mm 323 man sys 2012 fall 4 automation in manufacturing systems

8/14/2019 MM 323 MAN SYS 2012 FALL 4 Automation in Manufacturing Systems

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MM 323 MANUFACTURING SYSTEMS

AUTOMATION IN MANUFACTURINGSYSTEMS


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Automation is a technology concerned with the

application of mechanical, electronic, and computer-based systems to operate and control production.

Automation includes:

Automatic machine tools to process parts Automatic assembly machines

Industrial robots

Automatic material handling and storage systems

Automatic inspection systems for quality control

Feedback control and computer process control Computer systems for planning, data collection, and decision making

to support manufacturing activities


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Transfer Line (flow line, flow shop): dedicated machines, almost no flexibility; max. utilization & high throughput;

minimal labor; low unit cost.

Special Manufacturing System (Flexible Transfer Line):

fixed path material handling system; multi-spindle heads; low-level controller;

high production rate & low unit production cost.

Flexible Manufacturing System:

mid-volume & mid-variety; CNC + automated material handling +

supervisory computer control; sequential and random routing of parts.

Manufacturing Cell:

low-to-medium volume; batch production; more flexible than an FMS but

lower production rate.

Stand-Alone NC:

high flexibility; low utilization & low production volume; unit cost higher that

transfer line.

Various Manufacturing System Types thatare used in practice


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Volume Variety Relationship

Transfer

Line

SpecialSystem

Flexible

Manufacturing

SystemManufacturing

Cell

Stand-Alone

NC Machines

PartVolume

High

Medium

Low

Low Medium High

Variety of Parts


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QUESTIONS RELATED WITH AUTOMATION:

1) WHY IS AUTOMATION SO IMPORTANT?

2) HOW IS AUTOMATION APPLIED?

3) WHAT KIND OF SYSTEMS DO WE GET WITHTHE APPLICATION OF AUTOMATION?

4) WHAT ARE THE BENEFITS OBTAINED WITH

THE APPLICATION OF AUTOMATION?5) IS IT NECESSARY TO AUTOMATE THE

FACTORIES?


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Automation in Production Systems

Two categories of automation in the productionsystem:

1. Automation of manufacturing systems in the factory

2. Computerization of the manufacturing support

systems

The two categories overlap when manufacturing

support systems are connected to the factory

manufacturing systems Computer-Integrated Manufacturing (CIM)


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Mechanization is running a process oroperation with the use of mechanical,hydraulic, pneumatic, or electrical

devices.

In mechanized systems, the operator still

directly controls the process, and mustcheck each step of the machinesperformance.

MECHANIZATION


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Automation is a technology concerned withthe application of mechanical, electronic,

and computer-based systems to operate

and control production with little or nohuman interaction.

Who is the Controller and Decision Maker?

DESIGNER/PROGRAMMER not theoperator anymore.

AUTOMATION


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WHY AUTOMATION?

1. To increase labor productivity2. 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

10. Increased productivity and PRODUCTION RATE

11.To reduce COST PER DEFECT-FREE UNIT


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Manual Labor in Factory Operations

The long term trend is toward greater use of automated

systems to substitute for manual labor

When is manual labor justified?

Some countries have very low labor rates andautomation 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


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Human Participation in Manufacturing Systems

Three categories in terms of the humanparticipation in the processes performed by the

manufacturing system:

1. Manual work systems - a worker performing one or

more tasks without the aid of powered tools, but

sometimes using hand tools

2.

Worker-machine systems - workers operatingpowered equipments/machines

3. Automated systems - a process performed by a

system without direct participation of a human


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Manual Work System


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Worker-Machine System


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Automated System


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AUTOMATION

1. Phase 1 Manual production

Single-station manned cells working independently Advantages: quick to set up, low-cost tooling

2. Phase 2 Automated production (Manual

Handling)

Single-station automated cells operating independently

As demand grows and automation can be justified

3. Phase 3 Automated integrated production

Multi-station system with serial operations andautomated transfer of work units between stations


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Automated Manufacturing Systems

Examples:

Automated machine tools

Transfer lines

Automated assembly systems

Industrial robots that perform processing or

assembly operations

Automated material handling and storage

systems to integrate manufacturing operations

Automatic inspection systems for quality control


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Automated Manufacturing Systems

Three basic types:

1. Fixed automation

2. Programmable automation

3. Flexible automation


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Types of Automation

(As a Function of Production Volumeand Product Variety)

Types of Automation


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Product Variety and ProductionQuantity for Three Automation Types


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Types of Automation

1) Fixed (Hard) Automation:

The equipment is designed to manufacture a specific productwith stable product life and high demand

The sequencing of operations is fixed by the equipmentconfiguration

The operations in the sequence are usually simple

Can achieve high production rates (High Speed Production) Mass Production

High initial investment on custom-engineered equipment Not very adjustable and adaptable to product and process

changes (Not flexible)


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1) Fixed Automation

A manufacturing system in which the sequence ofprocessing (or assembly) operations is fixed by

the equipment configuration

Typical features: Suited to high production quantities

High initial investment for custom-engineered

equipment

High production rates

Relatively inflexible in accommodating product

variety


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1) Fixed Automation

The economic justification for fixed automation is found in

products with very high demand rates and volumes. The

high initial cost of the equipment can be spread over a very

large number of units, thus making the unit cost attractive

compared to alternative methods of production. Examples

of fixed automation include mechanized assembly lines

(the product moved along mechanized conveyors, but the

workstations along the line were manually operated-) and

machining transfer lines.


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2) Programmable Automation:

The system is designed with the capability to change the

sequence of operations to produce different products

with low and medium volume production rates.

The operation sequences are controlled by a program

Low production rates (relative to fixed automation)

High initial investment on general-purpose machines.

Adjustable and adaptable to product and process changes(Very flexible)

Suitable for Batch Production (The parts or products aretypically made in batches).

Types of Automation


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2) Programmable Automation

A manufacturing system is designed with the capability tochange the sequence of operations to accommodate differentproduct configurations.

Typical features: High investment in general purpose equipment

Lower production rates than fixed automation

Flexibility to deal with variations and changes in productconfiguration

Most suitable for batch production

Physical setup and part program must be changed betweenjobs (batches)


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2) Programmable Automation

In programmable automation both the physical setup of the

machine and machine programs can be changed over.

Tools must be loaded, fixtures must be attached to the

machine table, and the required machine settings must be

entered. This changeover procedure takes time.

Consequently, the typical cycle for a given product includes

a period during which the setup and reprogramming takes

place, followed by a period in which the batch is produced.

Examples of programmable automation include numericallycontrolled machine tools and industrial robots.


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3) Flexible (Soft) Automation:

The machines are designed with the capability to change thesequence of operations to produce different products

with no time lost for changeovers

Machines are programmable

High initial investment on custom-engineered machines

Continuous production of variable mixtures of products with no

changeover time Medium production rates

Flexible to deal with product design variations

Types of Automation


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3) Flexible Automation

An extension of programmable automation in whichthe system is capable of changing over from one

job to the next with no lost time between jobs

Typical features:

High investment for custom-engineered system

Continuous production of variable mixes of

products

Medium production rates

Flexibility to deal with soft product variety

3) Fl ibl A t ti


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3) Flexible AutomationA flexible automated system is one that is capable of producing a variety of

products (or parts) with virtually no time lost for changeovers from one product to

the next. The essential features that distinguish flexible automation from

programmable automation are;

the capacity to change part programs with no lost production time (hanging

the part programs is generally accomplished by preparing the programs off-

line on a computer system and electronically transmitting the programs to the

automated production system)

the capability to change over the physical setup, again with no lost production

time (changing the physical setup between parts is accomplished by making

the changeover off-line and then moving it into place simultaneously as the

next part comes into position for processing. The use of pallet fixtures that

hold the parts and transfer into position at the workplace is one way ofimplementing this approach)

the flexible automated system can produce various combinations and

schedules of products, instead of requiring that they be made in separate

batches.


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3) FLEXIBLE AUTOMATION

A workpart fixture

A flexible automated line withrobots (automatically adjusts to

product changes)

mm 323 man sys 2012 fall 4 automation in manufacturing systems

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