1. How does ISAT331 fit in the curriculum?
Automation in Manufacturing
How does ISAT331 fit in the curriculum?

2. ISAT 211 & 330 211,330 211, 330 211, 330 211, 330 Factory Operations

3. 331
331
331
331
ISAT 331

4. References
Groover, M.P, Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall 2001
Bedworth, D.D.,Henderson, M.R., and Wolfe P.M., Computer-Integrated Design and Manufacturing, McGraw-Hill, 1991.
Chang,T., Wysk,R..A, Wang, H. Computer Aided Manufacturing, Prentice Hall, 2nd Ed, 1991

5. Module 1 Introduction 1/10/05
Production Systems Facilities
Automation in Production Systems
Manual Labor in Production Systems
Automation Principles and Strategies
CAD, CAM and CIM

6. CIM Terminologies Production System ISAT330 ISAT331
Manufacturing Support Activities
ISAT331
Computerization
Manufacturing
System
CIM
Automation
Terminologies

7. Computers in Manufacturing
Automate physical system and information system in manufacturing
Automation is more related to automating the factory operations
Computerization is more related to automating information cycle
CIM is more related to automating of both factory operations and information cycle

8. Product Variety vs Production Quantity
Changeover (set up)Time
Hard
Soft
Job Shop
MH automated
Production Quantity
Product Variety
100
10,000
1 M
Mid Variety
Mid Production
(Most Difficult)
Mass Production
Low
High

9. Fig 1.3

10. Types of Production Plant (facilities) and Layout
Fixed Position (Large)
Process
Hard
Soft
Production Quantity
Product Variety
100
10,000
1 M
Job Shop
Process (Batch)
Cellular (GT families)
FMS (GT families- automated MH)
Mid Variety
Mid Production
(Apply GT)
Flexibility
Product (Flow line)
Process (Quantity)
Efficiency
Mass Production
Low
High

11. Characteristics of Production Plants
Job Shop has processes that cope with low volume and high number of products
- Uses Process or Fixed position layout
- Make to order.
- Production Rate = Demand Rate
Batch, cellular, and FMS Production has processes that cope with medium volume and medium variety in products
Cellular deals with harder variety products than FMS
FMS is highly automated (MH) when compared to cellular
- Repeated set up-a major disadvantage.
- Production rate > Demand rate.
- Make to Stock.

12. Characteristics of Production Plants
Mass Production has processes that cope with high volume and limited number of products
- Process or cellular layout is used for quantity production (single station ‘equipment’)
- Product layout ’Flow Line’ when multiple stations are required (single- or mixed model lines)
- Demand Rate ~ Production Rate

13. Automation of Production Plant
Definition of Automation
Why to Automate?
Arguments for Automation
Arguments against Automation
Examples
Types of Automated Manufacturing Systems
Categorized based on sequence of operations
Justified based on production volume and variety of products
Fixed Automation
Programmable Automation
Flexible Automation

14. Manual vs Automation Hard Soft Production Quantity Product Variety 100
10,000
1 M
Low
High

15. Fig 1.1 Automation/Production Volume/Product Variety
Programmable Automation
Hard
Soft
Job Shop
Production Quantity
Product Variety
100
10,000
1 M
Flexible Automation
Change Over (Set-up) Time
Manual
Automation
Mid Variety
Mid Production
(Most Difficult)
Fixed Automation
Mass Production
Low
High

16. Programmable Automation
MOST FLEXIBLE
Sequence of operations can be changed (variety of products that are made by similar processes)
High investment (general purpose equipment)
Low – Medium production rate (relatively longer time lost for changeovers of programming and set-up)
Automation of operations (processes or workstations)
is emphasized (not MH)

17. Fixed Automation MOST EFFICIENT
Sequence of operation is fixed (fixed configurations)
Many simple ( reliability) operations (complex system)
Initial investment is high (custom-engineered equipment)
Production rates are high (mass production-Examples)
Automated Operations (processes or workstations)
and Material handling

18. Flexible Automation Extension of Programmable Automation with
Lower time lost on changeovers (continuous production of a group of parts – GT family- that accommodate part variations within the family)
Mid volume/variety range
Higher investment (custom-engineered devices (e.g fixtures and Jigs) for changeover)

19. Automation Strategies & Migration
Automation is not the answer (Robotics application?)
Main principle Understand (charting?), Simplify, and Automate
Strategies?
Automation Migration Strategy

20. Fig 1.9

21. Back to our Conceptual Model
Manufacturing Support Activities
Manufacturing
System
Back to our Conceptual Model

23. Factory Operations (Fig 2.2) Processing ‘advance to completion’
(Basic, Secondary, Property Enhancement, Finishing)
Assembly
Material handling&Storage
Inspection (specifications)and Testing (function)
Control on shop floor (process control, quality control)

24. SAP system?

25. Manufacturing Support Activities
(Fig 2.4)
Business functions (type of orders?)
Product Design (source of specifications?)
Manufacturing Planning (process planning and route sheet?)
Manufacturing Control (management) ‘implement plans’(type of controls?), performance of processes “ # rejects, machine rate, etc”, performance of plant “operating cost, meeting schedule”, etc)

26. Manual Labor in Production System
Factory Operations
Supporting Activities

27. Fig 24.7 Scope of CAD, CAM and CIM

28. Fig 24.8

29. Definitions
CAD is any design activity that involves the effective use of computer technology to create,modify, or document an engineering design (part or system)
CAM is the effective use of computer technology in the planning, management, and control of the manufacturing function
CAD/CAM integration of the design and manufacturing activities. That is to automate the transition from design to manufacturing (e.g NC and process plan and Rapid Prototyping)

30. Home Work#1 Due Wednesday 1/18/2006
Explain and contrast the characteristics of the basic production systems
Explain and contrast the characteristics of the basic automated production systems
Discuss TWO situations in which humans are preferred over automation in Factory Operations (blue collar tasks)
Discuss TWO situations in which humans are preferred over automation in Manufacturing Support Systems (white collar tasks)
Explain THREE strategies for automating production systems

31. Unused Slides