAN

(INSTRUCTIONALAIDS)

MASA(TIME

LANGKAH PERSEDIAAN :(PREPARATION STEP)

1. Ucap selamat dan tanya khabar.

Assalamualaikum dan selamat sejahtera.

Tanya kehadiran dan keadaan pelatih.

Tulis KURSUS, TAHAP dan TARIKH.

2. Bawa pelajar kepada tajuk, cuba kaitkan dengan pembelajaran lain.

Bagaimana dengan pembelajaran yang lepas mengenai pengenalan

kepada Supervisory

Cuba pelajar jelaskan mengenai penyeliaan.3. Tuliskan tajuk di papan tulis.

PERFORM SUPERVISORY FUNCTION

4. Tuliskan aims/tujuan pembelajaran.

Nyatakan jenis-jenis garisan lukisan teknik.

Mengenali berbagai bagai jenis simbol.

Memahami spesifikasi mesin.

5. Nyatakan kepentingan pelajaran ini.

Dapat merancang proses dan jadual kerja.

6. Siasat pengetahuan pelajar :

Tanya pelajar samada pernahkah mereka tahu tentang penyeliaan.

10 min


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Code No: K030401-LE1-IS1-LP1 MUKA : 3 drp 6

TOPIK PENGAJARAN(INSTRUCTIONAL TOPICS)



(INSTRUCTIONALAIDS)

MAS(TIM

LANGKAH PENYAMPAIAN:(PRESENTATION STEP)

1 Mengenal jenis-jenis simbollukisan teknik, terma termalakaran, simbol danmengenal jenis jenisgarisan.

2 Meaning of Limit and Fits.

Orthographic projection - describe theshape of noncylindrical parts accurately on adrawing or print, the drafts person uses theorthographic view or projection method. Orthographic view shows the partfrom three sides: the front, the top, and theright-hand side. Contoh contoh garisan adalahseperti berikut,i. object line,

ii. Hidden lines

iii. Center lines

Common drafting terms and symbolsare used in shop and engineering drawingsfor the designer to describe each partaccurately.

Limits fig5.4 are the largest and the smallestpermissible dimensions of a part (themaximum and minimum dimensions) on ashop drawing both sizes would be given.

0.7530.750

Fit is the range of tightness between twomating parts. There are two general classesof fits:1. Clearance fits, whereby a part mayrevolve or move in relation to a mating part2. Interference fits, whereby two partsare forced together to act as a single piece

Scale size is used in most engineeringdrawings. It is because,- Impossible to draw part to the exactsize because some drawings would be toolarge while others would be too small.- The scale size of a drawing isgenerally found in the title block section and itindicates the scale to which the drawing hasbeen made which is a representativemeasurement.

PPT40

min


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(INSTRUCTIONALAIDS)

MAS(TIM

3 Nyatakan simbol permukaandan simbol bahan.

4 Proses asas pembuatan

- deviation from the nominal surface causedby the machining operation.- Surface finish includes roughness, waviness,lay, and flaws, and is measured by a surfacefinish indicator in micro inches.- Surface finish mark, used in many cases,indicates which surface of the part must befinished.- The number in the indicates the quality offinish required on the surface fig 5.7.- Roughness height of the finely spacedirregularities cause by the cutting tool cannotexceed 40 micro inches ( in.).

represents copper, brass, bronze, etc.

represents aluminium, magnesium, and theiralloys.

represents steel and wrought iron

represents cast iron and malleable iron.

- Planning the procedures so that it can bemachined accurately and quickly.- Many parts - spoiled because the incorrectsequence has been followed in themachining process.- impossible to list the exact sequence ofoperations that would apply to every type andshape of workpiece.

Manufacturing processes can be classified as:

Casting, foundry, or moldingprocesses

Forming or metalworking processes

Machining (material removal) Joining and assembly

Surface treatments (finishing)

Heat treating, Other


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(INSTRUCTIONALAIDS)

MAS(TIM

5 Production planning stategies

6 Level Schedule

- A laser used for joining or for metal removalor heat-treating.

- Assembly involves processes other thanjoining.- An important advantage of casting andmolding is a single step.- Secondary advantage is scrap material caneasily be recycled.- Casting processes are classified into twotypes: permanent mold (a mold can beused repeatedly) or nonpermanent mold(a new mold must be prepared for eachcasting made).

- Seven basic machining processes areshaping, drilling, turning, milling, and sawing,

broaching, and abrasive machining.-Eight basic types of machine tools-These are shapers (and planers), drillpresses, lathes, boring machines, millingmachine, saws, broaches, and grinders.- Advantage has led to the development ofmachining to combine many of the basicprocesses.

Production planning strategies

1. Chase strategy2. Stable workforce3. Level strategy

Relevant costs

1. Basic production costs.2. Costs associated with changes in the

production rate.3. Inventory holding costs.4. Backordering costs.

Level production has a number ofadvantages:1. The entire system can be planned tominimized inventory and work in process.

2. Product modifications are up-to-datebecause of the low amount of work inprocess.3. There is a smooth flow throughout theproduction system.4. Purchased items from vendors can bedelivered when needed, and in fact, oftendirectly to the production line.


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(INSTRUCTIONALAIDS)

MASA(TIME

LANGKAH PENGESAHAN :(CONFIRMATION STEP)

1. Arahkan pelajar untuk menyimpan kertas bertulis atau nota

2. Edarkan kertas soalan.Maklumkan kepada pelajar bahawa soalan yang

diberi adalah berdasarkan kepada pelajaran yang diajar

3. Nyatakan :-

I. Masa yang diberikan - 30 minit

II. Markah lulus

4. Pastikan semuanya jelas dan bersedia

5. Mulakan ujian

6. Berhenti ujian setelah tamat masa yang ditetapkan.

7. Minta pelajar semak mana, nombor KP dan sebagainya

8. Maklumkan kepada pelajar keputusan akan diumumkan pada pelajaran

akan datang

9. Beri ringkasan mengenai apa yang diajar, faedahnya dan minta bersedia

untuk topik yang akan datang

10. Umumkan tajuk pelajaran yang akan datang

Prepare time schedule and review material and tooling

11. Ucapan perpisahan

AS 30min


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TAJUK KEMAHIRAN DANTAHAP DIPLOMA TEKNOLOGI PEMBUATAN TAHAP 3

(SEMESTER 4)

No. DAN TAJUK MODUL M01 MACHINING SUPERVISORY

No. DAN TAJUKPENGALAMANPEMBELAJARAN


LE 2 COMMUNICATION SKILL

LE 3 PERFORM JOB

OBJEKTIF PRESTASI

AKHIRAN / TERMINALPERFORMANCEOBJECTIVE

PREPARE JOB PLANNING, PROCESS, SERVICE,

STATUS REPORT, MANPOWER PLAN, DETERMINE JOBPRIORITY INFORMATION, REVIEW MATERIAL &TOOLING REQUIREMENT, ENSUREDMACHINES/EQUIPMENT ARE ALWAYS MAINTAINED,MEDIATE STAFF/PERSONNEL MATTERS, RECOGNIZEDWORKERS CONTRIBUTE SO THAT THE PRODUCTIONWILL ESTABLISHED AND COMPLETE WITHIN TIME WITTHE COST BENEFIT RANGE


MALAYSIA

KERTAS PENERANGAN(K03-04-01-LE1-IS1a)


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ISI KANDUNGAN


TASK 13.01 PREPARE JOB PLANNING AND JOB PROCESS

.


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No. & TAJUK TUGASAN TASK 13.01 PREPARE JOB PLANNING AND JOB PROCESS

TEMPAT : Bilik Kuliah TEMPOH: 1 JAM 30 MIN Code No. : K03-04-01-LE1-IS1a Muka: 1 drp 16

TAJUK : PERFORM SUPERVISORY FUNCTION

TUJUAN :This Information sheet describes about orthographic projection in order to describe the shape of noncylindricalparts accurately on a drawing or print, the draftsperson uses the orthographic view or projection method.

PENERANGAN :

Type of engineering drawingsTypes of drawings and lines

Orthographic projection in order to describe the shape of non cylindrical parts accurately on a drawing or printhe draftsperson uses the orthographic view or projection method. The orthographic view shows the part fromthree sides: the front, the top, and the right-hand side.(figure 5.1)

Top

Front Right side

Figure 5.1 three views of orthographic projection make it easier to describe the details of the part.

These three views enable the drafter to describe a part or object so completely that the machinist knows exacwhat is required.

Cylindrical parts are generally shown on prints in two views: the front and the right side (figure 5.2). However, ipart contains many details, it may be necessary to use the top, bottom, or left-side views to describe the paaccurately to the machinist.

2


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Code No. K03-04-01-LE1-IS1a Muka: 2 drp 16

Sections views in many cases, complicated interior forms are difficult to describe in the usual manner bydraftsperson. Whenever this occurs, a sectional view, which is obtained by making an imaginary cut through object, is made. This imaginary cut can be made in a straight line in any direction to best expose the intercontour or form of a part (figure 5.3).

Figure 5.2 cylindrical parts are generally shown in two views.Drafting terms and symbolsCommon drafting terms and symbols are used in shop and engineering drawings in order for the designer describe each part accurately. If it were not for the universal use of terms, symbols, and abbreviations, tdesigner would have to make extensive notes describing exactly what is required. These would not only cumbersome but also could be misunderstood and therefore result in costly errors. Some of the common draftiterms and symbols are explained below.

Figure 5.3 section views are used to show complicated interior forms.Table 5.1 common lines used on shop drawings

Example Name Description Use

a

Objects lines

Thick black lines approximately

1/32 in. wide (the width may vary tosuit drawing size) Indicate the visible formor edges of an object.

bHidden lines

Medium weight black lines of 1/8-in.long dashes and 1/16 in. long.

Indicate the hiddencontours of an object.

c

Center lines

Thin lines with alternating long linesand short dashes. Long lines from to 3 in. long.Short dashes 1/16 to1/8 in. long, spaces 1/16 in. long.

Indicate the centers ofholes, cylindrical objects,and other sections.

1 d Dimension

lines

Thick black lines with an arrowheadat each end and a space in thecenter for a dimension.

Indicate the dimensionsof an object.

eCutting-planelines

Thick black lines make up a seriesof one long line and two shortdashes. Arrowheads show the lineof sight from where the section istaken.

Show where a section isimagined to be cut.

Cross-sectionlines

Fine evenly spaced parallel lines at45 degrees. Line spacing is inproportion to the part size.

Show the surfacesexposed when a sectionis cut.


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Figure 5.4 limits show the largest and smallest size of a part.

+0.0010.750 -0.003

Figure 5.5 tolerances is the permissible variation of a size

Figure 5.6 allowances is the intentional difference in the sizes of mating parts.

0.753

0.750


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Limits fig5.4 are the largest and the smallest permissible dimensions of a part (the maximum and minimudimensions) on a shop drawing both sizes would be given.

EXAMPLE

0.751 largest dimensions0.749 smallest dimensions

Tolerance (fig 5.5) is the permissible variation of the size of a part. On a drawing the basic dimension is givenplus or minus to variation allowed.

EXAMPLE

0.750 + 0.001- 0.003

The tolerance in this case would be 0.004 (the difference between + 0.001 oversize or - 0.003 undersize).

Allowance (figure 5.6) is the intentional difference in the sizes of mating parts such the diameter of a shaft athe size of the hole. On a shop drawing both the shaft and the hole would be indicated with maximum anminimum sizes in order to produce the best fit.

Fitis the range of tightness between two mating parts. There are two general classes of fits:1. Clearance fits, whereby a part may revolve or move in relation to a mating part2. Interference fits, whereby two parts are forced together to act as a single piece

Scale size is used in most shop or engineering drawings since it would be impossible to draw part to the exasize because some drawings would be too large while others would be too small. The scale size of a drawinggenerally found in the title block section and it indicates the scale to which the drawing has been made which isrepresentative measurement.

0.00240 40 0.001

Fig 5.7 surface finish symbols indicate fig. 5.8 surface finish specifications.

the type and finish of the surface.

SCALE DEFINITION

1:1

1:2

2:1

Drawing is made to the actual size of part or full scale

Drawing is made one-half the actual size of the part.

Drawing is made twice the actual size of the part.


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SYMBOLS

Some of the symbols and abbreviations used on shop drawings indicate the surface finish, type of materiroughness symbols, and common machine shop terms and operations.

SURFACE SYMBOLS

Surface finish is the deviation from the nominal surface caused by the machining operation. Surface finiincludes roughness, waviness, lay, and flaws, and is measured by a surface finish indicator in micro inches.The surface finish mark, used in many cases, indicates which surface of the part must be finished. The numberthe indicates the quality of finish required on the surface fig 5.7. In this case the roughness height or thmeasurement of the finely spaced irregularities cause by the cutting tool cannot exceed 40 micro inches ( in.).If the surface of a part must be finished to exact specifications, each part of the specifications is indicated on tsymbol (fig 5.8) as follows:

40 Surface finish in micro inches0.002 Waviness heights in thousands of an inch0.001roughness width in thousandths of an inchmachining marks run perpendicular to the boundary of the surface indicated.

The following symbols indicate the direction of lay (marks produced by machining operations on work surfaces)= Parallel to the boundary line of the surface indicated by the symbolX angular in both directions on the surface indicated by the symbolM multidirectional

C approximately circular to the center of the surface indicated by the symbolR approximately radial to the center of the surface indicated by the symbol

MATERIAL SYMBOLS

represents copper, brass, bronze, etc.

A

Represents aluminum, magnesium, and their alloys.

B

represents steel and wrought ironC

Represents cast iron and malleable iron.

DFIGURE 5.9 symbols used to indicate types of material.


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COMMON MACHINE SHOP ABBREVIATIONS

CBORECSKDIA

HDNL

LHMmNCNFPRRcRH

THDTIRTPI

UNCUNF

Counter boreCountersink

DiameterDiameter

HardenLead

Left handMillimeter

National coarseNational fine

PitchRadius

Rockwell hardness testRight hand

Thread or threadsTotal indicated run-out

Threads per inch

Unified national coarseUnified national form

BASIC MANUFACTURING PROCESS

Planning the procedures for machining any part so that it can be machined accurately and as quickly as possibis very important. Many parts have been spoiled because the incorrect sequence has been followed in tmachining process. Although it would be impossible to list the exact sequence of operations that would apply every type and shape of workpiece, some general rules should be followed to machine a part accurately and the shortest time possible.

Manufacturing processes can be classified as:

Casting, foundry, or molding processes

Forming or metalworking processes

Machining (material removal) Joining and assembly

Surface treatments (finishing)

Heat treating

OtherThese classifications are not mutually exclusive. For example, some finishing processes involve a small amouof metal removal or metal forming. A laser can be used either for joining or for metal removal or heat-treatinOccasionally, we have a process such as shearing, which is really metal cutting but is viewed as a (sheet) meforming process. Assembly may involve processes other than joining. The categories of process types are ffrom perfect.Casting and molding processes are widely used to produce parts that often require other follow-on processesuch as machining. Casting uses molten metal and a cavity. The metal retains the desired shape of the mocavity after solidification. An important advantage of casting and molding is that, is a single step, materials can converted from a crude form into a desired shape. In most cases, a secondary advantage is that excess or scrmaterial can easily be recycled.Casting processes commonly are classified into two types: permanent mold (a mold can be used repeatedly) nonpermanent mold (a new mold must be prepared for each casting made).Forming and shearing operations typically utilize material (metals or plastics) that previously has been cast molded. In many cases the materials pass through a series of forming or shearing operations, so the form of tmaterial for a specific operation may be the result of all the prior operations. The basic purpose of forming anshearing is to modify the shape and the size and / or physical properties of the material.Metal forming and shearing operations are done hot and cold, a reference to the temperature of the materialthe time it is being processed with respect to the temperature at which this material can recrystallise. (i.e. gronew grain structure)


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Machining or metal removal processes refer to the removal of certain selected areas from a part to obtaindesired shape or finish. Chips are formed by interaction of a cutting tool with the material being machined.The cutting tools are mounted in machine tools, which provide the required movements of the tool with respectthe work (or vice versa) to accomplish the process desired. In recent years many new machining processes habeen developed. The seven basic machining processes are shaping, drilling, turning, milling, and sawinbroaching, and abrasive machining. Historically, eight basic types of machine tools were developed to accomplithe basic processes. These are shapers (and planers), drill presses, lathes, boring machines, milling machinsaws, broaches, and grinders. Many of these machine tools are capable of performing more than one of the basmachining processes. This obvious advantage has led to the development of machining centers specificadesigned to combine many of the basic processes, and perform other related processes, all on a single machitool using a single work piece set-up. Included with the machining processes are processes wherein metal removed by chemical, electrical, electrochemical, or thermal sources. Generally speaking, these non-traditionprocesses have evolved to fill a specific need when conventional processes were too expensive or too slow whmachining very hard materials. One of the first uses of a laser was to machine holes in ultra high strength metaIt is being used today to drill tiny holes in turbine blades for jet engines.


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There are seven basic chip formation processes: shaping, turning, and milling, drilling, sawing, broachinand grinding (abrasive machining). For all metal-cutting processes, it is necessary to distinguish betweespeed, feed and depth of cut. The turning process will be used to introduce few terms.

In general speed (V) is the primary cutting motion, which relates the velocity of the rotating work piece wrespect to the stationary cutting tool. It is generally given in units of surface feet per minute (sfpm) or inches pminute (in./min), or meters per minute (m/m) or meters per second (m/s). Feed (fr) is the amount of materremoved per revolution or per pass of the tool over the work piece. In turning, feed is in inches/revolution and ttools feed parallel to the rotational axis of the work piece. Feed units are inches per revolution, inches per cycinches per minute, or inches per tooth, depending on the process. Feed is shown with dashes arrows. The depof cut (DOC), d,represents the third dimension.

Shaping

The process of shaping and planning are among the oldest single-point machining processes. Milling anbroaching, as production processes have largely replaced them. From a consideration of the relative motiobetween the tool and the workpiece, shaping and planning use straight line cutting motion with a single pocutting tool to generate a flat surface. In shaping, the workpiece is fed at right angles to the cutting motibetween successive stokes of the tool. These terms are commonly used:- fc, is the feed per stroke, Vis cutti

speed, and tis the DOC. (in planning, discusses next, the work piece is reciprocated and the tool is fed at rigangles to the cutting motion.) for either shaping or planning, the tool is held in a clapper box which prevents thcutting edge from being damaged on the return stroke of the tool. In addition to plain flat surfaces, the shapemost commonly produced on the shaper and planers are those illustrated in figure 26-31. Relatively skillworkers are required to operate shapers and planer, and most of the shapes that can be produced on them alscan be made by much more productive processes, such as milling, broaching, or grinding. Consequently, excefor certain special types, planers that will do only planning have become obsolete, and shapers are used mainin tool-and-die work, in very low volume production, or in the manufacture of gear teeth.


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Turning

Turning is the process of machining external cylindrical and conical surfaces. It is usually performed on a lathAs indicated in figure 23.1, relatively simple work and tool movements are involved in turning a cylinder surfacThe work piece is rotated into a longitudinally fed, single point cutting tool. If the tool is fed at an angle to the axof rotation, an external conical surfaces results. This is called taper turning. If the tool is fed at 90 degrees to t

axis of rotation, using a tool that is wider than the width of the cut, the operation is called facing, and a flat surfais produced.By using a tool having a specific form or shape and feeding it radically or inward against the work, externcylindrical, conical, and irregular surfaces of limited length can also be turned. The shape of the resulting surfais determined by the shape and size of the cutting tool. Such machining is called form turning. If the tool is fed the way to the axis of the work piece, it will be cut in two. This is called parting or cut-off and a simple, thin toolused. A similar tool is used for necking or partial cut-off.

Drilling

In manufacturing it is probable that more holes are produced than any other shape, and drilling makes a larproportion of these are made by drilling. Of all the machining processes performed, drilling makes up about 25Consequently, drilling is a very important process. Although drilling appears to be a relatively simple process, itreally a complex process. Most drilling is done with a tool having two cutting edges. These edges are at the eof a relatively flexible tool. Cutting action takes place inside the work piece. The only exit for the chips is the hothat is filled by the drill. Friction results in heat that is additional to that due to chip formation. The counter flow the chips makes lubrication and cooling difficult. There are four major actions taking place at the point of a drill:

1. The web forms a small hole chips are not cut here in the normal sense.2. The rotating lips form chips.3. Chips are removed from the hole by the screw action of the helical flutes.4. The drill is guided by the margins rubbing against the walls of the hole.

In recent years, new drill point geometries and TiN coatings have resulted in improved hole accuracy, longer lifself-centering action, and increased-feed-rate capabilities. However the great majority of drills manufactured atwist drills, having the conventional point and geometry. One estimate has U.S. manufacturing companiconsuming 250 million twist drills per year.When HSS drills wear out, the drill is reground. If regrinding is not done properly, the original drill geometry mabe lost and so will drill accuracy and precision. Drill performance also depends on the drilling machine tool, t

work holding device, the drill holder, and the surface of the work piece. Poor surface conditions (sand pockeand/or chilled hard spots on castings, hard oxide scale on hot-rolled metal) can accelerate early tool failure adegrade the hole-drilling process.

Milling

Milling is a basic machining process by which a surface is generated by progressive chip removal. The workpiece is fed into a rotating cutting tool. Sometimes the work piece remains stationary, and the cutter is fed to thework. In nearly, all cases, a multiple-tooth cutter are used so that the material removal rate is high. Often thedesired surface is obtained in a single pass of the cutter or work, and because very good surface finish can beobtained, milling is particularly well suited and widely used for mass-production work. Many types of millingmachines are used, ranging from relatively simple and versatile machines that are used for general purposemachining in job shops and tool and die work to highly specialize machines for mass production.Unquestionably, milling than produces more flat surfaces by any other machining process.

The cutting tool used in milling is known as a milling cutter. Equally spaced peripheral teeth will intermittentlyengage and machine the work piece. This is called interrupted cutting.

SawingSawing is a basic machining process in which chips are produced by a succession of small cutting edges, orteeth, arranged in a narrow line on a saw blade. Each tooth forms a chip progressively as it passes through thwork piece, and the chip is contained within the space between two successive teeth until these teeth pass fromthe work. Because sections of considerable size can be served from the work piece with the removal of only asmall amount of the material in the form of chips, sawing is probably the most economical of the basic machininprocesses with respect to the waste of material and power consumption, and in many cases with respect to labo


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In recent years vast improvements have been made in saw blades and sawing machines, resulting in improvedaccuracy and precision of the process. Most drawing is done to sever bar stock and shapes into desired lengthsfor use in other operations. There are many cases in which sawing are used to produce desired shapes.Frequently, and especially for producing only a few parts, contour sawing may be more economical than anyother machining process.

Grinding (abrasives machining)

Abrasive machining is a material-removal process that involves the interaction of abrasive grits with the wopiece at high speeds and shallow penetration depths. The chips that are formed resemble those formed by othmachining processes. Unquestionably, abrasive machining is the oldest of the basic machining processeMuseums abound with examples of utensils, tools, and weapons that ancient peoples produced by rubbing hastones against softer materials to abrade away-unwanted portions, leaving desired shapes. For centuries, onnatural abrasives were available, and other, more modern, basic machining, processes, were developed usisuperior cutting materials. However, the development of manufactured abrasives and a better fundamenunderstanding of the abrasives machining processes has resulted in placing abrasive machining and variations among the most important of all basic machining processes.The results that can be obtained by abrasive machining range from the finest and smoothest surfaces produceby any machining process, in which very little material is removed, to rough, coarse surfaces that accompahigh material-removal rates. The abrasive particles may be

1. Free2. Mounted in resin on a belt (called coated products)3. Close packed into wheels or stones, with abrasives held together by bonding material (called bond

product or a grinding wheel).There are few terms that are always being used. The depth of cut, dis determined by the in feed and is usuavery small, 0.002 to 0.005 in., so the arc of contact (and the chips) is small. The table reciprocates back and fobeneath the rotating wheel. The work feeds into the wheel (see cross feed direction) after the work is clear of twheel.The metal removal process is basically the same in all abrasive machining processes but with importadifferences due to spacing of active grains (grains in contact with work) and the rigidity and degree of fixation the grains. Table 27-1 summarizes the primary abrasives processes

Table 27-1 abrasive machining processes

Process Particle mounting Features

Grinding BondedUses wheels, accurate sizing, finishing, low MRR; can bedone at high speeds (over 12,000 sfpm)

Creep feedgrinding

Bonded open, softUses wheels with long cutting arc, very slow feed rate andlarge depth of cut

Abrasivemachining

BondedHigh MRR, to obtain desired shapes and approximatesizes.

Snagging Bonded beltedHigh MRR, rough rapid technique to clean up and deburrcastings, forgings

Honing BondedStones containing fine abrasives; primarily a hole finishingprocess

Lapping FreeFine particles embedded in soft metal or cloth; primarily a

surface finishing process.Abrasive waterjet

Free in jetWater jets with velocities up to 3000 ft/sec carry abrasiveparticles (silica and garnet)

Abrasives machining processes have two unique characteristics. First, each cutting edge is very small, and manof these edges can cut simultaneously. When suitable machines are employed, very fine cuts are possible andfine surfaces and close dimensional control can be obtained. Second, because extremely hard abrasive grits cabe produced, very hard materials such as hardened steel, glass, carbides, and ceramics, can readily bemachined. As a result, the abrasive machining processes are not only important as manufacturing processes,they are indeed essential. Many of our modern products, such as modern machine tools, automobiles, spacevehicles, and aircraft, could not be manufactured without these processes.


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BroachingThe process of broaching is one of the most productive of the basic machining processes. The machine tool called a broaching machine and the cutting tool. Broaching competes economically with milling and boring andcapable of producing precision-machined surfaces. The broach finishes an entire surface in a single pasBroaches are used in production to finish holes, splines, and flat surfaces.

The feed per tooth in broaching is the change in height of successive teeth. This is called the rise per tooBroaching is similar to sawing except that the saw makes, many passes through the cut, whereas the broacproduces a finished part in one pass. The heart of this process lies in the broaching tool, in which roughing, sefinishing, and finishing teeth are combined into one tool. Broaching is unique in that it is the only one of the basmachining processes in which feed, which determines the chip thickness, is built into the cutting tool. Tmachined surface is always the inverse of the profile of the broach, and in most cases, it is produced with a singlinear stroke of the tool across the work piece (or the work piece across the broach).

A broach is composed of a series of teeth, each tooth standing slightly higher than the last. This rise per too(RPT), also known as step or the feed per tooth, determines the amount of material removed. There is no feediof the broaching tool required. The frontal contour of the teeth determines the shape of the resulting machinsurface. As the result of these conditions built into the tool, no complex motion of the tool relative to the wopiece is required and the need for highly skilled machine operators is minimized. For the vertical pull dow

broaching machine; the pull end of the broach is passed through the part and a key mate to the slot. The broais pulled through the part. The broach is retracted (pulled up) out of the part. The part is transferred from the lefixtures to the right fixture. One finished part is completed in every time cycle.

OPERATIONS PLANNING ACTIVITIES

Figure 14.1 positions aggregate planning relative to other major operations planning activities presented in thetext. The time dimension is shown as long, intermediate, and short range. Long range planning is generally donannually, focusing on a horizon greater than one year. Intermediate range planning usually covers a period from6 to 18 months, with time increments that are monthly or sometimes quarterly. Short range planning covers aperiod from one day or less to six months, with the time increment usually weekly.


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The master production schedule (MPS) generates the amounts and dates of specific items required for eaorder. Rough cut planning is then used to verify that production and warehouse facility, equipment, and labor aavailable and that key vendors have allocated sufficient capacity to provide materials when needed. A materrequirement planning takes the end product requirements from the MPS and breaks them down into thcomponent parts and subassemblies to create material plan. This plan specifies when production and purchaorders must be placed for each part and subassembly to complete the product on schedule. This is callcapacity requirements planning. The final planning activity is daily or weekly order scheduling of jobs to specimachines, production lines, or work centers.

PRODUCTION PLANNING STRATEGIES

There are essentially three production planning strategies. These strategies involve trade-offs among tworkforce size, work hours, inventory, and backlogs.

1. Chase strategy match the production rate to the order rate by hiring and laying off employees as torder rate varies. The success of this strategy depends on having a pool of easily trained applicants draw on as order volumes increase. There are obvious motivational impacts. When order backlogs alow, employees may feel compelled to slow down out of fear of being laid off as soon as existing ordeare completed.

2. Stable workforce variable work hours. Vary the output by varying the number of hours worked throuflexible work schedules or overtime. By varying the number of work hours, you can match productiquantities to orders. This strategy provides workforce continuity and avoids many of the emotional antangible costs of hiring and firing associated with the chase strategy.

3. Level strategy. Maintain a stable workforce working at a constant output rate. Shortages and surplusare absorbed by fluctuating inventory levels, order backlogs, and lost sales. Employees benefit frostable work hours at the costs of potentially decreased customer service levels and increased inventocosts. Another concern is the possibility of inventoried products becoming obsolete.

RELEVANT COSTS

There are four costs relevant to aggregate production planning. These relate to the production costs itself as weas the cost to hold inventory and to have unfilled orders. More specifically, these are

1. Basic production costs. These are the fixed and variable costs incurred in producing a given producttype in a given time period. Included are direct and indirect labor costs and regular as well as overtimecompensation.

2. Costs associated with changes in the production rate.Typical costs in this category are thoseinvolved in hiring, training, and laying off personnel. Hiring temporary help is a way of avoiding thesecosts.

3. Inventory holding costs.A major component is the cost of capital tied up in inventory. Othercomponents are storing, insurance, taxes, spoilage, and obsolescence.

4. Backordering costs. Usually these are very hard to measure and include costs of expediting, loss ofcustomer goodwill, and loss of sales revenues resulting from backordering.


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CALCULATION ON COST PER UNIT

In solving this problem, we can exclude the material costs. We could have included this $100 cost in allour calculations, but if we assume that a $100 cost is common to each demanded unit, then we need onto concern ourselves with the marginal costs. Because the subcontracting cost is $120, our true cost fosubcontracting is just $20 because we save the materials.

Note that many costs are expressed in a different form than typically found in the accounting records of a firm.Therefore, do not expect to obtain all these costs directly from such records, but obtain them directly frommanagement personnel, who can help interpret the data.

Inventory at the beginning of the first period is 400 units. Because the demand forecast is imperfect, the CA&JCompany has determined that a safety stock (buffer inventory) should be established to reduce the likelihood ofstock outs. For this example, assume the safety stock should be one-quarter of the demand forecast.Before investigating alternative production plans, it is often useful to convert demand forecasts into productionrequirements, which take into account the safety stock estimates. In exhibit 14.4, note that these requirementsimplicitly assume that the safety stock is never actually used, so that the ending inventory each month equals thsafety stock for that month. For example, the January safety stock of 450 (25 percent of January demand of1800) becomes the inventory at the end of January. The production requirement for January is demand plussafety minus beginning inventory (1800 + 450 400 = 1850).


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Now we must formulate alternative production plans for the CA&J Company. Using a spreadsheet, we investigafour different plans with the objective of finding the one with the lowest total cost.

Plan 1.Produce to exact monthly production requirements using a regular eight-hour day by varying workforcesize.

Plan 2.Produce to meet expected average demand over the next six months by maintaining a constantworkforce. This constant number of workers is calculated by finding the average number of workers requiredeach day over the horizon. Take the total production requirements and multiply by the time required for each unThen, divide by the total time that one person works over the horizon [(8000 units x 5 hours per unit) / (125 days8 hours per day) = 40 workers]. Inventory is allowed to accumulate, with shortages filled from next monthsproduction by back ordering. Notice that in this plan we use our safety stock in January, February, march, andJune to meet expected demand.

Plan 3.Produce to meet the minimum expected demand (April) using a constant workforce on regular time.Subcontract to meet additional output requirements. The number of workers is calculated by locating theminimum monthly production requirement and determining how many workers would be needed for that month[(850 units x 5 hours per unit) / (21 days x 8 hours per day) = 25 workers] and subcontracting any monthlydifferent between requirements and production.

Plan 4.Produce to meet expected demand for all but the first two months using a constant workforce on regulatime. Use overtime to meet additional output requirements. The number of workers is more difficult to compute fthis plan, but the goal is to finish June with an ending inventory as close as possible to the June safety stock. Bytrial and error it can be shown that a constant workforce of 38 workers is the closest approximation.

LEVEL SCHEDULINGWe looked at four primary strategies for production planning: vary workforce size to meet demand, work overtimand under time, vary inventory through excesses and shortages, and subcontract.The just in time approach concentrates on keeping a level production schedule. A level production schedule.level schedule holds production constant over a period of time. It is something of a combination of the strategiwe have mentioned here. For each period, it keeps the workforce constant and inventory low, and depends demand to pull products through. Level production has a number of advantages:

1. The entire system can be planned to minimized inventory and work in process.

2. Product modifications are up-to-date because of the low amount of work in process.3. There is a smooth flow throughout the production system.4. Purchased items from vendors can be delivered when needed, and in fact, often directly to the producti

line.Toyota Motor Corporation, for example, creates a yearly production plan that shows the total number of carsbe made and sold. The aggregate production plan creates the system requirements to produce this total numbwith a level schedule. The secret to success in the Japanese level schedule is production smoothing. Taggregate plan is translated into monthly and daily schedules that sequence products through the productiosystem. The procedure is essentially this: two month in advance, the car types and quantities needed aestablished. This is converted to a detailed plan one month ahead. These quantities are given to subcontractoand vendors so that they can plan on meeting Toyotas needs. The monthly needs of various car types are thtranslated into daily schedules. For example, if 8000 units of car type A are needed in one month, along wi6000 type B, 4000 type C, and 2000 type D, and if we assume the line operates 20 days per month, then th

would be translated to a daily output of 400, 300, 200, and 100, respectively. Further, this would be sequenced four units of A, three of B, two of C, and one of D each 9.6 minutes of a two-shift day (960 minutes).Each worker operates a number of machines, producing a sequence of products. To use this level schedulintechnique,

1. Production should be repetitive (assembly line format)2. The system must contain excess capacity3. Output of the system must be fixed for a period of time (preferably a month).4. There must be a smooth relationship among purchasing, marketing, and production.5. The cost of carrying inventory must be high.6. Equipment costs must be low.7. The workforce must be multiskilled.


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Compare actual work activities to planned progress documentOnce order of prospective order has been finalized, the spec, variety, delivery and pricing will be thendetermined. The production person in charge (PIC) will ensure the machinery facilities, materials and otherproduction materials are being fully utilized by making the overall plan. As to enforce the plan, he will do thenecessary arrangement for the job and giving out the job instruction. He will see the variation between the actuaversus the plan during the progress of the work. Control would take in place when needs arise. Although the woshop or the production will observe the production instruction, however, it is very common to find a gap betweenthe planning value and the actual value.Process control department will determine the overall production procedures by leasing closely and have a goonetwork with the design, production, transportation, inspection, purchasing and others department. The planningof the production will be carried out as to ensure the required manpower, machinery, materials etc. will be input the line at the right time. Once it has proceeded to the implementation stage of the production, the control workwill come in as to monitor the progress of the production.

Operation instructionOperation instruction is to confirm if the materials, manpower and other necessary factors has been arranged aper arrangement plan. Beside this, it will give out green light to start the production once job have been allocateto each operator as per schedule.

1. Operation sheetIn the operation sheet, the manufacturing number, the name of the operator, the quantity, the delivery, thestandard time and others will be recorded. Once task completed, the name of the operator and the actualoperation time and ending time will be recorded.

2. Outgoing sheetOutgoing sheet consist of instruction on the outgoing of parts, materials, jigs and tools, inspection andmeasurement devices of the factory. It is also indicated details such as name of the products, manufacturingcode, destination, parts or name of the materials and the outgoing quantity.

3. Traveling sheetTraveling sheet indicating instruction on the movement procedure of the inventory between each process, theperiod and the destination. Its main objective is to confirm the receiving and dispatching period and the quantity

between each process.

4. Inspection sheetInspection sheet mainly used to record the confirmation on the production output and the quantity of QC passgoods.

Progress controlThe main objective of progress control is to grasp the progress of the operation and to make the necessaryadjustment as to ensure the production is executed as per schedule and adhering to the production instruction.Grasping of the progress and the capacity are vital due to the various spec of each products, the varioprocedure and delivery, unforeseen order, revision on order etc. unforeseen factors that occurred at the procewhich will become the obstacle for the materialization of the plan is unavoidable.


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The variation between production planning and production execution is as below.

At production planning Production on line stage

Insufficient knowledge on the current processcompetency

Machine down, blackout

Inadequate standard time Absenteeism

Inadequate prediction and precedent period Occurrence of defect on process parts

Change of time due to complicated design or delayof design

Lost or damage of materials

Inadequate of procedure planDelayed of sub-con incoming parts and defect

on incoming parts

Wrong capacity estimationLagging attitude on reporting the abnormality

or changes during production running

Inadequate schedule Insufficient knowledge on the progress

Unconsolidated standard time and operationstandard

Uncertain movement between process

Inadequate deliveryInconsiderable changes of the operation

instruction

Inadequate method of taking the planning period

Occurrence of sudden orderInsufficient of preventive measures

QUESTIONS:1. What are basic production costs?2. How many costs relevant to aggregate production planning and what are they?3. Rough cut planning is used for?4. What are four primary strategies for production planning?5. How many productions do we have and evaluate.6. List out metal-cutting processes?7. What are the two unique characteristics of abrasives machining processes?8. The abrasive particles may be9. The cutting tool are commonly used in what process and is known as

10. What is milling process?11. How can a drafter indicate the exact specifications required on a part?12. What is the purpose of

a. An assembly drawing?b. A detailed drawing?

13. What is the purpose of an orthographic view14. What lines are used to show:

a. The form of a part?b. The centers of holes, objects or sections?c. The exposed surfaces of where a section is cut?

15. What is the process control department determined?

16. Give four types of operation instruction.

17. of the progress and the capacity are vital due to the various , ,

unforeseen order, revision on order etc.

RUJUKAN1. Manufacturing Engineering and Technology ; Kalpakjian , 1995.2. Technology of machine tool; Krar, Oswald, St. Amand, 1969.3. Material and processes in manufacturing, E. Paul DeGarmo, JT Black, Ronald A. Kohser, 1997.

4. Production and operations management manufacturing and services; Chase, Aquilano,and

Jacobs, 1973.


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TAJUK KEMAHIRAN DANTAHAP DIPLOMA TEKNOLOGI PEMBUATAN TAHAP 3

(SEMESTER 4)




LE 2 COMMUNICATION SKILL

LE 3 PERFORM JOB

OBJEKTIF PRESTASIAKHIRAN / TERMINALPERFORMANCE

OBJECTIVE

PREPARE JOB PLANNING, PROCESS, SERVICE, STATUREPORT, MANPOWER PLAN, DETERMINE JOB PRIORITINFORMATION, REVIEW MATERIAL & TOOLINREQUIREMENT, ENSURED MACHINES/EQUIPMENT AR

ALWAYS MAINTAINED, MEDIATE STAFF/PERSONNEMATTERS, RECOGNIZED WORKERS CONTRIBUTE STHAT THE PRODUCTION WILL ESTABLISHED ANCOMPLETE WITHIN TIME WITH THE COST BENEFRANGE.


MALAYSIA

KERTAS TUGASAN(K03-04-01-LE1-AS1a)


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ISI KANDUNGAN


TASK 13.01 Prepare Job Planning And Job Process


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No. & TAJUKTUGASAN

TASK 13.01 PREPARE JOB PLANNING AND JOB PROCESS

TASK 13.02 PREPARE TIME SCHEDULE FOR JOB IN MACHINING AGAINST

MACHINE AND OPERATOR AVAILABLE.

TASK 13.03 REVIEW MATERIAL AND TOOLONG REQUIREMENT.

TASK 13.04 ENSURE MACHINES / EQUIPMENT ARE ALWAYS MAINTAIN.

TEMPAT: Bilik Kuliah TEMPOH: 1 jam Code No. : K03-04-01-LE1-AS1a Muka: 1 drp 2

TAJUK : PERFORM SUPERVISORY FUNCTION

TUJUAN: Kertas tugasan ini adalah bertujuan untuk menilai tahap kefahaman pelajar mengenai tahap

penyeliaan.Dimana ia akan dapat mempraktikkan kerja kerja penyeliaan setelah selesai duty ini.

SUMBER MAKLUMAT:

1) Kertas penarangan (H014)

2) Advance Machine Technology (1997) (m/s 90-95) (C. Thomas Olivo - Breton Publishers)


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Code No. K03-04-01-LE1-AS1a Muka: 2 drp. 2

SOALAN :

1. What is milling process?

2. How can a drafter indicate the exact specifications required on a part?

3. What is the purpose of

A. An assembly drawing?

B. A detailed drawing?

4. What is the purpose of an orthographic view

5. What lines are used to show:

A. The form of a part?

B. The centers of holes, objects or sections?

C. The exposed surfaces of where a section is cut?

6. What is the process control department determined?

7. Give four types of operation instruction.

8. Of the progress and the capacity are vital due to the various, , unfore

seen order, revision on order etc.

9. What is the responsibility of a supervisor?

10. Who must co-operate to produce some ideas?


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3

TAJUK KEMAHIRANDAN TAHAP

DIPLOMA TEKNOLOGI PEMBUATAN TAHAP 3(SEMESTER 4)

No. DAN TAJUKMODUL

M 01 MACHINING SUPERVISORY

No. DAN TAJUK



OBJEKTIF PRESTASIAKHIRAN / TERMINALPERFORMANCEOBJECTIVE

PREPARE JOB PLANNING, PROCESS, SERVICE,STATUS REPORT, MANPOWER PLAN, DETERMINEJOB PRIORITY INFORMATION, REVIEW MATERIAL &TOOLING REQUIREMENT, ENSUREDMACHINES/EQUIPMENT ARE ALWAYS MAINTAINED,MEDIATE STAFF/PERSONNEL MATTERS,RECOGNIZED WORKERS CONTRIBUTE SO THATTHE PRODUCTION WILL ESTABLISHED ANDCOMPLETE WITHIN TIME WITH THE COST BENEFITRANGE


MALAYSIA

PELAN MENGAJAR - TEORI(K03-04-01-LE1-IS1-LP1b)


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3

ISI KANDUNGAN


TASK 13.02 Review material & tooling requirement

TASK 13.03 Prepare time schedule for job in machining against machine and operator availed


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3



No. & TAJUKTUGASAN

TASK 13.02 Review material & tooling requirement

TASK 13.03 Prepare time schedule for job in machining against machine and operator

availed

TEMPAT:Bilik KuliahTEMPOH : 1 jam 30 min Code. : K030401-LE1-IS1-LP1b MUKA :1 drp 6

TAJUK: PREPARE TIME SCHEDULE AND REVIEW MATERIAL & TOOLING REQUIREMENT.(title)

TUJUAN PENGAJARAN :(instructional aims)Pelajar pelajar mesti boleh :-

1 Takrif jadual, PERT Merthod dan mengklasifikasikan jadual.

2 Rancangan Prosedur dan standard schedule.

3 Memahami production planning.

ALAT BANTUAN PENGAJARAN:(INSTRUCTIONAL AIDS)

ALAT BANTUAN PENGAJARAN TAJUK KOD No.

BAHAN PENGAJARANBERTULIS(WRITTEN INSTRUCTIONALMATERIALS)

Kertas Tugasan

Kertas Penerangan

K03-04-01-LE1b-AS1K03-04-01-LE1b-IS1b

ALAT PANDANG DENGAR(AUDIO VISUAL AIDS)

LCDWHITE BOARD

Perkara Kuantiti

Papan tulis 1unit

Pen marker 1unit

Pemadam papan tulis 1unit

PERALATAN, KELENGKAPAN

DAN BAHAN-BAHAN(TOOL, EQUIPMENT AND MATERIALS)


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Code No: K030401-LE1-IS1-LP1b MUKA : 2 drpd 6



(INSTRUCTIONALAIDS)

MASA(TIME

LANGKAH PERSEDIAAN :(PREPARATION STEP)

1. Ucap selamat dan tanya khabar.

Assalamualaikum dan selamat sejahtera.

Tanya kehadiran dan keadaan pelatih.

Tulis KURSUS, TAHAP dan TARIKH.

2. Bawa pelajar kepada tajuk, cuba kaitkan dengan pembelajaran lain.

Bagaimana dengan pembelajaran yang lepas mengenai pengenalan

kepada Supervisory

Cuba pelajar jelaskan mengenai penyeliaan.

3. Tuliskan tajuk di papan tulis.

PREPARE TIME SCHEDULE AND REVIEW MATERIAL TOOLING.

4. Tuliskan aims/tujuan pembelajaran.

Nyatakan jenis-jenis garisan lukisan teknik

Mengenali berbagai bagai jenis simbol

Memahami spesifikasi mesin.

5. Nyatakan kepentingan pelajaran ini.

Dapat mengemaskini laporan kerja, menghasilkan jadual kerja dan

prosedur dan dapat mangawal aktiviti kerja.

6. Siasat pengetahuan pelajar :

Tanya pelajar samada pernahkah mereka tahu tentang penyeliaan.

10 min


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Code No: K030401-LE1-IS1-LP1b MUKA : 3 drp 6




(INSTRUCTIONALAIDS)

MAS(TIM

LANGKAH PENYAMPAIAN:(PRESENTATION STEP)

1 What is schedule

2 Classsified schedule

3 Sequencing method

4 PERT method

To determine the starting time and theending timing of the operation and thesequence of the operation for workload ateach process.

3 categories. It is long term planning(periodical production planning), mid termplanning (monthly production planning) andshort term production planning (daily

production planning).

is to allocate the accumulated jobs in periodwise and process wise during thescheduling stage to the machine and todetermine each of the machine starting andcompleting time for the jobs.

The main feature of Project Evaluation and

Review Technique (PERT) method is theprecedent relation of the job and both knobof the arrow that is representing theoperation and the operation will bepresented in the network.

PPT40

min


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(INSTRUCTIONALAIDS)

MAS(TIM

5 Procedure planning

6 Standard schedule

7 The procedure for making the

standard schedule is:

8 What is objective material

9 Production planning

10 Material requirement planning(MRP)

11 Purposes of MRP

is based on the expanded parts and to

determine the process, the processingmethod, the required materials and therequired machinery facilities and the processprocedure.

Standard schedule is to visualize the requiredstandard operation time for each process andfor the basic schedule that is required for theoverall order

1. Compile the required time for eachprocess of the order under one table.Ensure the required operation time is in linewith the process procedure that was providedby procedure planning.2. In order to avoid any repetition of theprocess work at each process, it is necessaryto shift the operation at the starting point.3. In the standard schedule table,indicate 0 as the ending time of theoperation.

To control is to deliver a right quantity of therequired materials to the right places at theright time in addition to the minimum cost.

will be formed when production by prospectiveorder has finalized items like the type ofproducts, the spec, the quantity and themanufacturing date by the demand forecastand sales plan and for production by job shoporder is when item like the content of theorder, the fulfillment of the spec, delivery dateand the quantity

Material requirement planning (MRP) systemshave been installed almost universally in

manufacturing firms, even those consideredsmall.

The main purposes of a basic MRP systemare to control inventory levels, assignoperating priorities for items, and plancapacity to load the production system


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(INSTRUCTIONALAIDS)

MAS(TIM

12 What is buffer

13 The main roles of orderingmethod in production activityare as :

Buffer is independent from its precedent andsubsequent process and enhancing theefficiency of the production activities

- To ensure material, parts areavailable at the right time and quantity as tohave a smooth and economical productionactivity.

- To minimize the cost on stock bykeeping the stock of goods, work in progressmaterials and parts at the minimum level.

- To have consistent productioninstruction as to avoid any inconvenience thatwill cause to the factory and customer due thefluctuation on production instruction time andquantity.


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(INSTRUCTIONALAIDS)

MASA(TIME

LANGKAH PENGESAHAN :(CONFIRMATION STEP)

1. Arahkan pelajar untuk menyimpan kertas bertulis atau nota

2. Edarkan kertas soalan.Maklumkan kepada pelajar bahawa soalan yang

diberi adalah berdasarkan kepada pelajaran yang diajar

3. Nyatakan :-

I. Masa yang diberikan - 30 minit

II. Markah lulus

4. Pastikan semuanya jelas dan bersedia

5. Mulakan ujian

6. Berhenti ujian setelah tamat masa yang ditetapkan.

7. Minta pelajar semak mana, nombor KP dan sebagainya

8. Maklumkan kepada pelajar keputusan akan diumumkan pada pelajaran

akan datang

9. Beri ringkasan mengenai apa yang diajar, faedahnya dan minta bersedia

untuk topik yang akan datang

10. Umumkan tajuk pelajaran yang akan datang

Ensure machine / equipment are always maintain

11. Ucapan perpisahan

AS 30min


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TAJUK KEMAHIRAN DANTAHAP DIPLOMA TEKNOLOGI PEMBUATAN (TAHAP 3) SEMESTER 4



LE 1 PROCESS PLANNINGLE 2 COMMUNICATION SKILLSLE 3 PERFORM JOB

OBJEKTIF PRESTASI

AKHIRAN


STATUS REPORT, MANPOWER PLAN, DETERMINE JOPRIORITY INFORMATION, REVIEW MATERIAL &TOOLING REQUIREMENT, ENSUREDMACHINES/EQUIPMENT ARE ALWAYS MAINTAINED,MEDIATE STAFF/PERSONNEL MATTERS, RECOGNIZEWORKERS CONTRIBUTE SO THAT THE PRODUCTIONWILL ESTABLISHED AND COMPLETE WITHIN TIMEWITH THE COST BENEFIT RANGE


MALAYSIA

KERTAS PENERANGAN(K03-04-01-LE1-IS1b)


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ISI KANDUNGAN


Task 13.02 Prepare time schedule for job in machining against machine and operator availab


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No. & TAJUKPENGALAMANPEMBELAJARAN LE 1 PROCESS PLANNING

No. & TAJUKTUGASAN

Task 13.02 Prepare time schedule for job in machining against machine anoperator available

TEMPAT : Bilik Kuliah TEMPOH :1 jam 30 minit Code No. : K03-04-01-LE1-IS1b Muka :1 drp. : 6

TAJUK : PREPARE TIME SCHEDULE FOR JOB IN MACHINING AGAINST MACHINE AND

OPERATOR AVAILABLE.

TUJUAN:

At the end of this chapter, trainees should be able to obtain the updated work progress reports, produ

work plan schedules and procedures and gain the skill to monitor work activities.

PENERANGAN:

Prepare work schedule

It is essential to have a sensible schedule at the production stage in order to accommodate the

demands of the market and the customer as well as to improve the efficiency of the process. The

reason being, at the normal process control, the production arrangement, instruction and progress

control to the production workshop, tends to be focus on the strategic side of the production control.

However, from the view of production control it is more effective to have a good scheduling by the

strategic production planning.


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Code No. : K03-04-01-LE1-IS1b Muka : 2 drp : 6

The first purpose of planning is to find out when each part of the project may be carried out and what

overall time for completion of the project will be. The other primary purpose is to define a reference

against which actual progress can be compared in order to establish control.

Schedule is to determine the starting time and the ending timing of the operation and the sequence of

operation for workload at each process. Generally, schedule is classified into 3 categories. It is long te

planning (periodical production planning), mid term planning (monthly production planning) and shor

term production planning (daily production planning).

The quality of the schedule will affect the delay of the shipment and to prolong the period of job time;

will also have great impact on the performance ratio of the machinery and operator. The first step is

estimate the duration of each activity. This can only be found if an assumption is made about the

resources (people, machine, money) that are going to be made available for the activity. It is especia

important to involve the person responsible for each activity in this estimation process.


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Code No. K03-04-01-LE1-IS1b Muka : 3 drp : 6

Method for scheduling

Sequencing method is to allocate the accumulated jobs in period wise and process wise during the

scheduling stage to the machine and to determine each of the machine starting and completing time

the jobs. The priority rules is used to select what are the subsequent job should be done from the

processing work awaiting for the machine for the machine when the process is free; this method of

instructing the starting of the process job is called dispatching method. The priority method being use

consists of precedent method, delivery sequence, minimum operation time and minimum delivery

sequence.

Example of scheduling by priority rules

On the other hand, when one job is divided into few jobs and when the precedent relation between

each job become complicated, firstly the production plan should be set up for the overall order receiv

thus the overall control method on progress could be taken. These method of planning is called netw

scheduling and it is applicable for PERT and CPM method.

PERT Method

The main feature of Project Evaluation and Review Technique (PERT) method is the precedent relat

of the job and both knob of the arrow that is representing the operation and the operation will be

presented in the network. As the overall project is progressing, it could find the starting and the

completion time of the operation. The chain of the job (critical path) that has a direct impact on the

completion of the overall project will be sought. The control will be placed mainly on the progress of t

job that is found on the critical path. It is an effective way for the progress control.


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PERT can be used to consider the overall uncertainty in project duration. This involves making an

estimate of maximum, minimum and most likely durations for all activities and for each activity

calculating

(maximum time) + (4 x most likely time) + (minimum time)

6

These figure are then used in place of the normal activity duration figures to find the expected overal

duration. The standard deviation of the duration of each activity is assumed to be one sixth of the

difference between the maximum and minimum figures. These standard variations can then be used

generate a standard deviation for the time of the overall project.

Procedure Planning

Procedure planning is based on the expanded parts and to determine the process, the processing

method, the required materials and the required machinery facilities and the process procedure.

There are two main objectives of the procedure planning. First is to determine the process procedure

and the operation method economically. Second is to determine the parts and materials that will mee

the design spec, the quality and to cost factor to ensure it is at the economical level. The result of the

procedure planning is compiled under the procedure table by parts-wise and process-wise.


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The work hour planning is to work out the work hour required on man, date, and time for the required

job volume of the order or the processing of the parts. It is based on the procedure planning that was

determined by the process procedure and the information on production quantity. Information on qua

and quantity will be converted into work hour (job volume) and as the input information for work load

plan and daily schedule.

Standard Schedule

Standard schedule is to visualize the required standard operation time for each process and for the

basic schedule that is required for the overall order. Factors like lost time incurred during the

transportation between the process, the stagnant condition will be incorporated into the plan. It will be

based on the procedure planning.

The procedure for making the standard schedule is as follow:

1. Compile the required time for each process of the order under one table.

2. Ensure the required operation time is in line with the process procedure that was provided by

procedure planning.

3. In order to avoid any repetition of the process work at each process, it is necessary to shift th

operation at the starting point.

4. In the standard schedule table, indicate 0 as the ending time of the operation.

Operation Instruction

Once the operation procedures, starting time and the ending time are determined by the schedule, th

operation sheet, inspection sheet, outgoing sheet, traveling sheet will be circulated around the plant a

to giving out the job instruction.

For each of the operation, an order sheet consists of the contents and the criteria of the jobs that will

given to the worker. In the operation sheet the manufacturing number, the name of the operator and

actual operation time and ending time will be recorded and to be reported.


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QUESTIONS :

1) Why the work schedule must be prepared?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

2) Why the priority rule has been used?

_____________________________________________________________________

_____________________________________________________________________

_____________________________________________________________________

3) What is the function of PERT?

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

4) How many procedures that must be followed in the standard schedule? Explain briefly.

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

______________________________________________________________________

RUJUKAN

1. Millwright Manual of Instruction; Richard A. Michener; Province of British Columbia; 1980.


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TAJUK KEMAHIRAN DANTAHAP DIPLOMA TEKNOLOGI PEMBUATAN (TAHAP 3) SEMESTER 4




OBJEKTIF PRESTASI

AKHIRAN




MALAYSIA

KERTAS TUGASAN(K03-04-01-LE1-AS1b)


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ISI KANDUNGAN


Task 13.02 Prepare time schedule for job in machining against machine and operator availab


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No. & TAJUKPENGALAMANPEMBELAJARAN LE 1 PROCESS PLANNING

No. & TAJUKTUGASAN

Task 13.02 Prepare time schedule for job in machining against machine anoperator available

TEMPAT : Bilik Kuliah TEMPOH :1 jam 30 minit Code No. : K03-04-01-LE1-AS1b Muka :1 drp. : 2

TAJUK : PREPARE TIME SCHEDULE FOR JOB IN MACHINING AGAINST MACHINE AND

OPERATOR AVAILABLE.

TUJUAN:

This assignment sheet contains questions regarding the information sheet of K03-04-01-LE1-IS1b. A

the end of this chapter, trainees should be able to obtain the updated work progress reports, produce

work plan schedules and procedures and gain the skill to monitor work activities.

SUMBER MAKLUMAT :

1. KERTAS PENERANGAN K03-04-01-LE1-IS1b


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Code No. : K03-04-01-LE1-AS1b Muka : 2 drp : 2

SOALAN:

1) What is the meaning of schedule?_________________________________________________________________

__________________________________________________________________________________________________________________________________

2) Why schedule is important in production control?_________________________________________________________________

_________________________________________________________________

_________________________________________________________________

3) Schedule is classified into ____________________________________________

4) Summarize the type of work schedule.i. _______________________________________________________________

ii. _______________________________________________________________

iii. _______________________________________________________________

5) What is sequencing method?____________________________________________________________________________________________________________________________________

__________________________________________________________________

6) What is the main feature of PERT?__________________________________________________________________

____________________________________________________________________________________________________________________________________

7) Procedure planning is based on the _______________________________________________________________________________________________________process procedure.

8) What is the difference between standard schedule and work schedule?__________________________________________________________________

__________________________________________________________________

__________________________________________________________________


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TAJUK KEMAHIRAN DANTAHAP

DIPLOMA TEKNOLOGI PEMBUATAN (TAHAP 3) SEMESTER 4




OBJEKTIF PRESTASI

AKHIRAN




MALAYSIA

KERTAS PENERANGAN(K03-04-06-LE1-IS1c)


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ISI KANDUNGAN


Task 13.03 Review material & tooling requirement


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No. & TAJUKTUGASAN

Task 13.03 Review material & tooling requirement

TEMPAT : Bilik Kuliah TEMPOH :1 jam 30 minit Code No. : K03-04-06-LE1-IS1c Muka :1 drp. : 8

TAJUK : MATERIAL AND TOOLING REQUIREMENT

TUJUAN:

1) Estimate material and tooling required for the job.

2) Determine type of material and tooling available.

3) Communicate shortage to immediate officer.

PENERANGAN:

Material control

The objective of material control is to deliver a right quantity of the required materials to the right place

at the right time in addition to the minimum cost. It consists of the yield improvement, maintenance and

handling of materials, stock-on-hand control, transportation controls, store control and maintaining of

economy lot.

Products design

Product design is divided into functional design, production design and industrial design. Based on the

needs that were capt

Documents

Wim k03!04!01 Machining Supervisory