chapter 2 manufacturing processes and systems

Chapter 2Manufacturing Processes and Systems

2.1 An Overview of Discrete Manufacturing Processes

A large number of manufacturing equipment exist for the implementation of basicdiscrete manufacturing processes into production machinery. Kalpakjian andSchmid (2003) provide a list of discrete manufacturing processes available underdifferent categories of manufacturing, which are used in actual production. Thesemajor categories are

1. Metal forming processes2. Bulk deformation processes3. Sheet Metal forming processes4. Metal removal processes5. Metal joining processes6. Processing of Polymers and reinforced plastics7. Processing of Metal Powders, Ceramics, Glasses, Composites and Super

Conductors8. Thermal Treatment of materials9. Surface Treatment of materials

10. Fabrication of Micro-mechanical and Microelectronic Devices11. Nonconventional processes

The equipment used under each category of discrete manufacturing is furtherclassified according to1:

1. Type of manufacturing equipments that are discrete products capable ofmanufacturing components, assemblies, structure, mechanism and machine(Kalpakjian and Schmid 2003)

2. Size

1 Extracted with permission from Khan WA, Raouf A (2006) Standards for engineering designand manufacturing, Taylor & Francis/CRC, USA.

W. A. Khan et al., Virtual Manufacturing, Springer Series in Advanced Manufacturing,DOI: 10.1007/978-0-85729-186-8_2, Springer-Verlag London Limited 2011

57

3. Accessories4. Operation parameters, and5. Type of control

Each manufacturing process for implementation into mechanical artifacts hasthree distinct features:

1. The inputs to the equipment: raw material type, form, and feeding mechanism;final dimension of the product; energy source; and other auxiliaries.

2. The process implementation allowing transformation of raw material intorequired size, shape, and surface finish using tools (e.g., tools as used in metalcutting, high-energy beams, or various types of jets); utilizing tool- and work-holding devices; measuring devices and manufacturing instructions. In processsupplies such as lubricating oil and coolants may also be used.

3. The output from the equipment comprising a component (the building block ofstructure, mechanisms or machines); and scrap.

There may be several features present at the production machinery to make thetask of manufacturing simpler, easy to control and result in high production rate.

The design of manufacturing equipment relies on a systematic approach todesign and considers a few or all of the following special design requirements.

1. Structural consideration for machine frame and assemblies;2. Thermal effects on the equipment;3. Noise emission from the equipment;4. Vibration in the machinery;5. Environmental effects on the equipment;6. Geometric and kinematics behaviors of the manufacturing equipment;7. Static and dynamic behaviors of the equipment;8. Availability of Computer Numerical Control (CNC) or process control using

Programmable Logic Controllers (PLC);9. Electronic circuitry for implementing control features;

10. Foundation and Installation requirements

Like any other discrete product, the manufacturing equipment commonly uti-lizes standard mechanical components, machine elements, control elements,electrical and electronic components, and software components.

Special assemblies and other accessories utilized at the construction of manu-facturing equipment may also include

1. ToolReferring to mechanical tool, beams, jets, etc.);2. Toolholding devices;3. Work-holding devices;4. Lubricating oil pump assembly;5. Coolant circulation pump assembly;6. Material handling equipment; and7. Scrap handling equipment

58 2 Manufacturing Processes and Systems

A schematic detail implementation of the manufacturing process into produc-tion equipment is presented in Fig. 2.1.2

At present, special consideration is given to the automation, as the use ofComputer Numerical Controls and Programmable Logic Controllers have takenfirm roots.

2.2 Discrete Manufacturing Systems3

A manufacturing system comprises manufacturing equipment arranged in certainfashion. Tangibly, these manufacturing systems have a physical layout whileintangible production control operates on production philosophies. Other impor-tant elements of the manufacturing systems are methods of information, energy,and material transfer. The physical layout of the discrete manufacturing systems isnormally divided into two areas:

1. Processing area;2. Assembly area

Fig. 2.1 Manufacturing process implementation into equipment

2 Extracted with permission from Khan WA, Raouf A (2006) Standards for engineering designand manufacturing, Taylor & Francis/CRC, USA.3 Extracted with kind permission of Springer Science ? Business Media from Manufacturingsystemstheory and practice (1992), pp 223230; and Types of manufacturing systems,Chryssolouris G, Figs. 5.25.9 and Tables 5.1 and 5.2, 1992 Springer Verlag; New York, Inc.

2.1 An Overview of Discrete Manufacturing Processes 59

The processing area is used for manufacturing the components, while theassembly area is meant for assembling the product.

2.2.1 Job Shop

In industrial practice, there are four basic approaches to structuring the processingarea for discrete manufacturing [3]: the job shop, project shop, cellular system, andflow line.

In a job shop, Fig. 2.2, machines with the same or similar material processingcapabilities are grouped together: the lathes form a turning work center, the millingmachines form milling work center, and so forth.

The job shop is characterized by its high flexibility in the production of varioustypes of products while the volume of production in this type of manufacturingsystem is lowrefer to Fig. 2.5.

Fig. 2.2 Schematic of a jobshop


2.2.2 Project Shop

In a project shop, a products position remains fixed during manufacturing becauseof its size and/or weight. Materials, people, and machines are brought to theproduct as needed. Facilities organized as project shops can be found in the aircraftand shipbuilding industries and in bridge and building construction. A schematicof project shop is presented in Fig. 2.3 project shop has the lowest lot size pro-duction among all type of manufacturing systems.

2.2.3 Cellular Manufacturing

In manufacturing systems organized according to the cellular plan, the equipmentor machinery is grouped according to the process combinations that occur infamilies of parts. Each cell contains machines that can produce a certain family ofparts. Figure 2.4 provides arrangement of the equipment in the cellular systems.The cellular manufacturing system is highly automated and flexible. It has low-to-medium lot size production capability.

2.2.4 Flow Line

In flow line, equipments are ordered according to the process sequences of theproduct to be manufactured. A transfer line consists of a sequence of machines,which are typically dedicated to one particular part or at the most a few verysimilar parts/products. Only one product is produced at a time (Fig. 2.5).

Fig. 2.3 Project shop

2.2 Discrete Manufacturing Systems 61

Fig. 2.4 Schematic of acellular manufacturingsystem

Fig. 2.5 Schematic of a flowline


2.2.5 Continuous Manufacturing System

Continuous manufacturing systems produce liquid, gases, or powders. As in flowline, processes are arrayed in the processing sequence of the products. The con-tinuous system is the least flexible of the types of manufacturing systems(Fig. 2.6).

2.2.6 Flexible Manufacturing System

A flexible manufacturing system (FMS) is manufacturing system that comprisesthe properties of a job shop and a cellular manufacturing system. It has higherflexibility in manufacturing that can produce diverse product ranges as in thecase of a job shop, and, can manufacture larger numbers of group of productsas in the case in cellular manufacturing. The FMS arranges CNC machinestools through pick and place technology, and conveyors physically such that agroup of products can be produced efficiently in small-to-medium batches(Fig. 2.7).

Fig. 2.6 Schematic of acontinuous manufacturingsystem


2.2.7 Assembly System

Another substantial part of a manufacturing companys production facilities isthe assembly system. Assembly system can be categorized according to themotion of parts and workplaces. Stationary part systems are usually employedfor large assemblies, such as airplanes, which are difficult to be moved around.Moving part systems can be divided into stationary workplace systems, inwhich parts are brought to stationery workplaces, and moving workplace sys-tem, in which the workplaces move along with the parts. Assembly systemswith stationery parts tend to have higher floor area requirements. They alsotend to have more work at each workplace than moving part systems. Movingpart systems are generally more expensive because complicated material han-dling equipment is required to move parts quickly from workplace toworkplace.

In moving part-stationary workplace systems, the assembly operations at eachworkplace are usually short in duration and are highly repetitive. Moving part-moving workplace systems allow workers to work on each assembly for a longerperiod of time, making the assembly work less repetitive. The assembly systemsare presented in Fig. 2.8. The characteristics of different assembly systems areshown in Table 2.1.

Fig. 2.7 Schematic of a flexible manufacturing system


In the real-time manufacturing world, these standard manufacturing andassembly system structures often occur in combinations, or with slight changes.The choice of a manufacturing system depends on the design of the parts to bemanufactured, the lot sizes of the parts, and market factors such as the requiredresponsiveness. Suitable lot size for each manufacturing system described above ispresented in Fig. 2.9.

2.3 Production Planning and Control

Methods and procedures employed in handling materials, parts assemblies, andsubassemblies, from their raw or initial stage to the finished product stage in anorganized and efficient manner are called production control. It also includesactivities such as planning, scheduling, routing dispatching, storage, etc. Pro-duction control relies on the experience of the manager to worker level humanresourses, and algorithms used for efficient control.

Fig. 2.8 Types of assembly system

Table 2.1 Characteristics of different assembly systems

Stationary parts Moving parts

Stationaryworkplace

Movingworkplace

Stationaryworkplace

Movingworkplace

Area requirement High High Low MediumWork contents at each

workplaceHigh Medium Low Medium

Cost of system Low Medium High High


2.4 Virtual Reality for Manufacturing Systems and Processes

Discrete manufacturing utilizes diverse manufacturing processes and systems forproducing wide range of products. It is rare to find similar manufacturing setup forproducing same range of products.

Any manufacturing setup implementing Augmented Reality requires that all theproduction machinery is stored in the form of graphic models, all the decisionparameters are stored in forms of variables, and the inference engine is running ina distributed computing environment. The process systems and the inferenceengine have the interconnectivity among themselves as well as with the vendorsand businesses. There should be a mechanism for producing management infor-mation system reports so that the manager is capable of taking a simple to anintricate decision. Section 2.1 provides a scope of manufacturing process that maybe used in a real Discrete manufacturing system. Section 2.2 details types ofmanufacturing system that a discrete manufacturing unit may adopt.

2.5 A Survey of the CNC Controller and Their Applications

Computer numerical control controller is used with number of discrete processes.A survey of these controllers is presented to demonstrate the scope of use of ARfor CNC-based processes (Table 2.2).

Fig. 2.9 Suitable manufacturing system types as a function of lot size


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2.5 A Survey of the CNC Controller and Their Applications 67

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Tab

le2.

2(c

onti

nued

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o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

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trol

mod

els

App

lica

tion

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DE

LE

CT

RO

Nht

tp:/

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elec

tron

.it,

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yC

NC

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rS

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NC

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ies

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mil

ling

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cent

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es,

lase

rcu

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asm

acu

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lm

achi

nes

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ford

http

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ww

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ford

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page

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(continued)


http://www.delectron.ithttp://www.denford.com/http://www.deltatau.com/common/products/cnc.asp?node=id600&connectionStr=releasehttp://www.deltatau.com/common/products/cnc.asp?node=id600&connectionStr=releasehttp://www.deltatau.com/common/products/cnc.asp?node=id600&connectionStr=releasehttp://http//www.pgtechnology.co.uk/cnc_diaform.htmhttp://http//www.pgtechnology.co.uk/cnc_diaform.htmhttp://www.directmotion.comhttp://www.dynamechtronics.com/product.htmlhttp://www.dynamechtronics.com/product.htmlhttp://www.dynapath.com/page_controls.htmhttp://www.dynapath.com/page_controls.htmhttp://dynomotion.com/Calabasas

Tab

le2.

2(c

onti

nued

)N

o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

Con

trol

mod

els

App

lica

tion

33.

EC

KE

LM

AN

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tp:/

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lman

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any

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lass

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lect

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(continued)


http://www2.eckelmann.de

Tab

le2.

2(c

onti

nued

)N

o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

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trol

mod

els

App

lica

tion

Eng

ravi

ng:

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gm

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oval

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(continued)


Tab

le2.

2(c

onti

nued

)N

o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

Con

trol

mod

els

App

lica

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S(I

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rodu

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na.c

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(continued)


http://www.ecsitaly.ithttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://products.esabna.com/Cutting/EN/cutting/cutting_mechanized_cutting/mech_cutting_secondary_1180017524/q/display_id.id4367f4bblc3cb9.49585191/path.mechanized_cutting_computer_numerical_controlshttp://www.fagorautomation.com/

Tab

le2.

2(c

onti

nued

)N

o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

Con

trol

mod

els

App

lica

tion

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NC

To

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rol

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type

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dm

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For

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http://www.fanuc.co.jp

Tab

le2.

2(c

onti

nued

)N

o.C

NC

cont

rol

man

ufac

ture

rW

ebsi

te,

coun

try

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trol

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els

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Tab

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Tab

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2(c

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Tab

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Tab

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http://www.nutecl.com/index_files/Page506.htmhttp://www.nutecl.com/index_files/Page506.htmhttp://www.omniturn.com/bin/Controls.htmhttp://www.omniturn.com/bin/Controls.htmhttp://www.omtronix.com/http://www.okuma.com/products/mechatronics/http://www.okuma.com/products/mechatronics/http://www.osai.it/indexb.html

Tab

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http://www.powerautomation.com/http://pccontrols.net/http://www.sea.siemens.com/us/Industry_Solution/Machine-tools/Pages/Machine-Tools-Home.aspxhttp://www.sea.siemens.com/us/Industry_Solution/Machine-tools/Pages/Machine-Tools-Home.aspxhttp://www.sea.siemens.com/us/Industry_Solution/Machine-tools/Pages/Machine-Tools-Home.aspx

Tab

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http://www.slicercontrols.com/http://www.softlogcnc.com/machine-tool-automation-products.htmlhttp://www.softlogcnc.com/machine-tool-automation-products.htmlhttp://www.tauringroupusa.com/CNC_controls.htmhttp://www.tauringroupusa.com/CNC_controls.htmhttp://www.uerro.comhttp://www.unidexmachinery.com/http://www.isscnc.com/http://www.velocitechcnc.com/http://www.vertex-monaco.com/vertexcnchttp://www.vertex-monaco.com/vertexcnc

Tab

le2.

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http://www.naiky.com/Product.asphttp://www.yaskawa.com/site/Products.nsf/products/Multi-Axis%20Motion%20Controllers-MP2000iec_series.htmlhttp://www.yaskawa.com/site/Products.nsf/products/Multi-Axis%20Motion%20Controllers-MP2000iec_series.htmlhttp://www.yaskawa.com/site/Products.nsf/products/Multi-Axis%20Motion%20Controllers-MP2000iec_series.htmlhttp://www.yaskawa.com/site/Products.nsf/products/Multi-Axis%20Motion%20Controllers-MP2000iec_series.html

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5. http://www.abazandbusa.com/abamatic1.htm6. http://www.actekinc.com, Seattle, Washington7. http://www.acu-rite.com/view/millpwr-control-systems.aspx8. http://www.aerotech.com/products/controllers/motion_controllers.html9. http://www.ajaxcnc.com/, Howard

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