4. (a) Discuss Lean manufacturing, what is it, where is it used and what does it do to the manufacturing environment? Gi

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4. (a) Discuss Lean manufacturing, what is it, where is it used and what does it do to the manufacturing environment? Give an example of a lean process discussing the implementation and function of the system. [8 marks] (b) Discuss the ISO9000 Standard, what are the key principals? What are the advantages to a company of ISO9001 accreditation? [6 marks] (c) What are the key aspects of the 5S system? How do they affect the manufacturing environment? [6 marks] Total marks: 20
Formula sheet a. Casting Solidification time=0 TE Volume Area Bernoulli's Theorem ht+ P11 + =ht P2 + 12 pg 29 pg Mass continuity equation : Q = A v; = AzV2 = Area x velocity Reynold Number: Re = vDp Flow speed x Diamater x Fluid Density Dynamic viscosity of the fluid H b. Rolling Power per roll πFKN 60 where N(rpm) Roll force, approximate (frictionless condition) F = Lwo', Roll force, approximate (frictional condition) F = Lwo" (1+ ul 2h Contact Length L = VRAM Average flow stress in plain strain of material in the roll gap: 0; = 1.15 KE Average flow stress, og n+1 True strain, E = In c. Sheet metal forming Maximum punch force in shearing Fmax = 0.7SUTEL Average normal anisotropy ratio for rolled sheet R = Ro + 2R9s + Ryo D. Limited Drawing ratio, LDR Dp Springback estimation, approximate R = 4 RI ( ) - (2) - +1 Et
2R (284) + 1 af Sprinback factor, K = αι +1 = 2R () + 1 d. Generated Heat in resistance welding H = 12Rt Heat for melting certain volume of material, H = uvm