Automated Manufacturing

1
Introduction

• Automated Manufacturing

2
Contents

• Production System Facilities
• Manufacturing Support System
• Automation in Production System

3
Production system

Manufacturing support systems
Production system
Facilities Factory Equipment
4
Production System Facilities

• Facilities are the factory, machine, tooling,
  material handling equipment, inspection equipment
  and the computer system.
• Facilities also include the plant layout
• Manufacturing System refer to these equipment and
  the workers who operate them

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Production System Facilities

• Manufacturing can be individual work cells.
• Manufacturing system as groups of machines and
  worker, for ex. A production line.
• Manufacturing system touch the product.
• The quantity produced by a factory has a very
  significant and the way manufacturing is
  organized.

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Classified quantities production

1. Low production range of 1 to 100 units/year
2. Medium production range of 100 to 10,000
   units/year
3. High production 10,000 to millions of units

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Product variety

• Refer to the different product designs or types
  that are produced in a plant.
• Different product have different shapes and sizes
  and styles.
• When the number of product types made in a
  factory is high, this indicates high product
  variety.

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Relationship between product variety and
production quantity
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Product variety

• Hard product variety is when the product differ
  substantially, is characterized by a low
  proportion common parts among the products.
• Such as the differences between car and truck.
• Soft product variety is when there are only small
  differences between product.
• Such as differences between car models made on
  the same production line. Ex. Alto Lx Lxi

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Low Quantity Production

• is the job shop production.
• The product are typically complex.
• Customer orders are often special, and repeat
  orders may never occur. Ex. Ships, Aeroplanes
• Equipment is general purpose and the labor force
  is highly skilled.
• A job shop must be designed for maximum
  flexibility for hard product variety.

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Low Quantity Production (cont.)

• Fixed-position layout for job shop production is
  large and heavy and difficult to move.

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Airbus A380
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Low Quantity Production (cont.)

• Process layout, in which equipment is arranged
  according to function or type.

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Low Quantity Production (cont.)

• Process layout produced different parts, each
  requiring a different operation sequence.
• are routed through the departments in the
  particular order needed for their processing,
  usually in batches.
• Machinery and methods to produce a part are not
  designed for high efficiency.
• In-Process inventory can be high.

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Medium Quantity Production

• has two different types of facility.
• Batch production
• When product variety is hard, the traditional
  approach is batch production.
• The changeover between production runs takes time
  that called the setup time or changeover time

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Medium Quantity Production (cont.)

• The equipment is usually arranged in a process
  layout

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Medium Quantity Production (cont.)

• Cellular manufacturing
• Product variety is soft.
• Product can be made on the same equipment without
  significant lost time for changeover.
• Cells consisting of several workstations or
  machines.
• The layout is called a cellular layout.

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Cellular Manufac.
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Medium Quantity Production (cont.)

• Cellular manufacturing (cont.)
• Each cell is designed to produce a limited
  variety of part configurations.
• The cell specializes in the production of a given
  set of similar parts or products.

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High Production

• Refer to as mass production
• Two categories of mass production
• Quantity production
• Flow line production
• Quantity production
• Single parts on single pieces of equipment.
• The method of production typically involves
  standard machines.
• The typical layout is the process layout

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High Production (cont.)

• Flow line production
• Involves multiple workstation arranged in
  sequence.
• The parts or assemblies are physically moved
  through the sequence to complete the product.
• The work is usually moved between station by
  powered conveyor.
• The typical layout is the production layout

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Production Layout
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Hyundai
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Types of facilities and layouts
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High Production (cont.)

• Flow line production is where there is no
  variation in the products made on the line,
  called a single model production line.
• Mixed-model production line applies to a case of
  soft product variety in the products made on the
  line.

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Manufacturing Support Systems

• To operate the production facilities efficiently
• Support system do not directly contact the
  product, but they plan and control its progress
  through the factory
• Manufacturing support involve a cycle of
  information-processing activities.

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Manufacturing Support Systems

• Consisting of 4 function
• Business function
• Product design
• Manufacturing planning
• Manufacturing control

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Manufacturing Support Systems
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Automation in Production Systems

• Automation can be defined as a technology
  concerned with the application of mechanical,
  electronic, and comp.-based systems to operate
  and control production.
• Separated into 2 categories
• Automation of the Manufacturing system in factory
• Computerization of the manufacturing support
  systems.

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Automation in Production Systems
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Automated Manufacturing system includes (Operates
on Physical Product)

• Automated machine tools that process parts (Ex.
  NC CNC Machines)
• Automated Material handling (Ex. Power conveyor )
• Automated Guided vehicles
• Automated assembly system (Robots are used to
  perform assembly)
• Automatic storage retrieval
• Automatic inspection systems for quality control

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Automated Manufacturing Systems

• Classified into 3 basic types.
• Fixed Automation sequence of processing (or
  assembly) operations is fixed.
• Typical features of fixed automation are
• High initial investment (custom-engineered
  equipment)
• High production rate
• Relative inflexible in accommodating product
  variety

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Automated Manufacturing Systems

• Very large quantities and high production rate
• High initial cost of the equipment can be spread
  over a very large number of units
• Ex Machining transfer lines and Automated
  assembly machines.

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Automated Manufacturing Systems

• Programmable Automation
• The operation sequence is controlled by a
  program.
• New programs can be prepared and entered into the
  equipment to produce new products.
• Typical features of programmable automation are
• High investment in General purpose machines
• Low production rate than fixed automation

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Automated Manufacturing Systems

• Typical features of programmable automation are
• Flexibility to deal with variation and change in
  product configuration
• Changeover procedure takes time
• Include numerically controlled (NC) machine
  tools, in industrial robots, and programmable
  logic controllers.

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Automated Manufacturing Systems

• Flexible Automation
• No time lost for changeovers from one part style
  to the next
• Soft variety
• Typical features of flexible automation are
• High investment for Custom engineered systems
• Continuous production of variable mixtures of
  products

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Automated Manufacturing Systems

• Typical features of flexible automation are
• Medium production rate
• Flexible to deal with product design variations

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Automated Manufacturing Systems
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Computerization of the manufacturing support
systems

• Aimed at reducing the amount of manual clerical
  effort in production design, manufacturing
  planning control, and the business functions of
  the firm.
• CAD Computer Aided Design
• CAE Computer Aided Engineering
• CAPP Computer Aided Process Planning

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• CIM CAD CAE CAPP CAM
• Computer Integrated Manufacturing
• Extensive use of computer

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CIM
Top
Mgmt
OM
CAD
DNC
Robots
AGV
CAM
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Reasons for Automation

1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effect of labor shortage
4. To reduce or eliminate routing manual and
   clerical tasks
5. To improve worker safety

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Reasons for Automation

1. To improve product quality
2. To reduce manufacturing lead time
3. To accomplish processes that cannot be done
   manually
4. To avoid the high cost of not automating

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Manual Labor in Production System

• Is human operator needed in automated
  manufacturing plant?
• (1) Manual Labor in factory operation
• (2) Labor in Manufacturing Support system

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Manual Labor in factory operation

• Task is too difficult to automate
• Short Product life cycle
• Customized Product
• To Cope with ups downs in demand
• To reduce risk of product failure

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Labor in Manufacturing Support system

• CAD?
• Creativity
• CAE?
• Interpretation of result
• CAM?
• ----
• Decision making, learning, engineering,
  evaluating, managing, maintenance

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Automation principles Strategies

• Automation is not always right answer for a given
  production situation.
• Cautions
• 3 approaches for dealing with automation projects
• (1) The USA Principle
• (2) 10 Strategies for automation Production
  systems
• (3) Automation Migration Strategy

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(1) USA Principle

• APICS American Production Inventory Control
  Society
• 1 Understand existing process
• 2 Simplify the process
• 3 Automate the process

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(2) 10 Strategies for Aut. Prod.

• 1 Specialization of operations
• 2 Combined Operation
• 3 Simultaneous Operations
• 4 Integration of operations
• 5 Increased flexibility
• 6 Improved Material Handling Storage

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• 7 On-line inspection
• 8 Process control Optimization
• 9 Plant Operation Control
• 10 CIM

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Automation Migration Strategy

• Phase 1 Manual Production
• Phase 2 Automated Production
• Phase 3 Automated Integrated Production

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Automation Migration Strategy
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CNC Machines
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Power Conveyor
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Automatic Guided Vehicles
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Automatic assembly station
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Automatic Storage Retrieval
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Automatic Inspection system