1. Manufacturing Systems Automation Introduction*
Dr. L. K. Gaafar
*Based on information from Groover, Automation, Production Systems, and Computer-Integrated Manufacturing.
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2. The Production System Manufacturing support systems
Manufacturing facilities: factory, equipment
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3. Discrete Manufacturing
Variety
Job shop
MH Complexity
Batch Production
Mass Production
Quantity
Automation
Specialization
Skills
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4. Discrete Manufacturing
Mass production*
Automation easily justified
Objectives: (1) reduce operation cycle time, (2) increase system reliability
Line is rarely changed - setup time not critical
Inflexible: not suitable for products with many options or limited production runs
* Check the textbook on the two types: quantity and flow line
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5. Discrete Manufacturing
Job shop production
Products produced in small volume
Automation difficult to justify unless products are too complex to be produced manually
Objectives: (1) reduce setup time, (2) reduce processing time, (3) reduce WIP
Most flexible of production strategies
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6. Discrete Manufacturing
Batch production
Products produced in batches, lots or groups
Trade-off between job shop and mass production
Single setup for each batch
Increase batch size, but increase in waiting time, WIP and inventory result
Objectives are same as job shop
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7. Facility Layout Four types of layouts: Process: suitable for job shop
Fixed Position: suitable for large products
Cellular: suitable when products are similar in batch production and sometimes in job shop
Product flow: suitable for mass production
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8. Facility Layout Process layout For small, discrete-parts manufacturing
Machines are grouped into departments according to type of operation
Advantages: work schedule more flexible
Disadvantages: WIP is large (cost in inventory and storage space), high material handling cost, larger batches are made than are required (to justify setup), difficulty in maintaining control of parts, highest skill level required from operators
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9. Facility Layout Fixed position layout
Product must remain stationary throughout production sequence
Machines are brought to the product
Higher expense due to robustness and accuracy of equipment
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10. Facility Layout Product flow layout Suited for high volume production
Advantages: minimized material handling, easy to automate material handling, less WIP, easier to control
Disadvantages: inefficient to alter the sequence of operations, breakdown on one machine can stop the entire line
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11. Facility Layout Group technology (cellular) layout
Several different types of machines are grouped together to form a cell - each cell is designed to produce a family of parts
Suitable for small to mid-volume production of parts
Advantages: setup time is reduced, lead time is reduced, WIP is reduced, finished inventory is reduced, improved quality (group of workers responsible for a cell)
Disadvantages: parts must be grouped into families, layout is less flexible than process layout, batches from same family cannot be run simultaneously, higher skill level required from operators
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12. Example Industries Aerospace
Typically, complex, three-dimensional shapes, exotic materials, medium-volume to low-volume production quantities
Military and space technology filters down to industrial applications
Pioneered work in NC machining, CAD/CAM, composites and flexible manufacturing system applications
Goals: energy efficiency, high strength-to-weight ratio
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13. Example Industries Automotive
Relatively large production quantities, multiple options: automated assembly is difficult
Traditionally, primary processes were metalworking: machining of power train parts, forming and bending sheet metal; assembly by spot welding and mechanical fasteners; finishing by spray painting and plating
New materials: plastics, fiberglass
Increasing automation: robots for spot welding and spray painting
Improved quality with production groups that assemble large portions of the automobile
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14. Example Industries Chemical
Chemical processes for man-made fibers and plastics, oil distillation and pharmaceutical industries
Continuous flow of product and byproducts; some batch processing
reasonably easy to automate
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15. Example Industries Food Large volume industry
Standard products and operations, therefore reasonably easy to automate
Many products use continuous processes; discrete processes includes packaging
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16. Example Industries Semiconductor Large volume industry
Emphasis on design and production of low-cost integrated circuits
Smaller size and more stringent requirements for cleanliness
Process requirements have forced automation
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17. Reasons for Automating
Increase production rate eliminate portions of process that directly increase production time: machine processing time, handling time, setup times (SMED)
Remove humans from hazardous environments exposure to chemicals, fumes, temperature or radiation robotic applications: L/UL furnaces, spray painting, welding
Remove humans from processes that require extremely clean environments: e.g., semiconductors, drugs
Reduce number of defective products
Reduce direct labor one worker monitors a larger number of machines
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18. Reasons for Automating
Reduce work-in-process parts being processed, part waiting to be processed large WIP: longer time to fill orders, more storage space, value of unfinished goods that could be invested elsewhere reduced WIP: better control and scheduling
Reduce manufacturing lead time processing time, setup time, waiting time setup time: flexible automation, common fixtures and tooling processing time: combining or eliminating operations, increase speed (work measurement principles)
Increase quality repeatable operations through every cycle - tighter control limits, easier detection when process is out of control status of manufacturing operations
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19. Reasons for Automating
Increase productivity
Reduce labor cost
Address labor shortages
Reduce or eliminate routine manual and clerical tasks
Health and Safety
May be the only option
Stay up-to-date (avoid cost of catching up)
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20. OSHA Occupational Safety and Health Administration
The mission of the Occupational Safety and Health Administration (OSHA) is to save lives, prevent injuries and protect the health of America's workers. To accomplish this, federal and state governments must work in partnership with the more than 100 million working men and women and their six and a half million employers who are covered by the
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21. Automated Manufacturing Systems
Machines
Transfer lines
Assembly
Material Handling
Inspection (coordinate measuring machines, CMM)
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22. Computer Aided
CAD
CAE
CAPP
CAM
CIM
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23. Types of Automation Fixed Automation (transfer lines)
Hard automation, automation for mass production
Produces large numbers of nearly identical parts
High initial investment for custom engineered equipment
Product design must be stable over its life
Advantages: equipment fine tuned to application - decreased cycle time, infrequent setups, automated material handling - fast and efficient movement of parts, very little WIP
Disadvantage: inflexible
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24. Types of Automation Programmable Automation (NC, CNC, robots)
Sequence controlled by a program
High investment in general purpose equipment
Lower production rates
Flexibility to deal with variation
Suitable for batch production
Smaller volumes (than fixed) of many different parts
More flexible than fixed automation
Major disadvantage: setup prior to each new part
Large batch size (due to setups)
Speed sacrificed for flexibility
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25. Types of Automation Flexible Automation (FMS)
Extension of programmable automation
No time lost for change over
High investment in custom-engineered systems
Production of product mix
Flexibility to deal with design variations
Low to medium quantities
Compromise between fixed and programmable automation in speed and flexibility
Advantage: programming and setup performed off-line
More expensive - size and tool change capabilities
Small batch sizes are justified - reduced WIP and lead time
Typical parts are expensive, large and require some complex machining
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26. Manual Labor in Automated Systems
Strengths of Humans
Sense unexpected stimuli
Develop new solutions to problems
Cope with abstract problems
Adapt to change
Generalize from observations
Learn from experience
Make difficult decisions based on incomplete data
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27. Manual Labor in Automated Systems
Strengths of (computer-based) machines
Perform repetitive tasks consistently
Store large amounts of data
Retrieve data from memory reliably
Perform multiple tasks simultaneously
Apply high forces and power
Perform computations quickly
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28. Manual Labor in Automated Systems
Even if all of the manufacturing systems in the factory are automated, there will still be a need for the following kinds of work to be performed:
Equipment maintenance. Maintain and repair, improve the reliability, of automated systems.
Programming and computer operation.
Engineering project work. Upgrades, design tooling, continuous improvement.
Plant management.
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29. AUTOMATION PRINCIPLES AND STRATEGIES
USA Principle:
1. Understand the existing process
2. Simplify the process
3. Automate the process
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30. AUTOMATION PRINCIPLES AND STRATEGIES
Ten Strategies for Automation
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 (CIM).
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31. AUTOMATION PRINCIPLES AND STRATEGIES
Automation Migration Strategy
Phase 1: Manual production using single station manned cells operating independently.
Phase 2: Automated production using single station automated cells operating independently.
Phase 3: Automated integrated production using a multi-station automated system with serial operations and automated transfer of work units between stations.
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32. Historical Development of Manufacturing
3500 BC Use of Wheel and axle for transportation
500 BC Lathe used for wood turning
1569 Screw-cutting lathe developed -- Jacques Besson
1769 James Watt invented the steam engine -- later used to provide power to industry
1774 Precylinder-boring mill developed -- John Wilkinson
1790 Samuel Slater opens the first successful textile mill in the United States
1793 Eli Whitney builds the first cotton gin
1798 Eli Whitney invents a milling machine to produce standardized parts in muskets
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33. Historical Development of Manufacturing
1801 J.M. Jacquard invented a silk-loom-- punched cards controlled the machine
1851 Issac Singer patented his sewing machine
1900 High-speed steel cutting tools developed
1903 Oxyacetylene welding torch developed
1903 First fully automated machine-made bottles produced
1907 Paint spray gun developed
1913 Ford Motor Co. opens first moving assembly line
1914 Centrifugal casting of cast iron pipe -- re-usable molds are used
1920 Ford introduces continuous casting of cast iron for engine blocks
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34. Historical Development of Manufacturing
1921 Jigs and fixtures used in the jig-boring machine to make rifles and revolvers -- Enfield, England
1930 First automatic factory -- Made chassis frames for cars: one every six seconds
1952 First commercial NC machine
1962 First industrial robot
1963 Electro-coating methods for painting car bodies is developed
1964 Technique for fast-breaking electric motors developed -- machine tools can now be stopped quickly
1985 First products manufactured in space went on sale -- tiny plastic beads, perfectly round and uniform in size
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35. Cowboy after OSHA, by J. N. Devin ( 1972)
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