ME 335 Manufacturing Processes

AUTOMATION IN MANUFACTURING
 INTRODUCTION

Sections:
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected
under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing
from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P.
Groover. 2
 The Realities of Modern Manufacturing
• Globalization - Once underdeveloped countries (e.g., China,
India, Mexico) are becoming major players in
manufacturing
• International outsourcing - Parts and products once made in
the United States by American companies are now being
made offshore (overseas) or near-shore (in Mexico and
Central America)
• Local outsourcing - Use of suppliers within the U.S. to
provide parts and services
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected
under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing
from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P.
Groover. 3
 More Realities of Modern Manufacturing

• Contract manufacturing - Companies that specialize in

manufacturing entire products, not just parts, under contract to
other companies
• Trend toward the service sector in the U.S. economy
• Quality expectations - Customers, both consumer and
corporate, demand products of the highest quality
• Need for operational efficiency - U.S. manufacturers must be
efficient in in their operations to overcome the labor cost
advantage of international competitors
 Modern Manufacturing Approaches and
Technologies
• Automation - automated equipment instead of labor
• Material handling technologies - because manufacturing
usually involves a sequence of activities
• Manufacturing systems - integration and coordination of
multiple automated or manual workstations
• Flexible manufacturing - to compete in the low-volume/high-
mix product categories
• Quality programs - to achieve the high quality expected by
today's customers
• CIM - to integrate design, production, and logistics
• Lean production - more work with fewer resources
 Production System Defined
A collection of people, equipment, and procedures
organized to accomplish the manufacturing operations of
a company
Two categories:
• Facilities – the factory and equipment in the facility and the
way the facility is organized (plant layout)
• Manufacturing support systems – the set of procedures used
by a company to manage production and to solve technical
and logistics problems in ordering materials, moving work
through the factory, and ensuring that products meet quality
standards
 The Production System

FİG. 1.1

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected
under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing
from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P.
Groover. 7
 Production System Facilities

Facilities include the factory, production machines and

tooling, material handling equipment, inspection equipment,
and computer systems that control the manufacturing
operations
Plant layout – the way the equipment is physically arranged in
the factory
Manufacturing systems – logical groupings of equipment and
workers in the factory
1. Production line
2. Stand-alone workstation and worker
 Manufacturing Systems

Three categories in terms of the human participation in

the processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or
more tasks without the aid of powered tools, but
sometimes using hand tools
2. Worker-machine systems - a worker operating
powered equipment
3. Automated systems - a process performed by a
machine without direct participation of a human
 Manual Work System

FİG. 1.2 (A)

 Worker-machine System

FİG. 1.2 (B)

 Automated System

FİG. 1.2. (C)

 Manufacturing Support Systems
Involves a cycle of information-processing activities that
consists of four functions:
1. Business functions - sales and marketing, order entry,
cost accounting, customer billing
2. Product design - research and development, design
engineering, prototype shop
3. Manufacturing planning - process planning,
production planning, MRP, capacity planning
4. Manufacturing control - shop floor control, inventory
control, quality control
Information Processing Cycle in Manufacturing
Support Systems
 AUTOMATION IN PRODUCTION SYSTEMS

Two categories of automation in the production system:

1. Automation of manufacturing systems in the factory
2. Computerization of the manufacturing support systems
• The two categories overlap because manufacturing support
systems are connected to the factory manufacturing systems
• Computer-integrated manufacturing (CIM)
 THE SOLUTION IS:

COMPUTER-INTEGRATED-
MANUFACTURING

(CIM)
COMPUTER INTEGRATED
MANUFACTURING
CIM HAS DIFFERENT DEFINITIONS FOR
DIFFERENT USERS

I. Shop communications
Ii. Recurring processes
Iii. Non-recurring processes
Iv. Engineering/manufacturing communication
V. Other users
Vi. Improving communication through CIM
 COMPUTER INTEGRATED
MANUFACTURING

Refers to the technology, tool or method used to improve entirely the design and
manufacturing process and increase productivity, to help people and machines to
communicate. It includes CAD (computer-aided design), CAM (computer-
aided manufacturing), CAPP (computer-aided process planning, CNC (computer
numerical control machine tools), DNC (direct numerical control machine
tools), FMS (flexible machining systems), ASRS (automated storage and
retrieval systems), AGV (automated guided vehicles), use of robotics and
automated conveyance, computerized scheduling and production control, and a
business system integrated by a common database. (Houston cole library)
Is the process of automating various functions in a
manufacturing company (business, engineering, and
production) by integrating the work through computer
networks and common databases. CIM is a critical element
in the competitive strategy of global manufacturing firms
because it lowers costs, improves delivery times and
improves quality. (Amatrol)
 COMPUTER-INTEGRATED
MANUFACTURING DEFINED:

• CIM is the integration of the total manufacturing enterprise

through the use of integrated systems and data communications
coupled with new managerial philosophies that improve
organizational and personal efficiency.
 WHAT IS CIM?

 C = Computer
i. Enabling tool
ii. Information flow
iii. Information management
 WHAT IS CIM?

I = integrated
I. Integration vs. Interfacing
Ii. Shared information
Iii. Shared functionality
M = manufacturing
I. Production control
Ii. Production scheduling
Iii. Process design
Iv. Product design
V. Manufacturing enterprise
CIM COMPONENTS OR SUBSYSTEMS INCLUDE:

CAD CNC

CAM DNC

CAPP ROBOTICS

CAE CONTROLLERS

ERP FMS

PLC ASRS

CAE AGV

COMPUTERS MONITORING EQUIPMENT

AUTOMATED CONVEYORS OTHERS

 AUTOMATED MANUFACTURING
SYSTEMS
Examples:
• Automated machine tools
• Transfer lines
• Automated assembly systems
• Industrial robots that perform processing or assembly
operations
• Automated material handling and storage systems to
integrate manufacturing operations
• Automatic inspection systems for quality control
 AUTOMATED MANUFACTURING
SYSTEMS

Three basic types:

1. Fixed automation
2. Programmable automation
3. Flexible automation
 FIXED AUTOMATION

A manufacturing system in which the 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
 PROGRAMMABLE AUTOMATION

A manufacturing system designed with the capability to

change the sequence of operations to accommodate
different product configurations
Typical features:
• High investment in general purpose 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)
 FLEXIBLE AUTOMATION

An extension of programmable automation in which the system

is capable of changing over from one job to the next with no 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
Product Variety And Production Quantity For
Three Automation Types
 COMPUTERIZED MANUFACTURING
SUPPORT SYSTEMS

Objectives of automating the manufacturing support systems:

• To reduce the amount of manual and clerical effort in product
design, manufacturing planning and control, and the business
functions
• Integrates computer-aided design (CAD) and computer-aided
manufacturing (CAM) in CAD/CAM
• CIM includes CAD/CAM and the business functions of the
firm
 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
 Manual Labor in Production Systems

Is there a place for manual labor in the modern

production system?
• Answer: yes

• Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems
 Manual Labor in Factory Operations

The long term trend is toward greater use of automated

systems to substitute for manual labor
• When is manual labor justified?
• Some countries have very low labor rates and
automation cannot be justified
• Task is too technologically difficult to automate
• Short product life cycle
• Customized product requires human flexibility
• To cope with ups and downs in demand
• To reduce risk of product failure
 LABOR IN MANUFACTURING SUPPORT
SYSTEMS

• Product designers who bring creativity to the design task

• Manufacturing engineers who
• Design the production equipment and tooling
• And plan the production methods and routings
• Equipment maintenance
• Programming and computer operation
• Engineering project work
• Plant management
 AUTOMATION PRINCIPLES AND
STRATEGIES

1. The USA principle

2. Ten strategies for automation and process improvement
3. Automation migration strategy
 U.S.A 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
 Ten Strategies For Automation and Process
Improvement
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
 AUTOMATION MIGRATION STRATEGY
FOR INTRODUCTION OF NEW PRODUCTS

1. Phase 1 – manual production

• Single-station manned cells working independently
• Advantages: quick to set up, low-cost tooling
2. Phase 2 – automated production
• Single-station automated cells operating independently
• As demand grows and automation can be justified
3. Phase 3 – automated integrated production
• Multi-station system with serial operations and automated
transfer of work units between stations
AUTOMATION
MIGRATION
STRATEGY