Dr. Osama Al-Habahbah Automation Chapter 1 Introduction

The economic realities of the modern world that affect manufacturing enterprises are:  Globalization.  International outsourcing.  Local outsourcing.  Contract manufacturing.  Tend toward the service sector in developed economies.  Quality expectations.  Operational efficiency.

Globalization. More countries are be coming industrialized, such as China and India, due to their high population and low labor cost. Local outsourcing. International outsourcing. More parts and products are outsourced to companies outside the USA. Within the same country. Due to specialty of the suppliers, cheaper rate in smaller companies, lack of in hoes manufacturing capability

Contract manufacturing. The customer designs product while the supplier makes the product. Quality expectations. Tend toward the service sector in developed economies. Erosion of direct in manufacturing. perfect quality is expected Operational efficiency. used to offset the high labor cost

Some modern manufacturing technology that help to compete : AutomationMaterial handling technologiesManufacturing systemFlexible manufacturingQuality programsComputer Integrated Manufacturing (CIM)Lean production

Reduces labor cost, decreases production cycle time, and improves quality. Include transportation, storage, tracking. Production line, manufacturing cells. Helps to compete in the low-volume/hig-mix product categories.

Such as statistical quality control and six sigma. Includes (CAD) : Computer Aided Design,(CAM): Computer Aided Manufacturing, and integrating computer networks. Accomplish more with less resources  increases productivity

It is a collection of people, equipment, and procedures to perform the manufacturing operation they are two categories Factory Equipment Layout Factory Equipment Layout The set of procedures used by the company to manage production,such as product design.

Facilities Manual work system Worker machine Automated Using unpowered hand too ; Using power equipment Automated facility branches out-to: Semi-automated machines and fully automated machines

Functions of Manufacturing support system Business function Product design Manufacturing planning Manufacturing planning control Communicating with customer Either provided by customer or in house if it’s proprietary Scheduling, Capacity, planning and process planning Shop floor control Inventory control Quality control Product progress Balancing too little and too much inventory Product quality meets standard

Examples include :Automated machine tool that process parts, Automated assembly, industrial robots, Automatic material handling storage, Automatic quality control (inspection).

Type of automated manufacturing system Fixed automationprogrammableflexible High initial investment, high production rate, inflexibility High investment, low production rate, flexibility Minimalchange High initial investment, high production rate, inflexibility

Computer Integrated Manufacturing (CIM) : Such as CAD / CAM

 Increase labor productivity.  Reduce labor cost.  Mitigate the effect of labor shortages  Eliminate routine tasks  Improves safety  Improves quality  Reduce manufacturing lead time  Accomplish processes that can’t be done manual.  To avoid the high cost of not automating (competition)

It is still needed. It can be preferred to automation in some cases :

1- Task is technologically or economically too difficult to automate.. 2- Short product life cycle. 3- Customized product. 4- Ups and downs in demand. 5- To reduce risk of products failure. 6- Lack of capital to invest in automation.

Equipment maintenance Plant management. Engineering project work Programming and computer operation

Stand for

1- Specialization of operations: Use of special-purpose equipment for greatest efficiency. 2- Combined operations: Perform more than one operation at a given machine. 3- Simultaneous operations: To reduce processing time. 4- Integration of operations: Linking work-stations together → increasing output 5- Increased flexibility: Maximum utilization of equipment → Use the same equipment for a variety of products.

6- Improved material handling and storage: reduce work in process and shorter manufacturing lead times. 7- On-line inspection: (of quality) reduce scrap and improves quality. 8- Process control and optimization: process time decrease,quality increase. 9- Plant operations control (of the factory) 10-Computer-integrated manufacturing CIM: ( Design → Operations → Business ) Computer Network

Moving from manual to automated. Phase 1Phase 2Phase 3 Manual production. Automated production → single-station system. Automated integrated production → multi-station system.

 Shout product introduction time.  Gradual automation.  Lower risk at the start.