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Manufacturing Automation

Dr. Izhar
Assistant Professor
Institute of Mechatronics Engineering
(izhar@nwftuet.edu.pk)

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Manufacturing Automation

1. Production Systems
2. Manufacturing Systems
3. Automation in Production Systems
4. Manual Labor in Production Systems
5. Automation Principles and Strategies

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The Realities of Modern Manufacturing

• Globalisation
• International outsourcing
• Local outsourcing
• Contract manufacturing
• Services
• Quality
• Efficiency

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Manufacturing Approaches
• Automation
• Flexible manufacturing
• Quality programs
• Integration
• Lean production

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Production System Defined
A collection of people, equipment, and
procedures organized to accomplish the
manufacturing operations of a company

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Facilities – Factory and Equipment

Factory, production machines and tooling,


material handling equipment, inspection
equipment, and computer systems that
control the manufacturing operations

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Manufacturing Support Systems
– Business functions - sales and marketing,
order entry, cost accounting, customer billing
– Product design - research and development,
design engineering, prototype shop
– Manufacturing planning - process planning,
production planning, MRP, capacity planning
– Manufacturing control
shop floor control,
inventory control, quality control

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Automation of Manufacturing System
Computerization of manufacturing Support Systems
Computer Integrated Manufacturing

CIM term used to indicate extensive use of computers in production systems


through the automation of manufacturing systems and computerization of
manufacturing support system

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Automated Manufacturing System
Automated manufacturing systems operate in
the factory on the physical product. operation Periodic Automated
include processing, assembly, inspection, and Worker System
material handling

Examples:
• Automated machine tools Transformation
Process
• Transfer lines
• Automated assembly systems
• Industrial robots
• Automated material handling and storage systems
• Automatic inspection systems for quality control

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Automation

Automation is a set of technologies that results in


operation of machines and systems without significant
human intervention and achieves performance superior
to manual operation

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Three Automation Types

Programmable
Automation
Variety Flexible
Automation
Fixed
Automation

Quantity

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Fixed Automation
Sequence of processing (or assembly) operations is
fixed by the equipment configuration

Typical features:
• Suited to high production quantities
• High initial investment for custom-engineered
equipment
• High production rates
• Relatively inflexible in accommodating product
variety

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Programmable Automation
Capability to change the sequence of operations
throug reprogramming to accommodate different
product configurations

Typical features:
• High investment in programmable 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
System is capable of changing over from one job to
the next with little lost time between jobs

Typical features:
• High investment for custom-engineered system
• Continuous production of variable mixes of
products
• Medium production rates
• Flexibility to deal with soft product variety

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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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Automation Principle
1. Understand the existing process
– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production
systems
– Automation migration strategy

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Automation Strategies
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

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Production Facilities and Layout
• Facilities organized in the most efficient way to
serve the particular mission of the plant and
depends on:
– Types of products manufactured
– Production quantity
– Product variety

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Production Quantity (Q)
• Number of units of a given part or product
produced annually by the plant
• Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units

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Product Variety (P)
• Number of different product or part designs or types
• ‘Hard’ product variety – products differ greatly
– Few common components in an assembly and in many cases
there are no common parts – difference between car and truck is
hard
• ‘Soft’ product variety – small differences between products
– Many common components in an assembly – differences
between car models made on the same production line

Different products have different shapes and sizes, and


styles, they perform different functions, they are some
time intended for different markets, some have more
components then others.....
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Low Production Quantity (Qlow)
Job shop – makes low quantities of specialized and
customized products
• Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
• Equipment is general purpose
• Plant layouts:
– Fixed position
– Process layout

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Fixed-Position Layout

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Process Layout

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Medium Production Quantities (Qmed)
1. Batch production – A batch of a given product is
produced, and then the facility is changed over
to produce another product
– Changeover takes time – setup time
– Typical layout – process layout
– Hard product variety
2. Cellular manufacturing – A mixture of products is
made without significant changeover time
between products
– Typical layout – cellular layout
– Soft product variety

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Cellular Layout

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High Production (Qhigh)
1. Quantity production – Equipment is dedicated to
the manufacture of one product
– Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
– Typical layout – process layout
2. Flow line production – Multiple workstations
arranged in sequence
– Product requires multiple processing or assembly
steps
– Product layout is most common

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Product Layout

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PQ Relationships

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Manufacturing Systems in the
Production System

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Manufacturing Systems

1. Components of a Manufacturing System


2. A Classification Scheme for Manufacturing
Systems

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Manufacturing System Defined
“A collection of integrated equipment and human
resources, whose function is to perform one or
more processing and/or assembly operations on a
starting raw material, part, or set of parts”
• Equipment includes
– Production machines and tools
– Material handling and work positioning devices
– Computer systems
• Human resources are required either full-time or
periodically to keep the system running

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Typical Manufacturing
Operations

1. Processing

2. Assembly

3. Inspection

4. Material Handling

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Processing Operations
• Shaping operations
– Solidification processes
– Particulate processing
– Deformation processes
– Material removal processes
• Property-enhancing operations (heat
treatments)
• Surface processing operations
– Cleaning and surface treatments
– Coating and thin-film deposition

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Assembly Operations
• Joining processes
– Welding
– Brazing and soldering
– Adhesive bonding
• Mechanical assembly
– Threaded fasteners (e.g., bolts and nuts, screws)
– Rivets
– Interference fits (e.g., press fitting, shrink fits)
– Other

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Inspection and Testing
Inspection – conformance to design
specifications
– Inspection for variables - measuring
– Inspection of attributes – gauging
Testing – observing the product (or part,
material, subassembly) during operation

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Examples of Manufacturing Systems

• Single-station cells
• Machine clusters
• Manual assembly lines
• Automated transfer lines
• Automated assembly systems
• Machine cells (cellular manufacturing)
• Flexible manufacturing systems

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Components of a
Manufacturing System
1. Production machines
2. Material handling system
3. Computer system to coordinate and/or control
the preceding components
4. Human workers to operate and manage the
system

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Production Machines
• In virtually all modern manufacturing systems,
most of the actual processing or assembly work
is accomplished by machines or with the aid of
tools
• Classification of production machines:
1. Manually operated machines are controlled or
supervised by a human worker
2. Semi-automated machines perform a portion of the
work cycle under some form of program control, and
a worker tends the machine the rest of the cycle
3. Fully automated machines operate for extended
periods of time with no human attention
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Manually Operated Machine

Manually operated machines are controlled or supervised by a human


worker. The machine provides the power for the operation and the
worker provides the control. The entire work cycle is operator controlled.

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Semi-Automated Machine

A semi-automated machine performs a portion of the work cycle under


some form of program control, and a worker tends to the machine for the
remainder of the cycle. Typical worker tasks include loading and unloading
parts

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Fully-Automated Machine

Machine operates for extended periods (longer than one work cycle)
without worker attention (periodic tending may be needed).

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Material Handling System
• In most manufacturing systems that process or
assemble discrete parts and products, the
following material handling functions must be
provided:
1. Loading work units at each station
2. Positioning work units at each station
3. Unloading work units at each station
4. Transporting work units between stations in multi-
station systems
5. Temporary storage of work units

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Material Handling
• Material transport
– Vehicles, e.g., forklift trucks, AGVs, monorails
– Conveyors
– Hoists and cranes
• Storage systems
• Unitizing equipment
• Automatic identification and data capture
– Bar codes
– RFID
– Other AIDC
(Automatic Identification and Data Capture )

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Time Spent in Material Handling

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Work Transport Between Stations
• Two general categories of work transport in
multi-station manufacturing systems:
1. Fixed routing
• Work units always flow through the same sequence
of workstations
• Most production lines exemplify this category
2. Variable routing
• Work units are moved through a variety of different
station sequences
• Most job shops exemplify this category

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(a) Fixed Routing and
(b) Variable Routing

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Computer Control System
• Typical computer functions in a manufacturing system:
– Communicate instructions to workers (receive processing or assembly
instructions for the specific work unit)
– Download part programs to computer-controlled machines
– Control material handling system
– Schedule production
– Failure diagnosis when malfunctions occur and preventive
maintenance
– Safety monitoring (protect both the human worker and equipment)
– Quality control (detect and reject defective work units produced by
the system)
– Operations management (manage overall operations)

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Classification of
Manufacturing Systems
• Factors that define and distinguish
manufacturing systems:
1. Types of operations performed
2. Number of workstations
3. System layout
4. Automation and manning level
5. Part or product variety

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Types of Operations Performed
• Processing operations on work units versus assembly operations to combine
individual parts into assembled entities
• Type(s) of materials processed
• Size and weight of work units
• Part or product complexity
– For assembled products, number of components per product
– For individual parts, number of distinct operations to complete
processing
• Part geometry
– For machined parts, rotational vs. non-rotational

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Number of Workstations
• Convenient measure of the size of the system
– Let n = number of workstations
– Individual workstations can be identified by subscript i,
where i = 1, 2,...,n
• Affects performance factors such as workload
capacity, production rate, and reliability
– As n increases, this usually means greater workload
capacity and higher production rate
– There must be a synergistic effect that derives from n
multiple stations working together vs. n single stations

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System Layout
• Applies mainly to multi-station systems
• Fixed routing vs. variable routing
– In systems with fixed routing, workstations are
usually arranged linearly
– In systems with variable routing, a variety of layouts
are possible
• System layout is an important factor in
determining the most appropriate type of
material handling system
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Automation and Manning Levels
• Level of workstation automation
– Manually operated
– Semi-automated
– Fully automated
• Manning level Mi = proportion of time worker is in
attendance at station i
– Mi = 1 means that one worker must be at the station
continuously
– Mi  1 indicates manual operations
– Mi < 1 usually denotes some form of automation

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Part or Product Variety:
Flexibility
“The degree to which the system is capable of dealing with variations in
the parts or products it produces”
• Three cases:
1. Single-model case - all parts or products are identical (sufficient
demand/fixed automation)
2. Batch-model case - different parts or products are produced by the
system, but they are produced in batches because changeovers are
required (hard product variety)
3. Mixed-model case - different parts or products are produced by the
system, but the system can handle the differences without the need
for time-consuming changes in setup (soft product variety)

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Three Cases of Product Variety
in Manufacturing Systems

(a) Single-model case, (b) batch model case, and (c) mixed-model case

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