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The University of Jordan Mechatronics Engineering Department
Automation Chapter 1 Introduction Dr. Osama Al-Habahbah 2015
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1.0 Introduction The economic realities of the modern world that affect manufacturing enterprises are: Globalization. International outsourcing . Local outsourcing . Contract manufacturing . Trend towards the service sector in developed economies. Quality expectations. Operational efficiency.
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International outsourcing
Globalization More countries are becoming industrialized, such as China and India, due to their high population and low labor cost . International outsourcing More parts and products are outsourced to companies outside the USA . Local outsourcing Within the same country . Due to specialty of the suppliers, cheaper rate in smaller companies, lack of in-house manufacturing capability
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Contract manufacturing
The customer designs product while the supplier makes the product . Trend towards the service sector in developed economies Erosion of direct manufacturing . Quality expectations Perfect quality is expected Operational efficiency Used to offset the high labor cost
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Some modern manufacturing technologies that help to compete :
Automation Material handling technologies Manufacturing system Flexible manufacturing Quality programs Computer Integrated Manufacturing (CIM) Lean production
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Automation Reduces labor cost, decreases production cycle time, and improves quality. Material handling technology Include transportation, storage, tracking . Manufacturing system Production line, manufacturing cells. Flexible manufacturing Helps to compete in the low-volume/hig-mix product categories .
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Computer Integrated Manufacturing (CIM)
Quality programs Such as statistical quality control and six sigma. Computer Integrated Manufacturing (CIM) Includes (CAD) : Computer Aided Design,(CAM): Computer Aided Manufacturing, and integrating computer networks . Lean production Accomplish more with less resources increases productivity
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1.1 production system It is a collection of people, equipment, and procedures to perform the manufacturing operation they are two categories Facilities Manual support system Factory Equipment Layout The set of procedures used by the company to manage production ,such as product design.
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Facilities Manual work system Worker machine Automated
Using unpowered hand tool Using power equipment Automated facility branches out-to: Semi-automated machines and fully automated machines
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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 Product progress Inventory control Balancing too little and too much inventory Quality control Product quality meets standard
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1.2 Automation in production system
1.2.1 Automated Manufacturing System Examples include :Automated machine tool that process parts , Automated assembly , Industrial robots , Automatic material handling storage , Automatic quality control (inspection).
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Types of automated manufacturing systems Fixed automation programmable
flexible Minimal change High initial investment , high production rate, inflexibility High initial investment , high production rate, inflexibility High investment , low production rate, flexibility
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1.2.2 Computerized Manufacturing Support System
Computer Integrated Manufacturing (CIM) : Such as CAD / CAM
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1.2.3 Reason for Automating Increase labor productivity .
Reduce labor cost . Mitigate the effect of labor shortages Reduce manufacturing lead time Accomplish processes that can’t be done manual . To avoid the high cost of not automating (competition) Eliminate routine tasks Improve safety Improve quality
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1.3 Manual labor in production systems
It is still needed . 1.3.1 Manual labor in factory operations It can be preferred to automation in some cases :
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1.3.1 Manual labor in factory operations
1- Task is technologically or economically too difficult to automate . < E.g: hand-eye coordination >. 2- Short product life cycle <Automation takes time>. 3- Customized product . 4- Ups and downs in demand . 5- To reduce risk of products failure < In the market>. 6- Lack of capital to invest in automation.
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1.3.2 Labor in manufacturing support system
Equipment maintenance Programming and computer operation Engineering project work Plant management.
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1.4 Automation Principle And Strategies
The USA Principle Stand for Simplify the process. Automate the process. Understand the exiting process.
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1.4.2 Ten strategies for Automation and process improvement
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.
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1.4.2 Ten strategies for Automation and process improvement
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
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Moving from manual to automated.
Automation Migration Strategy Moving from manual to automated. Phase 1 Phase 2 Phase 3 Manual production. Automated production → single-station system. Automated integrated production → multi-station system.
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1.4.3 Automation Migration Strategy
Advantages of this strategy: Short product introduction time. Gradual automation. Lower risk at the start.
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