MR2007B Automation of Manufacturing Systems

Class #3: Introduction to Automated Manufacturing

Professor: Bryan Sandoval
Monterrey, Nuevo León, February 19th, 2024

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Agenda
1. Manufacturing Operations
1. Manufacturing Industries
2. Manufacturing Operations
3. Production Facilities

2. Production Systems
1. Automation in Production Systems
2. Automation Principles and Strategies

3. Q&A – Discussion
4. References

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The content from this presentation was extracted from [1], unless otherwise specified. 2
1. Manufacturing Operations

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1. Manufacturing Operations
• What is Manufacturing?
• Manus (Hands)
• Factus (Make)

• Commercial goods were made by hand

• The methods were handicraft

Manual Labor

[2] 4
1. Manufacturing Operations
• What is Manufacturing?
• Application of physical and/or chemical process to alter the …
• Geometry

• Properties

• Appearance

• … of a given material to make parts or products

• Manufacturing is also the joining of multiple parts to make assembled products

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1. Manufacturing Operations
• Technological Process
• Combination of:
• Machinery

• Tools

• Power

• Manual Labor

• Economic Process
• Adding value to the material
• By changing its shape or properties
• By combining it with other materials

• As engineers, we must be aware of

both
Figure 1.1 Alternative definitions of manufacturing: (a) as a
technological process and (b) as an economic process

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1.1 Manufacturing Industries
1. Primary Industries
 Cultivate and exploit natural
resources

2. Secondary Industries
 Convert outputs from primary
industries into products
 Manufacturing is the principal activity

3. Tertiary Industries
 Service sector

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1.2 Manufacturing Operations
1. Processing and Assembly Operations
2. Material Handling and Storage
3. Inspection and Testing
4. Coordination and Control

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1.2.1 Processing and Assembly Operations

• Processing Operation
• Transforms a material to a more advanced state of completion
• Usually done to discrete work parts, but can be applied to assembled items

• Assembly Operation
• Joins two or more components to create a new entity, i.e., assembly or subassembly

Figure 1.2 Classification of manufacturing processes

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1.2.1 Processing and Assembly Operations

Figure 1.2 Classification of manufacturing processes

Provide examples of the processes

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1.2.2 Material Handling and Storage

• Materials usually spend more time being moved and stored tan being processed
• In some cases, most of the labor cost in the factory is consumed in handling, moving, and storing materials
• It is important to do this as efficiently as possible
• Example time distribution in a machine shop [3]

Figure 1.3 How time is spent by a typical part in a batch

(Image from Onepullwire.com) (Image from Fractory.com) production machine shop [3].

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1.2.2 Material Handling and Storage

• 7 Wastes of Lean Manufacturing

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1.2.3 Inspection and Testing

• Quality control activities

• Determine whether the manufactured product meets the established design standards and specifications

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1.3 Production Facilities
• Production Quantity
• Number of units of a given part or product produced annually by the plant
• Low Production (1 – 100 units)
• Medium Production (100 – 10,000 units)
• High Production (10,000 – millions of units)

• Production Variety
• Different product designs or types that are produced
• Hard Product Variety
• Soft Product Variety
• Inverse correlation with Production Quantity

Figure 1.4 Relationship between product variety and

production quantity in discrete product manufacturing.

Where do you think we are right now?

Where do you think Industry 4.0 is headed?
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1.3.1 High Production

• Mass Production
• Characterized by a high demand rate for the product
• Quantity Production
• Flow-Line Production
• Single-Model Production Line
• Mixed-Model Production Line

• Low-Mix High-Volume (LM-HV)

• Traditional Manufacturing

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1.3.2 Medium Production

• The same production equipment is used by multiple models

• The Setup Time or Changeover Time is the time to change tooling and to set up and reprogram the machinery
• This time spent is a waste

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1.3.3 Low Production

• Low quantities of specialized and customized products

• Products are typically complex
• High-Mix Low-Volume (HM-LV)
• Spare Part Market
• Trend of the Industry 4.0
• Ability to adapt to changing market trends
• Flexibility

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2. Production Systems

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2. Production Systems
• A collection of people, equipment, and procedures organized to perform the manufacturing operations of a company
• Facilities
• Manufacturing Support Systems

Figure 1.5 The production system consists of facilities and

manufacturing support systems.

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2. Production Systems
• Facilities
• Includes the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control
manufacturing operations
• Physical elements of the production system
• Plant Layout
• The way the equipment is physically arranged in the factory

• Manufacturing Systems
• Groupings of equipment and workers that accomplish the processing and assembly operations on parts and products made by the factory

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2. Production Systems
• Manufacturing Systems
• Manual Work Systems
• One or more workers performing one or more tasks without the aid of powered tools

• Worker-Machine Systems
• A human worker operates powered equipment

• Automated Systems
• A process is performed by a machine without the direct participation of a human worker
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• Semiautomated machine

• Fully automated machine

Figure 1.6 Three categories of manufacturing systems: (a)

manual work system, (b) worker-machine system, and (c) fully
automated system. (Image from Unsplah.com)

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2. Production Systems
• Manufacturing Support Systems
• People and procedures by which a company manages its production operations
• These support systems do not directly contact the product
• Plan and control the progress of the product through the factory
1. Business Functions
2. Product Design
3. Manufacturing Planning
4. Manufacturing Control

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2.1 Automation in Production Systems
• Automation of the manufacturing systems in the factory
• Computerization of the manufacturing support

Figure 1.7 Opportunities for automation and computerization

in a production system.

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2.1.1 Automated Manufacturing Systems

• Automated manufacturing systems operate in the factory on the physical product

• Processing, assembly, inspection, material handling, etc.
• There are three categories:
• Fixed Automation
• Programmable Automation
• Flexible Automation

Figure 1.8 Three types of automation relative to production Figure 1.4 Relationship between product variety and
quantity and product variety. production quantity in discrete product manufacturing.

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2.1.1 Automated Manufacturing Systems

• Fixed Automation
• Sequence of processing or assembly operations is fixed by the equipment configuration
• High initial investment for custom-engineered equipment
• High production rates
• Inflexibility of the equipment to accommodate product variety
• Low cost of each individual work unit

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2.1.1 Automated Manufacturing Systems

• Flexible Automation
• Is capable of producing a variety of parts or products with virtually no time lost for changeovers from one design to the next
• High investment for a custom-engineered system
• Continuous production of variable mixtures of parts or products
• Medium production rates
• Flexibility to deal with product design variations

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2.1.1 Automated Manufacturing Systems

• Programmable Automation
• The production equipment is designed with the capability to change the sequence of operations to accommodate different product configurations
• High investment in general-purpose equipment
• Lower production rates than fixed automation
• Flexibility to deal with variations and changes in product configurations
• High suitability for batch production
• Physical setup must be changed, tools, fixtured, etc.

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2.1.2 Computerized Manufacturing Support Systems

• Computer-Integrated Manufacturing (CIM)

• Use of computer systems to:
• Design the products

• Plan the production

• Control the operations

• Perform information-processing functions

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2.1.3 Reasons for Automating

• Why should we automate? • Why should we keep manual labor?

• Increase labor productivity • Task is technologically too difficult to automate
• Reduce labor cost • Short product life cycle
• Mitigate the effects of labor shortages • Customized product
• Reduce or eliminate routine manual and clerical tasks • Ups and downs in demand
• Improve worker safety • Need to reduce risk of product failure
• Improve product quality • Lack of capital
• Reduce manufacturing lead time
• Accomplish processes that cannot be done manually
• Avoid the high cost of not automating

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2.3 Automation Principles and Strategies
• The USA Principle
• Understand the Existing Process
• What are the inputs?

• What are the outputs?

• What is the function of the process?

• How does it add value to the product?

• Simplify the Process

• Is this step necessary?

• Can it be eliminated?

• Is the technology used the appropriate one?

• Can it be done easier?

• Automate the Process

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3. Q&A - Discussion

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4. References
• [1] Groover, Mikell P, Automation Production Systems and Computer-Integrated Manufacturing, Fourth Edition., United
States: Pearson Education, 2016, Eng, 978-0-13-349961-2.
• [2] TheColumbusDispatch, “Harvesting wheat the old fashioned way,” YouTube, (accessed Feb. 14, 2024).
• [3] Merchant, M. E., “The Inexorable Push for Automated Production,” Production Engineering, January 1977, pp. 45–
46.

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