Reconfigurable Automation

&
Standard Assembly Cell
Development
Raul Fernandez
Program Manager
Automation and Robotics Research Institute
The University of Texas at Arlington

ARRI

Brian Huff
Associate Professor
Industrial & Manufacturing Systems Engineering
The University of Texas at Arlington

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 1, 06/10/15
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Presentation Outline

ARRI

Limitations of Manual Manufacturing and Traditional

Automation

The need for Strategic Cash Flow Justification

strategies

The structure of modular reconfigurable automation

systems

A case study presenting the deployment of modular

automation in a DoD high mix/low volume production
environment

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 2, 06/10/15
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Todays Manufacturing Environment

High Mix/Low Rate Production Environments

Shorter Product Lives & Production Runs

Emphasis on Cost with No Compromises on

Quality and Performance

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 3, 06/10/15
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Tactical Justification of
Manufacturing Technology

Conventional
Manufacturing
Methods

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Automated
Manufacturing
Methods

Traditional Economic Trade Studies based

on lowest cost alternatives bound by
minimum performance requirements
The University of Texas at Arlington
Automation & Robotics Research Institute

Page 4, 06/10/15
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Problems With Avoiding Automation

Implement Manual Assembly Systems

Outsource Assembly & Test Operations

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Low capital / high flexibility yet productivity,

precision, and quality issues

Avoid capital, but lose direct control of production

operations
Quality, delivery exposure
Lose critical product / process design feedback

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 5, 06/10/15
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Conventional Automation Systems

Jigsaw Puzzle of Custom Components

ARRI

Very Cost-Driven
Very Project and Product Specific
Life of system is tied directly to life of product
Limited opportunity for system re-use
The University of Texas at Arlington
Automation & Robotics Research Institute

Page 6, 06/10/15
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A Traditional Flexible Assembly Machine

Has a robot (versus hard

mechanical actuation)
No separate process
modules
Dedicated parts feeding,
tooling
Limited redeployment /
reuseability of capital
investment

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 7, 06/10/15
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Conventional Automation Systems

In conflict with current manufacturing needs:

ARRI

Inhibit manufacturing agility

Unable to adapt to changes in product mix and volume

Product life cycles are becoming shorter than the time

required to bid, design, install & debug traditional
automated assembly systems

Cost of re-implementing traditional automation is

prohibitive

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 8, 06/10/15
DMCFlexCell99.ppt

Reconfigurable Automation Systems

Product
Process
Base
A set of reusable modular system building blocks

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 9, 06/10/15
DMCFlexCell99.ppt

Modular Capacity to Match

Volatile Demand
Production Volume of 1st Model
: Required Production Volume

: System Production Capacity

Months

Production Volume of 2nd Model

: Required Production Volume
: System Production Capacity

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 10, 06/10/15

DMCFlexCell99.ppt

Layered System Architecture

PRODUCT LAYER - specific product

hardware and information which
identifies the processes and
production sequences required to
produce specific products
PROCESS LAYER - the base platform
and the process building blocks
provided determine the functional
capability of the system.
BASE LAYER - provides generic
production resources and application
development toolsets

A three-layered approach
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The University of Texas at Arlington

Automation & Robotics Research Institute

Page 11, 06/10/15

DMCFlexCell99.ppt

Reconfigurable Automation Technology

Base Layer Hardware
Small Number
of Commercially
Available
Components

Can Be Reconfigured
Into a Large Number of
Base Configurations
ARRI

Supports the Development

of a Large Number of Base
Cell Configurations

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 12, 06/10/15

DMCFlexCell99.ppt

Flexible Automation Technology

Flexible Cell Configuration Base Layer Software Development

Cell Configuration
Software

ARRI

Device Control
Software

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 13, 06/10/15

DMCFlexCell99.ppt

Process Layer Components

Process Specific
Tooling

Process Specific Control Software

and Knowledge Bases
ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 14, 06/10/15

DMCFlexCell99.ppt

Layered Software Architecture

Process
Process
Agent
Agent
Manager
Manager

Process
Layer

ABMOS
ABMOS
Application
Application

Intelligent
Process
Agents

Base
Layer

ARRI

Device
Control
Agents

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 15, 06/10/15

DMCFlexCell99.ppt

Flexible Automation Technology

Product Layer Configuration
Product Specific
Tooling

Software Applications to
support the specification of
product families

Attitude Control Section Holding

Fixture
ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 16, 06/10/15

DMCFlexCell99.ppt

New Technology Implementation

Strategy

Development & maintenance of a library of generic

intelligent automated process technologies

Design for Flexible Automation

Heavy use of COTS and open standards

Support the concept of Rapid Deployment

Automation

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 17, 06/10/15

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Affordable Multi-Missile Manufacturing

Case Studies

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 18, 06/10/15

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SAC End-User Implementations

Aerospace Applications

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 19, 06/10/15

DMCFlexCell99.ppt

Flexible Automation Technology

Flex Cell Process Simulation

Product
Process
Base
ARRI

The University of Texas at Arlington

Martin Proprietary
Information
AutomationLockheed
& Robotics
Research
Institute

Page 20, 06/10/15

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Prototype Process Development

Automated Process Prototyping - ACS Assembly

ARRI

The University of Texas at Arlington

Lockheed
Proprietary
Automation
& Martin
Robotics
Research Institute

Page 21, 06/10/15

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Camden Reconfigurable Cell

Process Hardware
ACM Insertion End Effectors

ACM Gripper
Probe
Product
Process

Clip Tool
Plunger Tool

ARRI

The University of Texas at Arlington

Martin Proprietary
Information
AutomationLockheed
& Robotics
Research
Institute

Page 22, 06/10/15

DMCFlexCell99.ppt

SAC End-User Implementations

Honeywell - light duty aerospace

Gyroscope Assembly

ARRI

DARPA / Honeywell Space

Systems Div. sponsorship
Small, intricate assemblies with
ESD sensitivity
High-mix / low volume
production environment
Multiple cell redeployment
scenarios justified

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 23, 06/10/15

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Flexible Automation Technology

Benefits Summary

ARRI

Use of Automation for Labor Reduction is Enabled by

Flex Cell Approach

Reduced Dependence on Product-Specific Systems

and Facilities

Reduced Implementation/Deployment Time

Improved Production Cycle Time

Improved Quality and Safety

De-couples Manufacturing Cost and Quantity

The University of Texas at Arlington
Lockheed
Proprietary
Automation
& Martin
Robotics
Research Institute

Page 24, 06/10/15

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Small Reconfigurable Cell

Configuration

Potential Applications

ARRI

Systems processing assemblies

fitting within a 30 liter, <5 kg envelope

Consumer electronics, medical

products, small electromechanical
assemblies for automotive,
aerospace, and defense industries

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 25, 06/10/15

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Medium Reconfigurable Cell

Configuration

Potential Applications

ARRI

Systems processing assemblies

fitting within a one cubic meter, <20
kg envelope

Automotive engine and transmission

assembly, appliance assembly, and
missile section assembly

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 26, 06/10/15

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Large Reconfigurable Cell

Configuration
Potential Applications

ARRI

Systems processing assemblies greater

than a one cubic meter and 20 kg,
envisioned to exceed the reach and
payload of all but the largest industrial
robots

Airframe assembly, heavy automotive

assembly, and large reach palletizing
applications

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 27, 06/10/15

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Reconfigurable Automation Enables

Scalable Systems

ARRI

Low volume / high

work content at
production introduction

Higher production
volumes are supported
by adding cells and
distributing work
content

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 28, 06/10/15

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Benefits of Reconfigurable
Manufacturing Systems

System can be reconfigured to meet the needs of highmix low-volume manufacturing

Base layer, which has highest capital investment, is

reusable but costs 10% to 25% more

The required process building blocks can be quickly

added to the base platform system

Process layer has plug-in reusable modules which can

be changed over from one process to the next within
minutes instead of hours or days

Product layer has minimal investment and is capable of

responding to instant changes in product demands

ARRI

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 29, 06/10/15

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In Conclusion

Production Volume stofModel

1

Product
Product

Required : Production Volume

: System Production Capacity

Months

Process
Process

Production Volume of 2nd Model

: Required Production Volume
System Production Capacity
:

Base
Base
Modular System
Architectures &
Rapid Deployment
Methodologies . . .

ARRI

. . . Creating
Reconfigurable
Automation Systems . . .

. . . That support
multiple product life
cycles in a rapidly
changing global
market place

The University of Texas at Arlington

Automation & Robotics Research Institute

Page 30, 06/10/15

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