lecture 1 introduction to manuf.systems and automation
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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
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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
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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,
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Course Objectives
Automated manufacturing process planning and analysis,including CNC programming, robotics, and elements of computer-aided manufacturing
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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
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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
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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
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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
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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
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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
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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
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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
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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
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The Production System
.
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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
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Manufacturing Systems in the
Production System.
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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
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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.
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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.
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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
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Components of a Manufacturing System
.Marketing Accounting Financing
Design Manufacturing Product
Planning/Control
Manufacturing system diagram
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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
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Manufacturing systems are generally quitecomple x, they almost involve the following
essential components
Workstations
Materials handling
Stora e subs stems
Manufacturing Systems
Manufacturing system functions can be
performed by humans or automated.
The following essential functions can be
identified in most manufacturing systems Procurement
Production
Distribution
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Manufacturing Systems
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
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Manual Work System
.
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Worker-Machine System
.
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Automated System
.
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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
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Information Processing Cycle in
Manufacturing Support Systems
.
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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.
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Computer Integrated Manufacturing
.
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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
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Automated Manufacturing Systems
Three basic types:1. Fixed automation
2. Programmable automation
3. Flexible automation
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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
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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)
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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
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Product Variety and Production
Quantity for Three Automation Types.
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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
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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
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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
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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
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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
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Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and ProcessImprovement
3. Automation Mi ration Strate
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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
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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
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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
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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
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.
AutomationMigrationStrategy
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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)
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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?
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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
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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.
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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.
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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.
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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
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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.