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Can you give three examples of advanced manufacturing tools and techniques? Industrial Robotics Modeling and Simulation Advanced Manufacturing Do you know the role of product design in Advanced Manufacturing? To produce a product with the best form, fit, and function possible. Can you name three impacts of computers on Advanced Manufacturing besides automation? Modeling and Simulation Production Efficiency Product Consistency Can you name three benefits of factory automation? Relieve humans from undesirable work Improve quality Increase flexibility Can you describe how a CNC machine works? A CNC (Computer numerical control) machine is a type of motion controller that can coordinate the speed and positioning of multiple axes at the same time to cut complex features into the metal part.
Do you know the difference between an additive and a subtractive manufacturing process? Additive manufacturing, often referred to as 3D printing, adds successive layers of material to create an object. Subtractive manufacturing removes material to create an object. Can you name two types of robots? Industrial Robot Mobile Robot Do you know the function of a PLC? A PLC is a general-purpose industrial computer that has been designed to wire directly to input and output devices. It is programmed to control different type of machines and processes. Besides alarm screens and error messages, do you know what else an HMI is used for? An operator can troubleshoot many problems directly from the HMI panel. Can you name some Software and New Emerging Technologies in Advanced Manufacturing? CAD (Computer Aided Design) CAM (Computer Aided Machine) The Internet of Things (IoT) Cloud Computing 3D Printing Do you know the four industrial revolutions and the cause and benefits of each?
Can you state the safety responsibilities within a company? Management is responsible for putting safety policies in place and an organizational structure to carry out these policies to ensure that employees get their jobs done without harm. What are the clothing safety guidelines for machine operators? Wear proper PPE. Hair must be tucked away if long. Wear close fitting clothes. Remove all jewelry and accessories. What happens if someone doesn't follow machine operation safety guidelines? The employee will have to be retrained. Can you name three types of machine guards and state what to do if one is missing? Fixed Guard Removable Guard with Interlock Adjustable Guard Self-Adjusting Guard You should hit the emergency stop, cycle stop, or halt pushbutton. Do you know how machine interlocks and emergency stop controls effect an operation? A machine interlock prevents a machine from operating without the proper guards in place.
All emergency stop controls are designed to shut down a machine if an operator is immediately in danger. Can you differentiate value added and non value added activities? Value-added activities transform or shape material and information that meets customer requirements. example: cutting metal to make a part shape, or adding paint to a product's surface. Non-value-added activities take time resources or space, but do not add to the value of the product or service. example: product inspection, or rework. Do you know what each S in 5S stands for?
- sort
- straighten
- shine
- standardize
- sustain Can you describe the 8 deadly wastes?
- excess inventory
- overproduction (more product than the next process or customer needs)
- excess motion (movement by a team member that doesn't add value)
- over processing (putting extra effort into a process that doesn't add value to the customer)
- transportation (any movement of the product within the facility)
- waiting
- underutilized people
- nonconforming product (any product that doesn't meet design specifications)
Can you transfer robot program files between a PC and robot controller? Robot program files and points files are often transferred between PC software and the robot controller via a serial or ethernet connection. some robots allow the user to transfer files using a thumb drive. Do you know how to run a robot program? To begin running the robot program, the operator selects RUN from the control software or pushes the start button on the robot controller. Do you know 4 types of robot classifications?
- stationary or mobile
- number of axes
- type of motion
- servo or non-servo Can you identify 5 types of servo robots?
- articulated
- cartesian
- gantry
- SCARA
- delta Do you know the basic operation of a servo robot?
To perform tasks automatically, robots require a program file to be stored in their memory. For each point in a program, the robot controller must have a value stored in its memory. Before the robot can run, both the program file and points file must be loaded into the controller. Points can be entered into a robot controller by downloading a points file from an offline PC. However, a more common method is to enter them directly using a teach pendant. Do you know the robot safety rules?
- follow dress code
- observe robot safety system
- locate emergency stops
- monitor controls
- monitor nearby personnel 6.complete safety training
- lockout/tagout when doing maintenance robot programing safety rules
- robot must be in teach mode
- a slow jogging speed must be set
- another worker must observe the robot and press emergency stop if needed
- carry teach pendant so you have immediate access to the emergency stop button Can you power up and power down a servo robot? Power up:
- remove lockout/tagout on the robot's circuit breaker and turn on the circuit breaker
- turn on the robot controller, which also powers the teach pendant
- select the teach pendant options on the controller and the teach pendant so they communicate with each other
- enable the drivers if they are not automatically enabled
do you know the six elements of control logic?
- AND - turns on the output only if all inputs are actuated.
- OR - turns on the output if anyone of the inputs are actuated.
- NOT - turns on the output if its one input is not actuated.
- NOR - turns off the output if any of the inputs are actuated.
- NAND - turns off the output only if all the inputs are actuated.
- Memory - uses an input tied to an output to keep the output energized after main input is no longer pressed. can you explain the operation of MEMORY logic? Memory logic is used to keep an output energized after the input signal that turned it on has been removed. Can you state common types of injuries and accidents? Repetitive motion, strains, sprains, cuts, abrasion, and hearing loss. Do you know seven types of PPE?
- Eye Protection
- Ear Protection
- Head Protection
- Hand and Arm Protection
- Foot Protection
- Lung Protection
- Protective clothing
Can you state the elements of an emergency action plan? Contact Information Shutdown Procedures Evacuation Procedures Headcount Procedures Rescue and Medical Care Assignments Emergency Reporting Procedures Do you know how to respond to an emergency? If an evacuation alarm is sounded, employees should immediately shut down their machines and evacuate the building. Do you know how to respond to a workplace accident? Designate a first responder to administer basic first aid. At the scene, evaluate, check with bystanders, and keep yourself safe. Do you know when and how to report a workplace accident? Workplace accidents should be reported immediately. Reporting an accident is as simple as filling out an accident form. Do you know the GHS and HCS communication standards? Do you know when and how to use an eyewash station? Eyewash stations are used when foreign objects need to be flushed out of the eyes.
do you know the operation of a fuse and circuit breaker and how to replace or reset them? Fuses are used in applications where an over-current problem rarely occurs. Fuses cannot be fixed or reset, they must be replaced. Circuit breakers are used where an over-current condition occurs more often. Circuit breakers can be reset and reused, they do not need to be replaced. do you know the resistance characteristics in series and parallel circuits? the more resistors there are in series, the higher the overall resistance. the equivalent resistance of a parallel load actually decreases as more branches are added. can you use Ohm's law to analyze a circuit? Ohm's law: E = I * R can you define continuity and state its importance? Electrical continuity means there's a complete path for current to flow in a circuit. Sometimes, a lack of continuity is desired, such as when a light switch is set to off. However, if a wire or a component doesn't have continuity when it should, it prevents current flow and circuit operation. can you state Kirchhoff's circuit laws? Voltage Law: the sum of voltage sources and voltage drops around any loop in a circuit must add up to zero.
Current Law: the current into any point in a circuit must equal the current out of the same point. do you know the basic characteristics of series and parallel circuits? Series: current is constant throughout the circuit. Voltage decreases as the electricity passes through each load. Parallel: the current that flows through each branch is different. The voltage across each branch is the same. do you know two types of ammeters? analog and digital can you use a DMM to measure current and voltage? The DMM has to replace a wire to measure current. To measure voltage, touch and hold the probes to the desired point in the circuit. Do you know the GHS and HCS communication standards? GHS uses pictograms to convey potential hazards in the workplace. There are 9 pictograms as follows:
- Toxic Substances
- Compressed Gases
- Pollutants
- Explosives
- Corrosives
- wear proper PPE.
- avoid exposure to the pressurized air.
- secure pressurized hoses and devices.
- use proper pressure when cleaning.
- use pressure-rated containers. Can you interpret the HazCom labeling and other hazardous material identification systems? HazCom includes pictograms but also requires: Chemical Identifierss Signal Word Hazard Statements Precautions Emergency Contact Information Can you state what a Safety Data Sheet does? Safety Data Sheets provide one place with information about proper handling, storage, PPE, and disposal of each chemical. Do you know the guidelines for handling, storing and shipping hazardous materials? A key for handling hazardous materials is PPE and having plans for spills and accidents. When storing them, labeling, storing with like materials, using the original storage container, and keeping away from heat and open flame. Do you know the DOT Hazardous Material Identification System? Colors: Orange-Explosive
Green-Non-Flammable Gas Red-Flammable Blue-Water Reactive Yellow-Oxidizer White-Health Hazard Do you know the elements of a fire? Fuel, Heat, & Oxygen. Do you know four types of fires and how to select a fire extinguisher for each type? A. Ordinary Flammable Fires B. Flammable and Combustible Liquid C. Energized Electrical D. Combustible Metals CO2 Extinguishers are for B & C. Dry Chemical are for A, B, & C. Dry Powder are for D. Halon Extinguishers are for B & C. Do you know how to use a fire extinguisher? Pull the pin, aim at the base of the fire, pull the trigger, and sweep the area the fire occupies until extinquished. Can you state the electrical safety guidelines? Use grounded equipment
