lecture 1 introduction to manuf.systems and automation

7/29/2019 Lecture 1 Introduction to Manuf.systems and Automation

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MECT 3360 Automated Manufacturing Systems

Manufacturing systems and

Production concepts

Dr. Tafesse Borena



Information on the Blackboard

Syllabus Schedule Updated regularly Homework will be available online

PowerPoint will be available online

My cont InformationEmail [email protected]

TAsRahul Avinash Email <[email protected]

Venkata Jayadeep Email



Reference materials

Text Book

Automation, Production Systems, and Computer-IntegratedManufacturing by Mikell P. Groover. (3rd Edition)

References

Computer Aided Manufacturing by,

Tien-Chien Chang ,Richard A.Wysk,Hsu-Pin Wang,

Copyright Declaration

Lectures materials are basically adopted from Mikell P. Grooverand Computer Aided Manufacturing by Tien-Chien Chang ,Richard A.Wysk, and Hsu-Pin Wang,



Course Objectives

Automated manufacturing process planning and analysis,including CNC programming, robotics, and elements of computer-aided manufacturing



Syllabus

1. Manufacturing systems and Production concepts (1,2)

2. Manufacturing Models and Metrics; Introduction toAutomation; 3, 4, 5

3. Hardware Components for Automation and Process

Control 6

4. Hardware Components of CNC machines andprinciples of CNC programming 7

5. Industrial Robotics, Discrete Control Using PLC and

Personal Computers 8, 9

6. Material Handling System; Storage Systems 10, 11



Syllabus

8. Automatic Identification and Data Capture 12

9. Introduction to Manufacturing Systems; Single-StationManufacturing ells 13, 14

10. Manual Assembly Lines, Automated Production Lines 15,

16 . , ,

12. Automated Assembly Systems 17, 18

13. Cellular Manufacturing and Flexible Manufacturing Systems

18, 1914. Product Design and CAD / CAM 23

15. Production Planning And Control Systems; Just –In-Time AndLean Production 25,26



Quiz – 1

1. Define Manufacturing and Manufacturing systems.(Explain how you understand these terms)

2. Describe the functions of Automation and the types of automations which you know.

3. Briefly explain the following terms ( a paragraph or

two)

a. Computer Integrated manufacturing

b. Flexible manufacturing systems

c. Computer Numerical Control Machines



Lecture outline

Manufacturing systems and Production concepts

Realities of modern manufacturing systems

Modern manufacturing approaches and technologies

Concept and elements of a manufacturing system

Three basic types of automation

Automation in manufacturing systems

Reasons for automation Automation principles and strategies

Automation migration strategy



Distinctive realities of Modern

Manufacturing

Globalization - Once underdeveloped countries(e.g., China, India, Mexico) are becoming major players in manufacturing

International outsourcing - Parts and productsonce made in the US b American com anies are

now being made offshore (overseas) or near-shore

Local outsourcing - Use of suppliers within theU.S. to provide parts and services



Distinctive realities of Modern

Manufacturing

Contract manufacturing - Companies thatspecialize in manufacturing entire products, not just parts, under contract to other companies

Trend toward the service sector in the U.S.

economy ua ty expectat ons - ustomers, ot consumer

and corporate, demand products of the highestquality

Need for operational efficiency - U.S.manufacturers must be efficient in in their operations to overcome the labor cost advantageof international competitors



Modern Manufacturing Approaches and

Technologies

Automation - automated equipment instead of labor

Material handling technologies - becausemanufacturing usually involves a sequence of activities

Manufacturing systems - integration and coor na on o mu p e au oma e or manua

workstations



Modern Manufacturing Approaches and

Technologies

Flexible manufacturing - to compete in the low-volume/high-mix product categories

Quality programs - to achieve the high quality expectedby today's customers

CIM - to integrate design, production, and logistics

Lean production - more work with fewer resources



Production System Defined

A collection of people, equipment, and proceduresorganized to accomplish the manufacturing operations of a company

Two categories:

Facilities – the factory and equipment in thefacility and the way the facility is organized (plant

layout)

Manufacturing support systems – the set of procedures used by a company to manage

production and to solve technical and logistics problems in ordering materials, moving work throughthe factory, and ensuring that products meet qualitystandards



The Production System

.



Production System Facilities

Facilities

factory, production machines and tooling, material

handling equipment, inspection equipment, and

computer systems that control the manufacturing

operations

Plant layout the way the equipment is physically arranged in the

factory

Manufacturing systems – logical groupings of equipment and

workers in the factory

Production line

Stand-alone workstation and worker



Manufacturing Systems in the

Production System.



Manufacturing Defined

Manufacturing is a collection of interrelated operations

and activities. It includes product design, material selection, planning,

production, inspection, management and marketing of

the products, for the manufacturing industries. (CIRP)

customer

marketing

accounting andfinancing

budget

stock of warehouse

purchasing

wholesaleand retail

engineeringdesign

planning andcontrol

manufacturing

qualitycontrol



Manufacturing production and processes

Manufacturing production is a series of processesadopted to fabricate a product.

Such processes exclude the activities for

designing, planning, and controlling the production.

-manufacturing activities used to make products.

Including traditional machining processes, for eg.,

turning, milling, and grinding, and more advanced

non chipping and additive manufacturingprocesses.



Manufacturing engineering and systems

Manufacturing engineering

involves the design, operation, and control of

manufacturing processes (planning, scheduling,

as well as control of the manufacturing production

and batch quality

Manufacturing system is an organization that comprises several interrelated manufacturing

subsets.

Its objective is to interface with outside

production functions in order to optimize the total productivity performance of the system, such as

production time, cost, and machine utilization.



Components of a Manufacturing System

1. Production machinesa. Manually operated machines

b. Semi-automated machines

c. Fully automated machines

2. Material handling systema. Loading

b. Positioning

c. Unloading

d. Transporting work

e. Temporary storage

3. Computer system to coordinate and/or control thepreceding components

4. Human workers to operate and manage the system



Components of a Manufacturing System

.Marketing Accounting Financing

Design Manufacturing Product

Planning/Control

Manufacturing system diagram



Manufacturing Systems

Functions encountered in most manufacturing

systems include:

Product and process design

product planning

production operations management

planning and control

material flow management and product

routing

Layouting

Accounting Personnel management

Marketing



Manufacturing systems are generally quitecomple x, they almost involve the following

essential components

Workstations

Materials handling

Stora e subs stems


Manufacturing system functions can be

performed by humans or automated.

The following essential functions can be

identified in most manufacturing systems Procurement

Production

Distribution




Three categories in terms of the human participationin the processes performed by the manufacturingsystem:

1. Manual work systems - a worker

performing one or more tasks without the hand tools

2. Worker-machine systems - a worker operating powered equipment

3. Automated systems - a process performedby a machine without direct participation of a human



Manual Work System

.



Worker-Machine System

.



Automated System

.



Manufacturing Support Systems

Involves a cycle of information-processingactivities that consists of four functions:

1. Business functions - sales and marketing, order entry, cost accounting, customer billing

2. Product design - research and development, es gn eng neer ng, pro o ype s op

3. Manufacturing planning - process planning,production planning, MPS,MRP, capacity

planning4. Manufacturing control - shop floor control,

inventory control, quality control



Information Processing Cycle in

Manufacturing Support Systems

.



Automation in Production Systems

Two categories of automation in the productionsystem:

1. Automation of manufacturing systems in thefactory

2.

Computerization of the manufacturingsu ort s stems

The two categories overlap becausemanufacturing support systems areconnected to the factory manufacturing

systems CIM- Computer-Integrated Manufacturing the

extensive use of computers in productionsystems.



Computer Integrated Manufacturing

.



Automated Manufacturing Systems

Examples: Automated machine tools

Transfer lines

Automated assembly systems

Industrial robots that erform rocessin or assembly operations

Automated material handling and storage systemsto integrate manufacturing operations

Automatic inspection systems for quality control



Automated Manufacturing Systems

Three basic types:1. Fixed automation

2. Programmable automation

3. Flexible automation



Fixed Automation

A manufacturing system in which the sequence of

processing (or assembly) operations is fixed by theequipment configuration

Typical features:

Suited to high production quantities

Hi h initial investment or custom-en ineered e ui ment

High production rates

Relatively inflexible in accommodating product variety



Programmable Automation

A manufacturing system designed with the capabilityto change the sequence of operations toaccommodate different product configurations

Typical features: High investment in general purpose equipment Lower production rates than fixed automation

Flexibility to deal with variations and changes in product configuration

Most suitable for batch production Physical setup and part program must be changed

between jobs (batches)



Flexible Automation

An extension of programmable automation in which the

system is capable of changing over from one job to thenext with no lost time between jobs

Typical features: High investment for custom-engineered system

Continuous production of variable mixes of products e um pro uct on rates

Flexibility to deal with soft product variety



Product Variety and Production

Quantity for Three Automation Types.



Computerized Manufacturing Support

Systems

Why to automate the manufacturing supportsystems:

To reduce the amount of manual and clerical effort in

product design, manufacturing planning and control, and

the business functions Integrates computer-aided design (CAD) and computer-

aided manufacturing (CAM) in CAD/CAM

CIM includes CAD/CAM and the business functions of

the firm



Reasons for Automating

1. To increase labor productivity 2. To reduce labor cost

3. To mitigate the effects of labor shortages

4. To reduce or remove routine manual and clerical

tasks

5. To improve worker safety

6. To improve product quality

7. To reduce manufacturing lead time

8. To accomplish what cannot be done manually

9. To avoid the high cost of not automating



Manual Labor in Production Systems

Is there a place for manual labor in the modern

production system?

Answer:YES

Two aspects:

1. Manual labor in factory operations

2. Labor in manufacturing support systems



Manual Labor in Factory Operations

The long term trend is toward greater use of automated systems to substitute for manuallabor

When is manual labor justified? Some countries have ver low labor rates and

automation cannot be justified

Task is too technologically difficult to automate

Short product life cycle

Customized product requires human flexibility

To cope with ups and downs in demand

To reduce risk of product failure



Labor in Manufacturing Support

Systems

Product designers who bring creativity to the

design task

Manufacturing engineers who

Design the production equipment and tooling And plan the production methods and routings

Equipment maintenance

Programming and computer operation

Engineering project work

Plant management



Automation Principles and Strategies

1. The USA Principle

2. Ten Strategies for Automation and ProcessImprovement

3. Automation Mi ration Strate



U.S.A Principle

1. Understand the existing process Input/output analysis

Value chain analysis

Charting techniques and mathematical modeling

.

Reduce unnecessary steps and moves

3. Automate the process

Ten strategies for automation and productionsystems

Automation migration strategy



Ten Strategies for Automation and

Process Improvement

1. Specialization of operations

2. Combined operations

3. Simultaneous operations

4. Integration of operations 5. Increased flexibility

6. Improved material handling and storage

7. On-line inspection

8. Process control and optimization

9. Plant operations control

10. Computer-integrated manufacturing



Automation Migration Strategy

An automation migration strategy, or a formalized planfor evolving the manufacturing system from onebased on manual labor, to one based on automation,may be deployed.

,introduced step-by-step, and not all at once.

Typically it contains the follow three steps:1. Manual production2. Automated Production

3. Automated integrated production



Automation Migration Strategy

For Introduction of New Products

1. Phase 1 – Manual production Single-station manned cells working independently

Advantages: quick to set up, low-cost tooling

2. Phase 2 – Automated production -

independently

As demand grows and automation can be justified

3.Phase 3 – Automated integrated production Multi-station system with serial operations and

automated transfer of work units between stations



.

AutomationMigrationStrategy



Summary

Production systems Manufacturing, manufacturing engineering, manufacturing

systems

Classifications of manufacturing systems

Functions of manufacturing support systems omputer ntegrate manu actur ng

Manual labor in manufacturing

Reason for automation

Types of automation Automation principles and strategies

Automation migration strategy (for new products)



Review Question

1. What is meant by a production system, and what categories of production system are generally specified?

2. Manufacturing systems depend for their operation on theinteraction of manual labour and automation. What are thecategories of manual labour / automation that can be identified?What mode of automation do these categories usually operate in?

3. Define briefly computer-integrated manufacturing. 4. en s automat on use n a manu actur ng system

5. Describe the three types of automation that can be used in amanufacturing system.

6. Manual labour is used alongside automation in productionsystems. Name a number of the issues that affect the use of

manual labour in production systems.7. What elements should a strategy for automation implementation

consider?



Review Question

1. What is meant by a production system, and what

categories of production system are generallyspecified?

A production system is a collection of people, equipment,and procedures organized to perform the manufacturing

operations of a company (or other organization).

Two categories recognized in production systems are

1. facilities—consisting of the factory, factory equipment,and equipment configuration; and

2. manufacturing support systems—consisting of the procedures used by the company to manage productionand to solve the technical and logistics problems faced in

production



Review Question

2. Manufacturing systems depend for their operation on the

interaction of manual labour and automation. What are thecategories of manual labour / automation that can beidentified ? What mode of automation do these categoriesusually operate in?

The three categories of manufacturing system manual a our automat on nteract on are:

1. Manual work systems;

2. Worker-machine systems; and

3. Automated systems.

Automated systems may be fully automated or semi-automated, depending on their operating characteristics.



Review Question

3. Define briefly computer-integratedmanufacturing.

Com uter-Inte rated Manu acturin is the term used to indicate the extensive use of computers in

production systems, through the automation of

manufacturing systems, and the computerisation of

manufacturing support systems.



Review Question

4. When is automation used in a manufacturing system?

Describe the three types of automation that can beused in a manufacturing system.

Automated manufacturing systems operate in thefactory on the physical product. There are three

t es: fixed automation—where the se uence of potential operations is fixed; programmable

automation—where a programme is coded into thesystem to allow for changes in the operationalsequence; and flexible automation—which extends

programmable automation techniques by taking advantage of product similarities to reduce productchangeover times, and boost production rates.



Review Question

6. Manual labor is used alongside automation in production systems. Name a number of the issues

that affect the use of manual labor in production

systems.

labor in factory operations. These include:

manual labor costs;

the tasks manual labor are expected to do;

the flexibility of using manual labor; and

the demand patterns under which we use manual labor



Review Question

7. What elements should a strategy for automationimplementation consider?

There are three specific areas that come into

consideration for a strategy for automation

implementation; these are:

. , ,

whether or not automation should be applied;

2. second, to assess various strategies for automation

and process improvement across the existing system,

and then to determine which to implement; and

3. finally, to implement a graduated migration strategy

from manual labor to automation, as product

demand increases.

lecture 1 introduction to manuf.systems and automation

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