MM 418 MANUFACTURING SYSTEMS

INTRODUCTION
 What is Manufacturing?
The word manufacture is derived from two Latin words
manus (hand) and factus (make); the combination
means “made by hand”
▪ “Made by hand” accurately described the fabrication
methods that were used when the English word
“manufacture” was first coined around 1567 A.D.
▪ Most modern manufacturing operations are
accomplished by mechanized and automated
equipment that is supervised by human workers
Production System:
All aspects of workers, machines, and
information, considered collectively
needed to manufacture products.

o- Manufacturing System:
The collection of manufacturing
processes and operations resulting in
specific end products; an arrangement
'» or layout of many processes
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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
Manufacturing Systems in the Production
System
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
 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
Example for Single-station cells
Job (Station):
A collection of operations done on
machines or a collection of tasks §
performed by one worker at one
location on an assembly line.
EXAMPLES: Operation of machines,
inspection, assembly, moving materials

Operation (Process):
A specific action or treatment, the
collection of which makes up the job
of a worker.
EXAMPLES: Drilling, milling, forging, etc.
Tools (Tooling)
Refers to the implements used to
hold, cut, shape or deform the work
materials.
Cutting Tools: for machining
Jigs & Fixtures: for workholding
Punches & Dies: for metal forming
 Manufacturing - Technologically
Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a starting material to make parts or products
▪ Manufacturing also includes assembly
▪ Almost always carried out as a sequence of
operations

Manufacturing
as a technical
process
 Manufacturing - Economically
Transformation of materials into items of greater
value by means of one or more processing and/or
assembly operations
▪ Manufacturing adds value to the material by
changing its shape or properties, or by combining
it with other materials

Manufacturing
as an economic
process
 Manufacturing Capability
A manufacturing plant consists of processes and
systems (and people, of course) designed to
transform a certain limited range of materials
into products of increased value
▪ The three building blocks - materials,
processes, and systems - are the subject of
modern manufacturing
▪ Manufacturing capability includes:
1. Technological processing capability
2. Physical product limitations
3. Production capacity
 Limitations and Capabilities of a
Manufacturing Plant

Manufacturing capability - the technical and physical

limitations of a manufacturing firm and each of its plants
Three dimensions of manufacturing capability:
1. Technological processing capability - the available set of
manufacturing processes
2. Physical size and weight of product
3. Production capacity (plant capacity) – max production
quantity that can be made in a given time under assumed
operating conditions
1. Technological Processing Capability
The available set of manufacturing processes in
the plant (or company)
▪ Certain manufacturing processes are suited to
certain materials
▪ By specializing in certain processes, the
plant is also specializing in certain materials
▪ Includes not only the physical processes, but
also the expertise of the plant personnel
▪ Examples:
▪ A machine shop cannot roll steel
▪ A steel mill cannot build cars
 2. Physical Product Limitations
Given a plant with a certain set of processes,
there are size and weight limitations on the
parts or products that can be made in the plant
▪ Product size and weight affect:
▪ Production equipment
▪ Material handling equipment
▪ Production, material handling equipment, and
plant size must be planned for products that lie
within a certain size and weight range
 3. Production Capacity
Defined as the maximum quantity that a plant
can produce in a given time period (e.g.,
month or year) under assumed operating
conditions
▪ Operating conditions refer to number of
shifts per week, hours per shift, direct labor
manning levels in the plant, and so on
▪ Usually measured in terms of output units,
such as tons of steel or number of cars
produced by the plant
▪ Also called plant capacity
There are certain basic activities that must be carried out
in a factory to convert raw materials into finished
products
For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control
A processing operation transforms a work material from one state of
completion to a more advanced state using energy to alter its shape,
properties or appearance to add value to the material.
 Manufacturing Processes
Manufacturing processes
▪ Converts unfinished materials to finished products
Often is a set of steps
▪ Machine tool is an assembly that produces a desired result

Two basic types:

1. Processing operations - transform a work material from one
state of completion to a more advanced state
▪ Operations that change the geometry, properties, or
appearance of the starting material
2. Assembly operations - join two or more components to
create a new entity
Classification of manufacturing processes
 Processing Operations

Alters a material’s shape, physical properties, or

appearance in order to add value
▪ Three categories of processing operations:
1. Shaping operations - alter the geometry of the
starting work material
2. Property-enhancing operations - improve
physical properties without changing shape
3. Surface processing operations - to clean,
treat, coat, or deposit material on exterior
surface of the work
Shaping Processes – Four Categories
1. Solidification processes - starting material
is a heated liquid or semifluid
2. Particulate processing - starting material
consists of powders
3. Deformation processes - starting material
is a ductile solid (commonly metal)
4. Material removal processes - starting
material is a ductile or brittle solid
 Solidification Processes
Starting material is heated sufficiently to
transform it into a liquid or highly plastic state
▪ Examples: metal casting, plastic molding
 Particulate Processing
Starting materials are powders of metals or
ceramics
▪ Usually involves pressing and sintering, in
which powders are first compressed and then
heated to bond the individual particles
 Deformation Processes
Starting workpart is shaped by application of
forces that exceed the yield strength of the
material
▪ Examples: (a) forging, (b) extrusion
 Material Removal Processes
Excess material removed from the starting piece
so what remains is the desired geometry
▪ Examples: machining such as turning, drilling,
and milling; also grinding and nontraditional
processes
 Waste in Shaping Processes
Desirable to minimize waste in part shaping
▪ Material removal processes are wasteful in
unit operations, simply by the way they work
▪ Most casting, molding, and particulate
processing operations waste little material
▪ Terminology for minimum waste processes:
▪ Net shape processes - when most of the
starting material is used and no
subsequent machining is required
▪ Near net shape processes - when
minimum amount of machining is required
Property-Enhancing Processes
Performed to improve mechanical or physical
properties of work material
▪ Part shape is not altered, except
unintentionally
▪ Example: unintentional warping of a heat
treated part
▪ Examples:
▪ Heat treatment of metals and glasses
▪ Sintering of powdered metals and ceramics
 Surface Processing Operations
▪ Cleaning - chemical and mechanical
processes to remove dirt, oil, and other
contaminants from the surface
▪ Surface treatments - mechanical working
such as sand blasting, and physical
processes like diffusion
▪ Coating and thin film deposition - coating
exterior surface of the workpart
 Assembly Operations
Two or more separate parts are joined to form a new entity.
In assembly, the distinguishing feature is that two or more separate
components are joined together. Examples are; 1) mechanical fastening
operations, which make use of screws, nuts, rivets, etc., and 2)joining
processes, such as welding, brazing, and soldering.

▪ Types of assembly operations:

1. Joining processes – create a permanent joint
▪ Welding, brazing, soldering, and adhesive bonding
2. Mechanical assembly – fastening by mechanical
methods
▪ Threaded fasteners (screws, bolts and nuts); press
fitting, expansion fits
Other Factory Operations that require new sytems

• Material Handling and

Storage Systems
• Inspection and testing Systems
• Coordination and control Systems
Inspection and Testing
Inspection and testing are generally considered part of
quality control. The purpose of inspection is to determine
whether the manufactured product meets the established
design standards and specifications. For example,
inspection examines whether the actual dimensions of a
mechanical part are within the tolerances indicated on the
engineering drawing for the part.

Testing is generally concerned with the functional

specifications of the final product rather than the individual
parts that go into the product. For example, final testing of
the product ensures that it functions and operates in the
manner specified by the product designer.
Inspection and Testing

Inspection – examination of the product and its

components to determine whether they conform to
design specifications
▪ Inspection for variables - measuring
▪ Inspection of attributes – gaging
Testing – observing the product (or part, material,
subassembly) during actual operation or under
conditions that might occur during operation
Hardness testing equipments
Measurement by a gage
A tensile testing machine
An ultrasonic testing device
 Computer Control System
The control function in manufacturing includes both the
regulation of individual processing and assembly
operations, and the management of plant-level activities.

• Control at the process level involves the achievement of

certain performance objectives by proper manipulation of
the inputs to the process.
• Control at the plant level includes effective use of labor,
maintenance of the equipment, moving materials in the
factory, shipping products of good quality on schedule,
and keeping plant operating costs at the minimum level
possible.
Manufacturing control
Manufacturing control is concerned with managing
and controlling the physical operations in the factory to
implement the manufacturing plans. The flow of
information is from planning to control. Information also
flows back and forth between manufacturing control and
the factory operations.

Included with the control function are shop floor control,

inventory control, quality control, and various other
control activities. Process control is also included if the
plant uses automatic process control in its operations.
 Shop Floor Control
Shop floor control is concerned with the problem of monitoring the
progress of the product as it is being processed, assembled, moved, and
inspected in the factory. The sections of a traditional production planning
and control department that are involved in shop floor control include
scheduling, dispatching, and expediting. Production scheduling is
concerned with assigning start dates and due dates to the various parts
(and products) that are to be made in the factory. This requires that the
parts be scheduled one by one through the various production machines
listed on the route sheet for each part. Based on the production schedule,
dispatching involves issuing the individual work orders to the machine
operators to accomplish the processing of the parts. The dispatching
function is performed in some plants by the shop foremen, in other plants
by a person called the dispatcher. Even with the best plans and
schedules, things sometimes go wrong (e.g., machine breakdowns,
improper tooling, parts delayed at the vendor). The expediter compares
the actual progress of a production order against the schedule. For orders
that fall behind, the expediter attempts to take the necessary corrective
action to complete the order on time.
Inventory control

Inventory control attempts to strike a proper

balance between the danger of too little inventory (with
possible stock-outs of materials) and the expense of
having too much inventory. Shop floor control is also
concerned with inventory in the sense that the materials
being processed in the factory represent inventory
(called work-in-process).
Quality control

Quality control assures that the quality of the

product and its components meet the standards
specified by the product designer. To accomplish
its mission, quality control depends on the
inspection activities performed in the factory at
various times throughout the manufacture of the
product. Also, raw materials and components from
outside sources must be inspected when they are
received. Final inspection and testing of the
finished product is performed to ensure functional
quality and appearance.
Computer Control System
Typical computer functions in a manufacturing
system:
▪ Communicate instructions to workers
▪ Download part programs to computer-controlled
machines
▪ Control material handling system
▪ Schedule production
▪ Failure diagnosis when malfunctions occur
▪ Safety monitoring
▪ Quality control
▪ Operations management
 MM 418 MANUFACTURING SYSTEMS

MATERIAL HANDLING AND STORAGE SYSTEMS

 Material Handling
A means of moving and storing materials between
processing and/or assembly operations
Material transport
▪ Vehicles, e.g., forklift trucks, AGVs, monorails
▪ Conveyors
▪ Hoists and cranes
Also used as storage systems
Unitizing equipment
Automatic identification and data capture (AIDC)
▪ Bar codes
▪ RFID
▪ Other AIDC equipment
 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
 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
(a) Fixed Routing and (b) Variable Routing
Material Transport Equipment

Five categories:
1. Industrial trucks
2. Automated guided vehicles
3. Monorails and other rail guided vehicles
4. Conveyors
5. Cranes and hoists
Industrial Trucks
Two basic categories:
1. Non-powered
▪ Human workers push or pull loads
2. Powered
▪ Self-propelled, guided or driven by human
▪ Common example: forklift truck
 Nonpowered Industrial Trucks
(Hand Trucks)

(a) Two-wheel hand truck, (b) four-wheel dolly, (c) hand-

operated low-lift pallet truck
Unit Load Containers

(a) Wooden pallet, (b) pallet box, (c) tote box

Powered Trucks:
Walkie Truck

Wheeled forks insert into pallet openings

No provision for riding; truck is steered by worker
using control handle at front of vehicle
 Powered Trucks:
Forklift Truck

Widely used in factories and

warehouses because
pallet loads are so
common
Capacities from 450 kg
(1000 lb) up to 4500 kg
(10,000 lb)
Power sources include on-
board batteries and
internal combustion
motors
Powered Trucks:
Towing Tractor

Designed to pull one or more trailing carts in

factories and warehouses, as well as for airport
baggage handling
Powered by on-board batteries or IC engines
Automated Guided Vehicles
An Automated Guided Vehicle System (AGVS) is
a material handling system that uses
independently operated, self-propelled vehicles
guided along defined pathways in the facility
floor
Types of AGV:
▪ Driverless trains
▪ Pallet trucks
▪ Unit load AGVs
 Automated Guided Vehicles:
Driverless Automated Guided Train
First type of AGVS to be
introduced around
1954
Common application is
moving heavy
payloads over long
distances in
warehouses and
factories without
intermediate stops
along the route
 Automated Guided Vehicles:
AGV Pallet Truck
Used to move palletized
loads along
predetermined routes
Vehicle is backed into
loaded pallet by
worker; pallet is then
elevated from floor
Worker drives pallet
truck to AGV guide
path and programs
destination
Automated Guided Vehicles:
Unit Load Carrier

Used to move unit loads from station to station

Often equipped for automatic loading/unloading of
pallets and tote pans using roller conveyors,
moving belts, or mechanized lift platforms
 Rail-Guided Vehicles

Self-propelled vehicles that ride on a fixed-rail system

Vehicles operate independently and are driven by electric
motors that pick up power from an electrified rail
Fixed rail system
▪ Overhead monorail - suspended overhead from the ceiling
▪ On-floor - parallel fixed rails, tracks generally protrude up
from the floor
Routing variations are possible: switches, turntables, and
other special track sections
Overhead Monorail
 Conveyor Systems

Large family of material transport equipment designed

to move materials over fixed paths, usually in large
quantities or volumes
1. Non-powered
▪ Materials moved by human workers or by gravity
2. Powered
▪ Power mechanism for transporting materials is
contained in the fixed path, using chains, belts, rollers
or other mechanical devices
 Conveyor Types

Roller
Skate-wheel
Belt
In-floor towline
Overhead trolley conveyor
Cart-on-track conveyor
 Roller Conveyor

Pathway consists of a series

of rollers that are
perpendicular to direction
of travel
Loads must possess a flat
bottom to span several
rollers
Powered rollers rotate to drive
the loads forward
Un-powered roller conveyors
also available
 Skate-Wheel Conveyor

Similar in operation to roller

conveyor but use skate
wheels instead of rollers
Lighter weight and
unpowered
Sometimes built as portable
units that can be used for
loading and unloading
truck trailers in shipping
and receiving
 Belt Conveyor

Continuous loop with

forward path to move
loads
Belt is made of reinforced
elastomer
Support slider or rollers
used to support forward
loop
Two common forms: (Support frame not shown)
▪ Flat belt (shown)
▪ V-shaped for bulk
materials
 In-Floor Tow-Line Conveyor

Four-wheel carts powered by

moving chains or cables in
trenches in the floor
Carts use steel pins (or
grippers) to project below
floor level and engage the
chain (or pulley) for towing
This allows the carts to be
disengaged from towline
for loading and unloading
 Overhead Trolley Conveyor

A trolley is a wheeled carriage

running on an overhead
track from which loads can
be suspended
Trolleys are connected and
moved by a chain or cable
that forms a complete loop
Often used to move parts and
assemblies between major
production areas
 Cart-On-Track Conveyor

Carts ride on a track

above floor level
Carts are driven by a
spinning tube
Forward motion of cart
is controlled by a
drive wheel whose
angle can be
changed from zero
(idle) to 45 degrees
(forward)
 Powered Conveyor
Operations and Features
Types of motions
1. Continuous - conveyor moves at constant velocity
2. Asynchronous - conveyor moves with stop-and-go motion
They stop at stations, move between stations
Another classification of conveyors:
1. Single direction
2. Continuous loop
3. Recirculating
 (a) Single-Direction Conveyor and
(b) Continuous Loop Conveyor

(a) Single direction

conveyor

(b) Continuous loop

conveyor
 Cranes and Hoists

Handling devices for lifting, lowering and transporting

materials, often as heavy loads
Cranes
▪ Used for horizontal movement of materials
Hoists
▪ Used for vertical lifting of materials
Cranes usually include hoists so that the crane-and-hoist
combination provides
▪ Horizontal transport
▪ Vertical lifting and lowering
 Hoist

Hoist with mechanical

advantage of four:
(a) sketch of the hoist
(b) diagram to
illustrate mechanical
advantage

(a) (b)
Bridge Crane
 Gantry Crane

A half-gantry crane
Jib Crane
EXAMPLES (An inclined conveyor system)
EXAMPLES (A chain drive conveyor)
EXAMPLES (An overhead travelling crane)
EXAMPLES (A fork lift unit)
Time Spent in Material Handling
 Storage Systems
to store materials (e.g., parts, work-in-process, finished
goods) for a period of time and permit retrieval when
required
Performance measures for storage systems:
Storage capacity - two measures:
▪ Total volumetric space
▪ Total number of storage compartments (e.g., unit loads)
Storage density - volumetric space available for storage relative to total
volumetric space in facility
Accessibility - capability to access any item in storage
System throughput - hourly rate of storage/retrieval transactions
Utilization and availability (reliability)
 Conventional Storage Methods

Bulk storage - storage in an open floor area

▪ Problem: achieving proper balance between storage density
and accessibility
Rack systems - structure with racks for pallet loads
▪ Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural frame
▪ Steel shelving comes in standard sizes
▪ Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
 Bulk Storage

Bulk storage arrangements:

(a) high-density bulk storage provides low accessibility,
(b) bulk storage with loads forming rows and blocks for improved accessibility
(c) Low cost per sq meter
 Pallet Rack System

Pallet loads placed on

racks in multi-rack
structure
(a) Low cost
(b) Good stroge density
(c) Good accessibility
 Drawer Storage

Contents easily visible

Good accessibility
Relatively high cost

Small items (tools,

repair parts, etc.)
 Automated Storage Systems

Mechanized and automated storage equipment to reduce

the human resources required to operate a storage facility
Significant investment
Level of automation varies
▪ In mechanized systems, an operator participates in each
storage/retrieval transaction
▪ In highly automated systems, loads are entered or retrieved
under computer control
 Objectives and Reasons for
Automating Storage Operations
To increase storage capacity
To increase storage density
To recover factory floor space currently used for WIP
To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput
 Types of Automated Storage System

1. Automated Storage/Retrieval System (AS/RS)

▪ Rack system with mechanized or automated crane to
store/retrieve loads
2. Carousel Storage System
▪ Oval conveyor system with bins to contain individual items
 AS/RS

Unit load on
pallet AS/RS
with one aisle
 AS/RS Types

Unit load AS/RS - large automated system for pallet loads

Deep-lane AS/RS - uses flow-through racks and fewer
access aisles
Miniload AS/RS - handles small loads contained in bins or
drawers to perform order picking
Man-on-board AS/RS - human operator rides on the
carriage to pick individual items from storage
Automated item retrieval system - picks individual items
Vertical lift storage modules (VLSM) - uses a vertical aisle
rather than a horizontal aisle as in other AS/RS types
 AS/RS Applications

1. Unit load storage and retrieval

▪ Warehousing and distribution operations
▪ AS/RS types: unit load, deep lane (food industry)
2. Order picking
▪ AS/RS types: miniload, man-on-board, item retrieval
3. Work-in-process storage
▪ Helps to manage WIP in factory operations
▪ Buffer storage between operations with different production rates
▪ Supports JIT manufacturing strategy
▪ Kitting of parts for assembly
 Carousel Storage Systems

Horizontal
▪ Operation is similar to overhead conveyor system used in
dry cleaning establishments
▪ Items are stored in bins suspended from the conveyor
▪ Lengths range between 3 m and 30 m
▪ Horizontal is most common type
Vertical
▪ Operates around a vertical conveyor loop
▪ Less floor space required, but overhead room must be
provided
 Horizontal Carousel Storage System

Manually operated
horizontal
carousel storage
system
 Carousel Applications

1. Storage and retrieval operations

▪ Order picking
▪ Kitting of parts for assembly
2. Transport and accumulation
▪ Progressive assembly with assembly stations located
around carousel
3. Work-in-process
▪ WIP applications in electronics industry are common
4. Unique applications
▪ Example: time testing of electrical products
MM 418 MANUFACTURING SYSTEMS

PRODUCTION AND LAYOUT TYPES

 THERE ARE TWO INDUSTRY TYPES
THAT FACTORIES ARE LOCATED IN
1) Process industries, e.g., chemicals, petroleum, basic metals,
foods and beverages, power generation
– Continuous production
– Batch production
2) Discrete product (and part) industries, e.g., cars, aircraft,
appliances, machinery, and their component parts
– Continuous production (MASS PRODUCTION)
– Batch production
 Production Facilities
• A manufacturing company attempts to organize
its facilities in the most efficient way to serve the
particular mission of the plant
• Certain types of plants are recognized as the most
appropriate way to organize for a given type of
manufacturing
• The most appropriate type depends on:
– Types of products made (in this course only DISCRETE)
– Production quantity per product type per year (Q)
– Product variety (N)
∑(Production Quantity per product type per year) must be
high enough to recover FIXED COSTS.

• If we can find a product which has high production quantity per

type (STANDART PRODUCTS), then we don’t need to increase the
product variety.

• Otherwise, to make the total production quantity HIGH enough

to recover fixed costs and pay annual variable expenses we have
to increase the variety which reduces similarity in the product
types as we include more different types.

• QUANTITY PER PRODUCT TYPE IS CRITICAL. VARIETY DEPENDS ON

PRODUCTION QUANTITY PER TYPE.
 Production Quantity
Number of units of a given part or product
type 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
 Product Variety
Refers to the number of different product or part
designs or types produced in the plant
• Inverse relationship between production quantity
and product variety in factory operations
• Product variety is more complicated than a number
– Hard product variety – products differ greatly
• Few common components in an assembly
– Soft product variety – small differences between
products (MODELS)
• Many common components in an assembly
 Product Variety vs.
Production Quantity
Relationships between Plant Layout and
Type of Production Facility
PRODUCTION AND LAYOUT TYPES
Product Variety
High

JOB SHOP
Process (Function)
Layout

Medium
BATCH PRODUCTION
Process (Function) Layout
CELLULAR MANUFACTURING
Group Technology (Cellular)
Layout

MASS PRODUCTION
JOB SHOP
Product Layout
Low Fixed Position (Production Line; Flow
(Location) Layout Shop; Assembly Line)

Low Medium High Volume

(Production quantity per product type per year)
 Few High
Low Multiple Major Volume,
Volume, Products, Products, High
One of a Low Higher Standard-
Kind Volume Volume ization
I. Commercial Flexibility (High)
Job Printer Unit Cost (High)
Shop French Restaurant
These are
the major
II. Heavy stages of
Batch Equipment product and
process life
III. cycles
Automobile
Mass Production
Assembly
Burger King
IV.
Sugar
Continuous Refinery Flexibility (Low)
Flow Unit Cost (Low)
 Low Production Quantity
JOB SHOP PRODUCTION TYPE – makes low quantities of specialized and customized products

• Low volume production, often one of a kind

• Large variety of parts
• Small lot sizes
• Generally used for specific customer orders
• Flexible and general purpose equipment
• Flexible material handling (human-driven)
• Skilled workers
• Products are typically complex
Examples: Space vehicles, aircraft, specialized machinery and machine tools, special tools,
prototypes of future products
• Also includes production of components for these products

In Job Shop Productıon Type two types of plant layouts are used:
– FIXED POSITION LAYOUT
– PROCESS (FUNCTION) LAYOUT
Fixed Position Layout
 Fixed Position Layout

lathe welding

Raw materials
PRODUCT

press paint
 Fixed Position Layout
Production is executed at a fixed location; materials, equipment, and
personnel flow into this location.

This type of layout is usually required by the nature of the product

• Advantages
– Material movement is reduced
– An individual can complete the whole process
– Highly flexible; can accommodate any changes in design
• Disadvantages
– Personal and equipment movement is increased
– Risk of duplication of equipment
– Requires greater worker skills
– Not suitable for high production volumes
AN EXAMPLE FOR FIXED POSITION LAYOUT: Assembly operations on the
Boeing 777
Process Layout
 Process Layout

STORAGE
assemble assemble
lathe lathe
drill

lathe assemble assemble

drill

assemble assemble

mill mill
grind paint paint

mill
mill grind paint paint
mill
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 In PROCESS LAYOUT
Similar/Same processes are grouped together.

• Advantages
– General purpose equipments can be used
– General purpose equipments are cheaper
– Robust against machine breakdowns
– Robust again design, volume changes

• Disadvantages
– Material handling requirements are increased
– Increased WIP
– Difficult to schedule the jobs
– Higher skills are required
– Difficult to analyze the process performance
 Characteristics
of Process Layouts
• Low Volume, High Variety Production with Random Routing
(Spaghetti-Like Flow)
• General Purpose Machines--
– Machine setups are frequent and long
– Work-In-Process -- High
– Throughput Rates tend to be Low
– Material Handling -- High
– Operator Utilization -- Low?
– Throughput Times (Lead Time) -- High
• System is Very Flexible, produces many different types of
parts: gears, shafts, pinions, housings, clamps, etc.
 Lathe Milling Drilling
Department Department Department
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 Medium Production Quantities
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
 In Batch Production:

• Medium-sized lots of the same product

• Lots are often produced at regular intervals
• Generally used for continuous customer demand
for a product
• General purpose equipment but designed for
high production rate
• Examples: Machine shops, casting foundries,
plastic molding factories, pressworking shops
Cellular Layout (MACHINE CELLS)
1)Part Families are formed.
2) Machines are grouped according to the processes required for part families. (MACHINE
CELLS)
3) Each cell is in fact a production line for its part family and it becomes independent for
detailed scheduling and control.
A machining cell consisting of two horizontal machining centers supplied by an in-
line pallet shuttle
High Production (MASS PRODUCTION)
1. Quantity production – Equipment is dedicated to the mass manufacture
of one/single product
– Standard machines tooled for high production (e.g., stamping presses,
molding machines Punch presses, injection molding machines,
automatic screwdrivers)
– Typical layout: process layout

2. Flow line production (automated flow lines, assembly lines)

– Multiple workstations arranged in sequence
– Product requires multiple processing or assembly steps
– Physical flow of products

– Typical Layout: Product layout (PRODUCTION LINE;

TRANSFER LINE) is most common
 In Mass Production:
• Continuous specialized production of identical
products.
• Very high production rates
• Special purpose equipment, dedicated to one
product
• Often entire plant is designed for the
manufacture of a particular product
• Lower labor skills
 In QUANTITY Production:
Quantity production involves the mass production of
single parts on fairly standard machine tools such as
punch presses, injection molding machines, and
automatic screw machines. Examples of items in
quantity production include components for
assembled products that have high demand rates
(automobiles, some household appliances, light
bulbs, etc.), hardware items (such as screws, nuts,
and nails), and many plastic molded products.
 In FLOW LINE Production:
In “Flow production” either complex single parts
(such as automotive engine blocks) or assembled
products are made to "flow" through a sequence of
operations by material handling devices (conveyors,
moving belts, transfer devices, etc.). Examples of
flow production include automated transfer
machines for the production of complex discrete
parts, and manual assembly lines for the assembly
of complex products. These products require
multiple operations at different machines; they can
not be manufactured in one single machine.
 CHARACTERISTICS
Product Line Layout
• High volume production
• Machines are ordered in lines according to the
operation sequence of one or more part types which
are very similar to each other

• Dedicated/Special purpose machines and automated

material handling equipment
– Throughput rates--high
– Work-in-process--low
– Long setup times but Setup/Run time ratio--low
• System is very inflexible
• Control is relatively simple
Production Line (FLOW LINE---
ASSEMBLY LINE) Layout
 Production Line (FLOW LINE---ASSEMBLY
LINE) Layout
The product flows through an flow line while the personnel
and equipment movements are limited

Customer, WS 3 WS 4 Finished
WS 1 WS 2
Material, or Goods
Components

Suitable for Repeated and Continuous Processes

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IN
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MACHINES ARE
LOCATED
ACCORDING
TO THE
PROCESS PLAN
(SEQUENCE OF
PROCESSES)
The moving assembly line for cars is an example of the flow shop.
Robotic Assembly Line
Assembly workers on an engine assembly line inFord Motor Company.
 Manufacturing Models and Metrics

Sections:
1. Mathematical Models of Production Performance
2. Manufacturing Costs
 Production Concepts and
Mathematical Models

▪ Production rate Rp
▪ Production capacity PC
▪ Utilization U
▪ Availability A
▪ Manufacturing lead time MLT
▪ Work-in-progress WIP
 Operation Cycle Time

Typical cycle time for a production operation:

Tc = To + Th + Tth
where
Tc = cycle time,
To = processing time for the operation,
Th = handling time (e.g., loading and unloading the
production machine), and
Tth = tool handling time (e.g., time to change tools)
 Production Rate

Batch production: batch time Tb = Tsu + QTc

Average production time per work unit Tp = Tb/Q
Production rate Rp = 1/Tp
Job shop production:
For Q = 1, Tp = Tsu + Tc
For quantity high production:
Rp = Rc = 60/Tp since Tsu/Q → 0
For flow line production
Tc = Tr + Max To and Rc = 60/Tc
In FLOW LINES, it is easy to calculate OVERALL PRODUCTION
RATE (units/hour) and Capacity (units/month).
12 Units/Hr 10 Units/Hr 12 Units/Hr
5 Mins/Unit 6 Mins/Unit 5 Mins/Unit

Work Work Work

Centre Centre Centre
1 2 3

• Overall Production Rate = 10 Units per Hour

• Slowest Work Centre (BOTTLENECK) Determines
OVERALL PRODUCTION RATE OF THE SYSTEM.
CAN WE EASILY CALCULATE PRODUCTION RATE
OF A JOB SHOP (which has FUNCTION LAYOUT)?

In function layouts, there are more than one product type.

Each product type has a unique routing and process plan.
When product mix or new product types are introduced to
the system, changes, the overall production rate also
changes. There is NO single production rate for the
function layout. There may be more than one bottleneck in
the system. The bottleneck(s) also change(s) in the system.
 Production Capacity

Plant capacity for facility in which parts are made in

one operation (no = 1):
PCw = n Sw Hs Rp
where PCw = weekly plant capacity, units/wk
Plant capacity for facility in which parts require
multiple operations (no > 1):

nSw H s R p
PCw =
no
where no = number of operations in the routing
 Utilization and Availability
Q
Utilization: U =
PC

where Q = quantity actually produced, and

PC = plant capacity

MTBF − MTTR
Availability: A =
MTBF
where MTBF = mean time between failures, and
MTTR = mean time to repair
Availability -
MTBF and MTTR Defined
 Manufacturing Lead Time

MLT = no (Tsu + QTc + Tno)

where MLT = manufacturing lead time,

no = number of operations,
Tsu = setup time,
Q = batch quantity,
Tc = cycle time per part, and
Tno = non-operation time
 Work-In-Process

AU ( PC )( MLT )
WIP =
S w H sh
where WIP = work-in-process, pc;
A = availability, U = utilization,
PC = plant capacity, pc/wk;
MLT = manufacturing lead time, hr;
Sw = shifts per week,
Hsh = hours per shift, hr/shift
 Costs of Manufacturing Operations

▪ Two major categories of manufacturing costs:

1. Fixed costs - remain constant for any output level
2. Variable costs - vary in proportion to production
output level
▪ Adding fixed and variable costs
TC = FC + VC(Q)
where TC = total costs,
FC = fixed costs (e.g., building, equipment, taxes),
VC = variable costs (e.g., labor, materials, utilities),
Q = output level.
Fixed and Variable Costs
 Manufacturing Costs

▪ Alternative classification of manufacturing costs:

1. Direct labor - wages and benefits paid to workers
2. Materials - costs of raw materials
3. Overhead - all of the other expenses associated with
running the manufacturing firm
▪ Factory overhead
▪ Corporate overhead
Typical Manufacturing Costs
 Overhead Rates

Factory overhead rate:

FOHC
FOHR =
DLC
Corporate overhead rate:

COHC
COHR =
DLC

where DLC = direct labor costs

 Cost of Equipment Usage

Hourly cost of worker-machine system:

Co = CL(1 + FOHRL) + Cm(1 + FOHRm)

where Co = hourly rate, $/hr;

CL = labor rate, $/hr;
FOHRL = labor factory overhead rate,
Cm = machine rate, $/hr;
FOHRm = machine factory overhead rate
MM 418 MANUFACTURING SYSTEMS

AUTOMATION IN MANUFACTURING
SYSTEMS
 Automation is a technology concerned with the
application of mechanical, electronic, and computer-
based systems to operate and control production.
Automation includes:
• Automatic machine tools to process parts
• Automatic assembly machines
• Industrial robots
• Automatic material handling and storage systems
• Automatic inspection systems for quality control
• Feedback control and computer process control
• Computer systems for planning, data collection, and decision making
to support manufacturing activities
Various Manufacturing System Types that
are used in practice
▪ Transfer Line (flow line, flow shop):
❑ dedicated machines, almost no flexibility; max. utilization & high throughput;
minimal labor; low unit cost.
▪ Special Manufacturing System (Flexible Transfer Line):
❑ fixed path material handling system; multi-spindle heads; low-level controller;
high production rate & low unit production cost.
▪ Flexible Manufacturing System:
❑ mid-volume & mid-variety; CNC + automated material handling +
supervisory computer control; sequential and random routing of parts.
▪ Manufacturing Cell:
❑ low-to-medium volume; batch production; more flexible than an FMS but
lower production rate.
▪ Stand-Alone NC:
❑ high flexibility; low utilization & low production volume; unit cost higher that
transfer line.
 Volume – Variety Relationship

High Transfer
Line

Special
Part Volume

System
Medium Flexible
Manufacturing
System
Manufacturing
Cell
Stand-Alone
Low NC Machines
Low Medium High

Variety of Parts
QUESTIONS RELATED WITH AUTOMATION:

1) WHY IS AUTOMATION SO IMPORTANT?

2) HOW IS AUTOMATION APPLIED?
3) WHAT KIND OF SYSTEMS DO WE GET WITH
THE APPLICATION OF AUTOMATION?
4) WHAT ARE THE BENEFITS OBTAINED WITH
THE APPLICATION OF AUTOMATION?
5) IS IT NECESSARY TO AUTOMATE THE
FACTORIES?
 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 when manufacturing
support systems are connected to the factory
manufacturing systems
❑ Computer-Integrated Manufacturing (CIM)
 MECHANIZATION
▪ Mechanization is running a process or
operation with the use of mechanical,
hydraulic, pneumatic, or electrical
devices.

▪ In mechanized systems, the operator still

directly controls the process, and must
check each step of the machine’s
performance.
 AUTOMATION

▪ Automation is a technology concerned with

the application of mechanical, electronic,
and computer-based systems to operate
and control production with little or no
human interaction.

▪ Who is the Controller and Decision Maker?

DESIGNER/PROGRAMMER not the
operator anymore.
WHY AUTOMATION?
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
10. Increased productivity and PRODUCTION RATE
11. To reduce COST PER DEFECT-FREE UNIT
 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

Human Participation in 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 - workers operating
powered equipments/machines
3. Automated systems - a process performed by a
system without direct participation of a human
Manual Work System
Worker-Machine System
Automated System
 AUTOMATION
1. Phase 1 – Manual production
❑ Single-station manned cells working independently
❑ Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production (Manual
Handling)
❑ 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
 Phase 1 Manual workstations Manual handling

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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
Types of Automation

Types of Automation
(As a Function of Production Volume
and Product Variety)
 Product Variety and Production
Quantity for Three Automation Types
 Types of Automation
1) Fixed (Hard) Automation:

The equipment is designed to manufacture a specific product

with stable product life and high demand

▪ The sequencing of operations is fixed by the equipment

configuration
▪ The operations in the sequence are usually simple
▪ Can achieve high production rates (High Speed Production) →
Mass Production
▪ High initial investment on custom-engineered equipment
▪ Not very adjustable and adaptable to product and process
changes (Not flexible)
 1) 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
1) Fixed Automation

The economic justification for fixed automation is found in

products with very high demand rates and volumes. The
high initial cost of the equipment can be spread over a very
large number of units, thus making the unit cost attractive
compared to alternative methods of production. Examples
of fixed automation include mechanized assembly lines
(the product moved along mechanized conveyors, but the
workstations along the line were manually operated-) and
machining transfer lines.
 Types of Automation
2) Programmable Automation:

The system is designed with the capability to change the

sequence of operations to produce different products
with low and medium volume production rates.

▪ The operation sequences are controlled by a program

▪ Low production rates (relative to fixed automation)
▪ High initial investment on general-purpose machines.
Adjustable and adaptable to product and process changes
(Very flexible)
▪ Suitable for Batch Production (The parts or products are
typically made in batches).
 2) Programmable Automation
A manufacturing system is 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)
2) Programmable Automation

In programmable automation both the physical setup of the

machine and machine programs can be changed over.
Tools must be loaded, fixtures must be attached to the
machine table, and the required machine settings must be
entered. This changeover procedure takes time.
Consequently, the typical cycle for a given product includes
a period during which the setup and reprogramming takes
place, followed by a period in which the batch is produced.
Examples of programmable automation include numerically
controlled machine tools and industrial robots.
 Types of Automation
3) Flexible (Soft) Automation:

The machines are designed with the capability to change the

sequence of operations to produce different products
with no time lost for changeovers

▪ Machines are programmable

▪ High initial investment on custom-engineered machines
▪ Continuous production of variable mixtures of products with no
changeover time
▪ Medium production rates
▪ Flexible to deal with product design variations
3) 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
 3) Flexible Automation
A flexible automated system is one that is capable of producing a variety of
products (or parts) with virtually no time lost for changeovers from one product to
the next. The essential features that distinguish flexible automation from
programmable automation are;

❑ the capacity to change part programs with no lost production time (hanging
the part programs is generally accomplished by preparing the programs off-
line on a computer system and electronically transmitting the programs to the
automated production system)

❑ the capability to change over the physical setup, again with no lost production
time (changing the physical setup between parts is accomplished by making
the changeover off-line and then moving it into place simultaneously as the
next part comes into position for processing. The use of pallet fixtures that
hold the parts and transfer into position at the workplace is one way of
implementing this approach)

❑ the flexible automated system can produce various combinations and

schedules of products, instead of requiring that they be made in separate
batches.
3) FLEXIBLE AUTOMATION

A flexible automated line with

robots (automatically adjusts to
product changes) A workpart fixture
MM 418 MANUFACTURING SYSTEMS

PRODUCTION MACHINES
 Production Machines

▪ In virtually all modern manufacturing systems, most of the

actual processing or assembly work is accomplished by
production machines.
▪ 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
Classification of Production Machines
 Automation and Manning Levels at
Production Machines

▪ Level of machine automation

▪ Manually operated
▪ Semi-automated
▪ Fully automated
▪ Manning level Mi = proportion of time worker is in
attendance at machine i
▪ Mi = 1 means that one worker must be at the machine
continuously
▪ Mi  1 indicates manual operations
▪ Mi < 1 usually denotes some form of automation
 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. Worker loads and
unloads parts and operates machine.
 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 parts (resupply of starting work units),
unloading parts (removal of finished work units), starting semi-
automatic work cycle and periodic attention.
 Applications of Semi-Automated Production
Machines (with LOAD/UNLOAD WORKERS)
▪ CNC machining center with worker to load/unload
▪ CNC turning center with worker to load/unload
▪ Cluster of two CNC turning centers with time sharing of one
worker to load/unload
▪ Plastic injection molding on semi-automatic cycle with
worker to unload molding, sprue, and runner
▪ One worker at electronics subassembly workstation
inserting components into PCB
▪ Stamping press with worker loading blanks and unloading
stampings each cycle
 Fully-Automated Machine

Machine operates for extended periods (longer than one

work cycle) without worker attention.
 Applications of Fully-Automated
Production Machines
▪ CNC Machining Center with APC and parts storage
subsystem
▪ CNC Turning Center with robot and parts storage carousel
▪ Cluster of ten CNC Turning Centers, each with robot and
parts storage carousel, and time sharing of one worker to
load/unload the carousels
▪ Plastic injection molding on automatic cycle with robot arm to
unload molding, sprue, and runner
▪ Electronics assembly station with automated insertion
machine inserting components into PCBs
▪ Stamping press stamps parts from long coil
 PRODUCTION MACHINE

WHAT DO WE WANT FROM A PRODUCTION MACHINE?

----FLEXIBILITY HIGH
----MANUFACTURING LEAD TIME (LOADING; SET-UP
(CHANGEOVER); ADJUSTMENT; ACTUAL OPERATION;
UNLOADING TIMES) LOW
----CONSİSTENCY (REPEATABILITY) HIGH
----ACCURACY (TOLERANCES) HIGH
----CAPABILITY (MULTIPLE OPERATIONS WITH THE SAME
SET-UP IN THE SAME MACHINE) HIGH
 WHAT IS FLEXIBILITY FOR A
PRODUCTION MACHINE?
Flexibility of a production machine is directly proportion to the
degree to which the system is capable of dealing with
variations in the parts or products it produces.
▪ Three flexibility levels (from lowest to highest):
1. Single-model case - all parts or products are identical.
2. Batch-model case - different parts or products are
produced by the system, but they are produced in batches
because changeovers are required.
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.
The difference between 2. and 3. is SET-UP TIME.
 SET-UP TIME

WHEN THE SET-UP (CHANGEOVER) TIME TO PRODUCE

A DIFFERENT PART/PRODUCT TYPE AFTER THE
CURRENT ONE IS HIGH, WE ARE FORCED TO
PRODUCE IN BATCHES TO INCREASE UTILIZATION
OF THE MACHINE. BATCH PRODUCTION INCREASES
MANUFACTURING LEAD TIME AND WORK-IN
PROCESS (WIP) INVENTORY. TO PRODUCE IN MIXED
MODEL CASE WE HAVE TO REDUCE SET-UP TIMES.
SO, THE KEY TO HIGH FLEXIBILITY THROUGH MIXED-
MODEL CASE IS TO REDUCE SET-UP TIMES AT
PRODUCTION MACHINES.
 Three Cases of Flexibility
1.Single-model case

2. Batch model case,

3. Mixed-model case

When we can produce in mixed-model case (lot size =1) what

happens to manufacturing lead time for a single part/
product?—much lower. When manufacturing lead time is
lower, then we can react to customers’ actual orders
(PRODUCE TO ORDER) instead of trying to anticipate and
produce to stock (PRODUCE TO STOCK).
 How do we achieve high flexibility
(Mixed model case) at a production
machine?---reduce set-up time
TO REDUCE SET-UP TIME
▪ Automatic identification of the different work units
▪ The machine must be able to identify the differences
between work units in order to perform the correct
processing sequence
▪ Quick changeover of operating instructions
▪ The required work cycle programs must be readily
available to the control unit
▪ Quick changeover of the physical setup
▪ System must be able to change over the fixtures and
tools required for the next work unit in minimum time
 REMOVE WORKERS to achieve high repeatability,
high accuracy, low production time and high
production rates.

FULLY AUTOMATED production machines capable of

operating unattended for longer than one work cycle. The
ROUTINE functions (loading parts, adjusting, operating,
control, changing the tools, removing chips, measurement,
quality control and unloading parts, etc.) are performed by
the machine itself. The maintenance and recovery from
unexpected failures are also perfomed by the machine.
----GOAL OF THE MACHINE PRODUCERS: Produce A
MACHINE that needs no (or minimum essential) human
involvement while producing in mixed model case.
----A fully automated machine is a first step in implementing an
integrated multi-station fully automated flexible system.
 Enablers for FULLY AUTOMATED MACHINE
(Unattended Machine Operation)—
NOW AUTOMATED MACHINES HAVE
▪ Programmed and automated (without interruption for removal of chips
or changing tools) operation for all steps in work cycle
▪ Parts storage subsystem
▪ Automatic loading, unloading, and transfer between parts storage
subsystem and machine
▪ Automatic measurement and quality control and ability to adjust
automatically based on measurements.
▪ Built-in safeguards to avoid self-destructive operation or damage to
work units and RECOVERY FROM FAILURES when failures occur.
▪ Automatic identification (e.g., bar codes) that recognize alternative
features of starting units with the usage of sensors/bar-code readers
and communication devices.
▪ Capability to download programs for each work unit style (programs
prepared in advance)
▪ Capability for quick changeover of physical setup
 AUTOMATED MACHINES
How do they function without workers?

▪ Machining centers:
▪ Various designs of parts storage unit interfaced to
automatic pallet changer (or other automated transfer
mechanism) for automatic part loading and unloading
▪ Turning centers:
▪ Industrial robot interface with parts carousel for part
loading and unloading.
▪ Plastic molding or extrusion:
▪ Hopper contains sufficient molding compound for
unattended operation
▪ Sheet metal stamping:
▪ Starting material is sheet metal coil
 Automated Machines:
CNC MACHINING CENTERS

Machine tool capable of performing multiple operations (more

operations mean more capability) that use rotating tools on
a workpart in one setup under NC control.

▪ Typical operations: milling, drilling, and related operations

▪ Typical features to remove worker from machines:
▪ Automatic tool changer (to change cutting tools)
▪ Automatic workpart positioning (automatic adjustment)
▪ Automatic pallet changer (automatic loading and unloading
parts) with part storage unit.
CNC
Machining
Center
Example
CNC Machining Center Example
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Machining Center with Automatic Pallet
Changer - Stores One Part

PERFORM ALL NECESSARY SET-UP FOR THE NEW PART ON A PALLET WHILE THE MACHINE IS
MACHINING THE EXISTING WORK PART. IN SUCH A CASE THE MACHINE DOES NOT STOP FOR ANY
SET-UP. WHATEVER PRODUCT/PART TYPE ARRIVES AFTER THE EXISTING WORK PART, THERE IS NO
STOPPAGE FOR A SET UP. The CYCLE ‘loading time+machining time+tool changing time+ unloading time’ repeats
for the machine without set-up time for a new product type.

With the usage of automatic pallet

changer and part storage unit, the set-
up of the new work part can be
performed while the machine is
operating on the existing work part.
There is still a set-up for the new part
but we do NOT LOSE ON-LINE
SET-UP TIME with the usage of
automatic pallet changer and part
storage unit.
 PALLETS --An automatic moveable table that supports a workpiece and slides or
pivots into and out of the machining center. Multiple pallets allow an operator to set up a part while
another is being machined.
--The fixture clamps the part to the pallet for loading and unloading in the machine.

Precision blank tooling plates

that are ready to mount on
standard machining-center
pallets, reducing tooling cost
and lead time considerably.
PALLET EXAMPLES (QUICK PALLETS)
ANOTHER QUICK PALLET EXAMPLE
http://www.thame-eng.com/downloads/Quick%20Point.pdf
MOUNTING QUICK PALLETS ON MACHINE TABLES
http://www.thame-eng.com/downloads/Quick%20Point.pdf
PALLET EXAMPLES
PALLET EXAMPLE http://www.schunk.com/
AUTOMATIC PALLET LOADING
Automatic loading of a milling machining center with
the clamping pallet prepared on the assembly system.
After the introduction of the clamping pin, the quick-
change pallet module positions and clamps the pallet.
 Sofety Pictform
PALETTE SHUTTLE Lood Stotion #1 Guerd Roll and
Engineered Machine Tool custom designs Chip Contoinment
and builds special application tool pallet Sofety
systems for large machining centers.

We can build a single pallet system servicing

a single cell as well as multi-pallet systems Guord
servicing several cells. Our specialty is Railing
handling larger parts and fixtures.

Pictured here is a special two pallet shuttle

system for a 5-axis Henri-Line vertical mill.
The machining centerhas afixed Machine Ve...
bed and two pallets effectively giving the
Mochine
system three tables. The pallets are 10 feet wD
wide and 16 feetlong. The pallet system Safety
allows for large tool/part loading and
unloading outside the environmentally
controlled machining area.
Lood Stotion #2
Engineered Machine Tool automatic pallet
changers can keep your work cell idle time to EMT Poalet Henri-Line
a minimum. Shuttle Mill Shoan

Pallet System Configuration

Single Tronsporter
Two Pollet System
Todle Tops Fluah with Floor Level

Pallet system configuration (4 pallets)

Storage Stations

Maching Center

Load / Unload
Station

EK oe
Cam-Driven Pallet Changer
Auto pallet changer allows operator to setup a part while another part is being machined. Spindle idle time is
greatly reduced. The pallet changer utilizes heavy duty cam-driven design that features high speed and high
load capacity: a pallet change takes only 5 seconds and each side of the pallet table can hold up to 770 lbs. A
3-piece clutch gear clamping mechanism allows table unclamp, rotate and clamp all without raising table
elevation. Table positioning accuracy and stability are both greatly improved.
 AUTOMATIC TOOL CHANGER

When the machining center is operating

on the existing work part, a worker can
put new cutting tools which will be
needed to machine the arriving work part.
NO LOST ON-LINE SET-UP TIME with
the usage of TOOL STORAGE UNIT.
TOOL STORAGE UNIT (TOOL MAGAZINE)
 TOOL STORAGE UNIT (TOOL MAGAZINE)

Chain Type Automatic Tool Changer (ATC) Drum Type Automatic Tool Changer (ATC)
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and automatic pallet changer with pallet

holders arranged radially; PART STORAGE CAPACITY = 5.
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and in-line shuttle cart system with pallet

holders along its length; PART STORAGE CAPACITY = 16
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center with pallets held on indexing table;

PART STORAGE CAPACITY = 6.
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and parts storage carousel with parts

loaded onto pallets; PART STORAGE CAPACITY = 12.
CNC Machining Center Example
 CNC Machining
Center Structure:

The main parts of CNC machining centers are the bed, saddle, column, table, servomotors, ball screws, spindle, tool changer, and the
machine control unit (MCU)
Bed: The bed is usually made of a high quality cast iron which porvides for a rigid machine capable of performing heavy-duty machining and
maintaining high precision. Hardened and ground ways are mounted to the bed to provide rigid support for all linear axes.
Saddle: The saddle, which is mounted on the hardened and ground bedways, provides the machining center with the X-axis liear movement.
Column: The column, which is mounted to the saddle, is designed with high torsional strength to prevent distorsion and deflection during
machining. The column provides the machining center with the Y-axis movement.
Table: The table, which is mounted on the bed provides the machining center with the Z-axis linear movement.
Servo System: The servo system, which consists of servo drive motors, ball secrews, and position feedback encoders, provides fast, accurate
movement and positioning the XYZ axes slides. The feedback encoders mounted on the ends of the ball scrwes form a closed-loop system which
maintains consistent high positioning unidirection repeatability of 0.0001 in.
Spindle: The spindle, which is programmable in 1-r/min increments. Has a speed range of from 20 to 6000 r/min. The spindle can be of a fixed
position (horizontal) type, or can be a tilting/contouring spindle which provides for an additional (A) axis.
Tool Changers: There are basically two types of tool changers, the vertical tool changer and the horizontal tool changer. The tool changer is
capable of storing a numberof preset gram. Tool changers are usually bidirectional, which allows for the shortest travel distance to randomly
access a tool. The actual tool change time is usually only 3 to 5 sec.
MCU: The MCU allows the operator to perform a variety of operations such as programming, machining, diagnostics, tool and machine
monitoring, atc. MCUs vary according to manufacturers’ specifications; new MCUs are becoming more sophisticated, making machine tools
more reliable and the entire machining operations less dependent on human skills.
 MACHINE AXES:Five-axis machining Center
1) X axis Linear Movement; 2) Y axis Linear Movement; 3) Z axis Linear Movement;
4) A axis Tilt/contour spindle; 5) B axis Rotary Table
 Automated Machines:
CNC TURNING CENTERS
Machine tool capable of performing multiple operations on a rotating workpart in one setup under NC control.
▪ Typical operations:
▪ Turning and related operations, e.g., contour turning
▪ Drilling and related operations along workpart axis of rotation
In turning centers, off-line set-up is not
possible. We should reduce set-up time
or eliminate the need for set-up.
 EXAMPLE FOR AUTOMATED MACHINES:
CNC Mill-Turn Center
Machine tool capable of performing multiple operations either with
single point turning tools or rotating cutters in one setup
under NC control. We reduced the number of set-ups.
▪ Typical operations:
▪ Turning, milling, drilling and related operations
▪ Enabling feature:
▪ Capability to control position of c-axis in addition to x- and z-
axis control (turning center is limited to x- and z-axis control)
Example Part which can be processed in
one set-up at CNC Mill-Turn Center:
---turning, milling, and drilling operations
are required to produce this part.
 Sequence of Operations for the
example part at the Mill-Turn Center

(1) Turn smaller diameter, (2) mill flat with part in

programmed angular positions, four positions for square
cross section; (3) drill hole with part in programmed
angular position, and (4) cutoff of the machined piece
EXAMPLE FOR MILL TURN CENTER
WATCH THE VIDEOS at the web site:
http://www.compumachine.com/regional/mill-turn.htm
EXAMPLE FOR MILL TURN CENTER
WATCH THE VIDEOS at the web site:
http://www.compumachine.com/regional/mill-turn.htm
 EXAMPLE FOR AUTOMATED MACHINES:
Automated Stamping Press

Stamping press on automatic cycle producing stampings

from sheet metal coil