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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)