Industrial Automation(IE423 Computer Integrated Manufacturing)(IE215 Design and Make)

David OSullivanwww.owl.ie

Industrial Automation - MachinesStorage SystemsHandling SystemsAssembly LinesAssembly CellsMachinesActuatorsSensorsProduction LinesProduction CellsMachinesActuatorsSensors

Industrial Automation - ComputingComputersControllersActuatorsSensorsSoftware

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Unit 1 Industrial AutomationSections:Production SystemsAutomation in Production SystemsManual Labor in Production SystemsAutomation Principles and StrategiesOrganization of the Course

The Realities of Modern ManufacturingGlobalization - Once underdeveloped countries (e.g., China, India, Mexico) are becoming major players in manufacturingInternational outsourcing - Parts and products once made locally are now being made offshore (in China or India) or near-shore (in Eastern Europe)Local outsourcing - Use of suppliers locally to provide parts and services

More Realities of Modern ManufacturingContract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companiesTrend toward the service sectorQuality expectations - Customers, both consumer and corporate, demand products of the highest qualityNeed for operational efficiency - manufacturers must be efficient in in their operations to overcome the labor cost advantage of international competitors

Manufacturing ApproachesAutomationFlexible manufacturingQuality programsIntegrationLean production

Production System DefinedA collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company

Facilities Factory and EquipmentFactory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations

Manufacturing Support SystemsBusiness functions - sales and marketing, order entry, cost accounting, customer billingProduct design - research and development, design engineering, prototype shopManufacturing planning - process planning, production planning, MRP, capacity planningManufacturing controlshop floor control, inventory control, quality control

Computer Integrated Manufacturing

Automated System

Examples:Automated machine toolsTransfer linesAutomated assembly systemsIndustrial robotsAutomated material handling and storage systemsAutomatic inspection systems for quality control

AutomatedSystemPeriodicWorkerTransformation Process

Three Automation TypesProgrammableAutomationFlexibleAutomationFixedAutomationVarietyQuantity

Fixed AutomationSequence of processing (or assembly) operations is fixed by the equipment configuration

Typical features:Suited to high production quantitiesHigh initial investment for custom-engineered equipmentHigh production ratesRelatively inflexible in accommodating product variety

Programmable AutomationCapability to change the sequence of operations throug reprogramming to accommodate different product configurations

Typical features:High investment in programmable equipmentLower production rates than fixed automationFlexibility to deal with variations and changes in product configurationMost suitable for batch productionPhysical setup and part program must be changed between jobs (batches)

Flexible AutomationSystem is capable of changing over from one job to the next with little lost time between jobs

Typical features:High investment for custom-engineered systemContinuous production of variable mixes of productsMedium production ratesFlexibility to deal with soft product variety

Reasons for AutomatingTo increase labor productivityTo reduce labor costTo mitigate the effects of labor shortagesTo reduce or remove routine manual and clerical tasksTo improve worker safetyTo improve product qualityTo reduce manufacturing lead timeTo accomplish what cannot be done manuallyTo avoid the high cost of not automating

Automation PrincipleUnderstand the existing process Input/output analysisValue chain analysisCharting techniques and mathematical modeling Simplify the process Reduce unnecessary steps and moves Automate the processTen strategies for automation and production systemsAutomation migration strategy

Automation StrategiesSpecialization of operationsCombined operationsSimultaneous operationsIntegration of operationsIncreased flexibilityImproved material handling and storageOn-line inspectionProcess control and optimizationPlant operations controlComputer-integrated manufacturing

Automation Migration Strategy

TopicsDefinition of Industrial AutomationMathematical Models for ManufacturingIndustrial SystemsControl SystemsSensors and ActuatorsAutomated Machine ToolsIndustrial RoboticsLogic ControllersHandling SystemsStorage SystemsIdentification SystemsManufacturing CellsAssembly LinesFlexible Manufacturing Systems

PedagogyLecturesDesign and Make ProjectMore details later Course Notes (www.owl.ie)Text BookExam see textbook

YouTubeControl SystemsSensors and ActuatorsAutomated Machine ToolsIndustrial RoboticsLogic ControllersHandling SystemsStorage SystemsIdentification SystemsManufacturing CellsAssembly LinesFlexible Manufacturing Systems