flexible automation

8/8/2019 Flexible Automation

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FLEXIBLE AUTOMATION

Mechanical Assembly Process is widely recognized asthe most problematic areas for automation inmanufacturing.

Multi-directional assembly Tight tolerances

Multiplicity of component shapes and sizes. Etc.

The great challenge is to the medium and small volumeassembly. Human assembler has been and stillcontinues to be the simplest solution technically.

Transfer of assembly work to cheap labour locations.The robot has proved to be both technically andcommercially limited. Where flexibility is paramount, thelow cost human operator, with his/her unparalleleddexterity and sensory systems, remains unchallenged.


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FLEXIBLE AUTOMATION

Flexible Automation addresses the technical deployment ofautomation in the area of medium to small volumeassembly. It proposes to flexibility in assembly centred on

the deployment of arrays of dedicated assembly fixturesserved by a multi-tool robotic assembler. It is based onlong term experience arising out of the ongoingdevelopment of a research laboratory Flexible AssemblyManufacturing System.

This defines the decision making process involved in theintroduction of new products into the system whichidentifies both the product limitation and product flexibility

of the system. It outlines a procedure for the design anddevelopment of the dedicated assembly fixtures: this fixturedevelopment is the critical activity required for systemsuccess; it is highly creative prototyping and provingprocess, which is at the core of automated flexible

assembly.


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FLEXIBLE AUTOMATION

Flexible Automation is an operational response to thisneed. Manufacturing is shifting from attempting to

exploit economies of scale to exploiting economies ofscope. As a result, the ability to adapt to changingmarket requirements, product designs, and

technological developments is becoming a key factorin the competitiveness of an organisation.

Viewed from the shopfloor, this translates into dealingefficiently with frequent changeovers of parts andsmall production batches.


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FLEXIBLE MANUFACTURING SYSTEM

Flexible Manufacturing System is an integratedcomputer controlled system of automated material

handling devices and CNC machine tools that cansimultaneously process medium sized volumes ofvariety of parts. Therefore, an FMS incorporates manydifferent automation concepts into one system. Flexiblemeasures the ability to adapt to wide range of possibleenvironments. The dynamic, probabilistic andindividualistic world in which we competes makesflexibility a requirement for long-term survival.

FMS technology represents an evolutionary stepsbeyond transfer lines and offers one means by whichmanufacturing can address the growing customerdemand for quick delivery of customized products.


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FLEXIBLE MANUFACTURING SYSTEM

The ideal system uses reprogrammableprocessing, material-handling machinery, andcomputer coordination of cycles to enable thesimultaneous production of different part typeswith zero on-line setup time and costs. Nosystem has thus far lived up to this idealcompletely. Still, new developments inhardware and software are bringing state-of-the-art systems closer all the time.


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FLEXIBLE MANUFACTURING SYSTEMFlexible Manufacturing System (FMS) [State-Of-ArtHardware and Software]Product used :C218Turbo Country:Japan Company:OMRON Corp.

Flexible Manufacturing System (FMS) offers manufacturers a flexibleand reliable system to control and monitor their manufacturing

process. By using FMS, manufacturers can produce customizedproducts at a faster rate, making it easier for them to meet marketdemand.OMRON Corp. has developed just such an FMS, and a PCwith MOXA C218Turbo is a key component of the product linemonitoring system. Each product line is equipped with one PC and

one MOXA multiport board.MOXA multiport boards not onlyconnect to the overhead signboards toinform the operators of currentoperation status, but also connect to a

high precision digital scales to makesure products are not over the weightlimit. Other devices, such astemperature/humidity sensors, PLCs,and quality ratio counters, can also beconnected to the PC via C218Turbo's

serial ports.


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Flexible Manufacturing System (FMS)

[State-Of-Art Hardware and Software]


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BENEFITS OF FMS TO PHILIPS SEMICONDUCTOR,SEREMBAN

Improved Productivity (30%)

Reduced Production Costs (50% - Reduced Inventories and

Increase Machine Efficiency)

Reduction in changeover costs (50%)

Reduction in changeover time (70%)

Reduction in Assembly Line Footprint (50% -Reduced employeesmovement)

Improved Machine Efficiency (50%)

Reduction of Parts Inventories (40%)

Labour Productivity (30% - 1 opr: 3 machines)


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Flexible ManufacturingSystems (FMSs)

Computer controls both the workstationComputer controls both the workstationand the material handling equipmentand the material handling equipment

Enhance flexibility and reduced wasteEnhance flexibility and reduced waste

Can economically produce low volume atCan economically produce low volume athigh qualityhigh quality

Reduced changeover time and increasedReduced changeover time and increased

utilizationutilization

Stringent communication requirementStringent communication requirementbetween componentsbetween components


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Computer-IntegratedManufacturing (CIM)

Extension of flexible manufacturingExtension of flexible manufacturingsystemssystems

Backwards to engineering and inventoryBackwards to engineering and inventorycontrolcontrol

Forward into warehousing and shippingForward into warehousing and shipping

Can also include financial and customerCan also include financial and customerservice areasservice areas

Reducing the distinction between lowReducing the distinction between low--volume/highvolume/high--variety, and highvariety, and high--volume/lowvolume/low--variety productionvariety production


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12.09.2006 11Slide 1

Computer-Integrated

Manufacturing

(CIM)

Figure 7.12Figure 7.12


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CONCLUSION

The area in which flexible automation is mostpervasive is the automotive industry. The industry not

only has a great need for automation systems butalso has the budget to afford such expensive andelaborate system. However, as system pricesdecreases steadily, flexible automation is beginningto penetrate virtually every sector of manufacturing.

Eventually, anyone in a factory floor will be able touse a flexible automation system just like he or sheuses any other tool.

Harlow said, A significant benefit of this is thatcompanies will no longer need to worry about a keyemployee retiring or changing jobs. The knowledgewill be retained in the software and accessible to any

authorized user.

flexible automation

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