Introducing a Real Production Case of an Automated Process Leads to the Understanding of the Theoretical Bases and Complexity of the Production Systems for Vocational College Students of Mechatronics

Helena Mladenović Jerman
(Vocational College of Design and Mechatronics, Solski Center Ljubljana, Slovenia)

Abstract: The case study presented in this paper represents an optimized process time flow of die production operations. Die production is usually organized within small production organizations that employ around 50 people. Hence their products are intended for mass production, which increases the importance of die and tool production. Die production includes CAD/CAM design of a tool, which usually requires customer cooperation. The CAD/CAM design is followed by the process of machining. The next stage is quality control protocol. The automated process continues with EDM machining, which is intended for the finishing of special details, textures and the required quality of the surfaces. The last stage in the process is the final quality control protocol. Presenting the optimisation case of the technological process enables the teachers to present numerous optimisation methods that are used in production processes within different industries. Within the case of smart industry these concepts can be introduced, as well, with an emphasis on the economic benefits. Students learn about lean production, KAIZEN, 5S, cost/effect as well as CSI aspects. Today we must discuss sensing, efficient data collection, device-to-device communication, high-speed communication, simulation, statistical models and artificial intelligence. This case enables the students to learn about how the new production environment creates new value through 3 zones of improvement, which are productivity, quality and safety.

The case presented here teaches vocational college students of mechatronics that, together with a systematic and analytical approach, a creative approach to die tool design is required, as well, since it considers lean production principles and the benefits from production as well as the process-simulation software, based on smart industry concepts and results in high ROI and OEE. All the technical knowledge combined with the flipped-classroom approach generates a higher level of knowledge for the students and a higher level of satisfaction for the teacher.

Key words: tool and die production, smart industry, lean production, RFID identification, flipped classroom