Wollo University

Kombolcha institute of technology

School of textile, leather and

Fashion technology

Department of leather engineering

(Footwear technology)

Computer integrated manufacturing (CIM)

Group assignment

Done by: ID

Ali mamo (0219/12)

Endale lule (0699/12)

Esayas eshetu (0724/12)

Submitted to MR. abriham.a

Submission date: 8/14/2016

 Types of manufacturing systems

Table of Contents
Introduction................................................................................................................................2

1. Different types manufacturing systems..................................................................................3

1.1 assembly manufacturing system.......................................................................................3

1.1.1 understanding an assembly manufacturing system....................................................3

1.1.2 assembly manufacturing system in shoe manufacturing...........................................4

1.1.3 strategic steps to implement an asssembly manufacturing system in a shoe

manufacturing.....................................................................................................................5

1.1.4 The advantages of an assembly manufacturing system for a shoe manufacturing

company..............................................................................................................................7

1.2 Single station manufacturing cell.....................................................................................8

1.2.1 Understanding Single – station manufacturing cell...................................................8

1.2.2 Single – station manufacturing cell in shoe manufacturing.......................................9

1.2.3 How to implement a single station manufacturing cell...........................................10

1.2.4 The advantages of using Single-Station Manufacturing Cells in the context of shoe
manufacturing...................................................................................................................12

1.3 A flexible manufacturing system....................................................................................13

1.3.1 understanding of fms...............................................................................................13

1.3.2 Flexible Manufacturing Systems in Shoe Manufacturing.......................................14

1.3.3 Implementing a flexible manufacturing system in shoe manufacturing..................14

1.3.4 Advantages and disadvantages of FMS for shoe manufacturers.............................16

1.4 A transfer manufacturing system....................................................................................18

1.4.1 Understanding a transfer manufacturing system.....................................................18

1.4.2 A transfer manufacturing system in shoe manufacturing........................................18

1.4.3 How to implement transfer lines in shoe manufacturing process............................19

1.4.4 The advantages and disadvantages of transfer lines in shoe manufacturing:.........21

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 Types of manufacturing systems

Reference..................................................................................................................................23

INTRODUCTION

Manufacturing systems play a pivotal role in shaping our modern world. From the production
of everyday consumer goods to complex machinery, the choice of manufacturing system
significantly impacts efficiency, quality, and cost-effectiveness.

There are various manufacturing systems used by many industries such as assembly
manufacturing, singlem station, transfer lines, group technology and flexible manufacturing
system. which have their characteristics, advantages, and limitations .

Understanding the nuances of different manufacturing systems empowers businesses to make

informed decisions. Whether optimizing for volume, flexibility, or customization, each
system contributes uniquely to the industrial landscape. As technology evolves,
manufacturers must adapt to stay competitive and meet ever-changing demands.

This assignment provides an overview of various manufacturing systems, highlighting their

distinct characteristics,implementing strategies,and their advantages and disadvantages.

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 Types of manufacturing systems

1. Different types manufacturing systems

Different types manufacturing systems are:-

 Assembly manufacturing system

 Single – station manufacturing cell
 Flexible manufacturing system
 Transfer lines
 Group technology manufacturing systems

1.1 Assembly manufacturing system

1.1.1 Understanding an assembly manufacturing system

Definition:

An assembly system is one of the subsystems in a manufacturing environment where the

various components of a product are assembled to form a complete or partially assembled
unit. This integration process ensures that the product is ready for shipping and
implementation by the client.

The Assembly Line Concept:

At the heart of assembly manufacturing systems lies the concept of the assembly line. This
process, often called progressive assembly, involves adding parts in a specific sequence as
the semi-finished assembly moves from one workstation to another.

Here’s how it works:

Workstations: These are designated stations along the assembly line where specific tasks are
performed. Each workstation focuses on a particular assembly step.

Interchangeable Parts: The components used are usually interchangeable. This means that
different units of the same part can be used interchangeably during assembly.

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 Types of manufacturing systems

Sequential Addition: As the assembly moves along the line, workers add parts in a sequential
order. Each workstation contributes to the gradual completion of the final product.

Final Assembly: The process continues until the final assembly is produced—a fully
functional product ready for use or sale.

1.1.2 Assembly manufacturing system in shoe manufacturing

Assembly manufacturing in the context of shoe manufacturing is a fascinating interplay of

craftsmanship, technology, and innovation. Let’s see into the intricate process that brings
favorite pair of shoes to life:

Design and Development:

Conceptualization of Shoe Designs: It all begins with an idea—a vision sketched out by
designers who meticulously refine their concepts. Imagination transforms into tangible forms.

Material Selection and Sourcing: Every element matters, from supple leather sourced
globally to resilient synthetic fabrics and eco-friendly alternatives driven by sustainability
challenges.

Prototyping and Testing: Innovations like 3D printing revolutionize prototyping, allowing

rapid iterations and precise adjustments.

Shoe Production Process:

Cutting and Shaping the Materials: Precision machinery and skilled hands work in tandem
to cut and shape materials.

Stitching and Assembly or lasting : here, the cut components are assembled or stitched
together to get upper of the shoe and it is performed by using different sewing machines and
the next process is lasting which is giving the required shape or structure of the shoe using
different latest computerized machines. Expertise and attention to detail are crucial during
stitching and assembly.

Quality Control and Inspection: Ensuring each pair meets high standards.

Technology and Innovation in Shoe Manufacturing:

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 Types of manufacturing systems

Automation and Robotics: These aid in precision cutting, stitching, and assembly,
streamlining processes without compromising craftsmanship.

Sustainable Practices and Eco-friendly Materials: Responding to environmental

challenges, manufacturers explore innovative materials and practices.

3D Printing and Customization: Customized designs and rapid prototyping are made
possible.

Global Supply Chain and Distribution:

Global Sourcing of Materials: Shoe production involves a network of suppliers worldwide.

Manufacturing Hubs and Facilities: These hubs orchestrate the intricate dance of shoe
creation.

1.1.3 Strategic steps to implement an asssembly manufacturing system in a

shoe manufacturing

Implementing an assembly manufacturing system in a shoe company involves several

strategic steps. Let’s break it down:
1. Assessment and Planning:

 Evaluate Current Processes: Understand the existing shoe production workflow.

Identify areas where assembly line principles can be applied.
 Define Objectives: Clearly outline the goals of implementing assembly
manufacturing. Is it to improve efficiency, reduce costs, or enhance quality?

2. Design the Assembly Line:

 Product Flow: Map out the flow of materials and components. Determine the
sequence of assembly steps.
 Workstations: Design workstations where specific tasks will be performed. Consider
ergonomics, safety, and ease of access.
 Automation: Decide on the level of automation (e.g., manual, semi-automated, fully
automated).

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 Types of manufacturing systems

3. Materials and Components:

 Standardization: Ensure uniformity in materials and components. Standardize sizes,

shapes, and specifications.
 Supplier Collaboration: Work closely with suppliers to align their processes with the
assembly line requirements.

4. Training and Workforce:

 Training Programs: Train employees on assembly line procedures. Focus on

consistency, quality, and safety.
 Skill Development: Enhance skills related to specific assembly tasks.

5. Quality Control:

 In-Process Checks: Implement checks at each assembly point. Detect defects early
and rectify them promptly.
 Final Inspection: Ensure the finished shoes meet quality standards.

6. Layout and Infrastructure:

 Factory Layout: Arrange workstations logically. Optimize space utilization.

 Infrastructure: Invest in necessary equipment (conveyors, cutting machines,
stitching stations).

7. Pilot Implementation:

 Start Small: Test the assembly line on a smaller scale. Identify challenges and refine
processes.
 Collect Data: Measure productivity, defect rates, and overall efficiency.

8. Continuous Improvement:

 Feedback Loop: Gather feedback from workers. Encourage suggestions for process
enhancement.

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 Types of manufacturing systems

 Kaizen Philosophy: Continuously seek ways to improve efficiency, reduce waste,

and enhance quality.

9. Collaboration Across Departments:

o Cross-Functional Teams: Involve design, production, and quality assurance teams.
Collaborate to address any bottlenecks.
10. Scaling Up:
o Gradual Expansion: As the pilot proves successful, expand the assembly line to cover more
shoe models.
o Monitor Performance: Regularly assess performance metrics and adjust as needed.

Remember, successful implementation requires commitment, adaptability, and a culture of

continuous improvement

1.1.4 The advantages of an assembly manufacturing system for a shoe

manufacturing company

1. Efficiency and Consistency:

 Streamlined Process: Assembly lines allow for a systematic flow of work,

minimizing delays and bottlenecks.
 Consistent Quality: Standardized procedures ensure that each shoe meets quality
standards, reducing variations.

2. Cost Savings:

 Labour Efficiency: Assembly lines optimize labor utilization, reducing the need for
redundant tasks.
 Economies of Scale: Mass production lowers per-unit costs due to bulk material
purchases and efficient processes.

3. Speed and Scalability:

 Faster Production: Assembly lines enable rapid production, meeting market

demands promptly.

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 Types of manufacturing systems

 Scalability: Easily ramp up or down production volumes based on market

fluctuations.

4. Customization and Flexibility:

 Modularity: Components can be assembled in various combinations, allowing

customization.
 Quick Changes: Adapt to design modifications or seasonal trends swiftly.

5. Quality Control:

 Systematic Inspection: Each shoe undergoes checks at specific assembly points,

ensuring defects are caught early.
 Traceability: Easy tracking of components and processes for quality assurance.

6. Labor Skill Requirements:

 Semi-Skilled Labor: Assembly tasks can be performed by semi-skilled workers,

reducing training time.

7. Reduced Space Requirements:

 Compact Layout: Assembly lines optimize floor space, maximizing efficiency.

1.2 Single station manufacturing cell

1.2.1 Understanding Single – station manufacturing cell

A Single-Station Manufacturing Cell is a common system used in industry where the

operation at a particular station is independent of other stations. These cells can perform
either processing or assembly operations. Here are some key points about single-station
manufacturing cells:
1. Classification:
o Single-Station Manned Workstations: In this model, one worker tends to one production
machine. It’s widely used, especially in job shops and batch production. Reasons for its

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popularity include quick implementation, low capital investment, ease of installation and
operation, and flexibility for product or part changeovers.
o Single-Station Automated Cells: These are fully automated production machines capable of
operating unattended for longer than one work cycle. Labor costs are reduced, and production
rates are usually higher than manned cells. They serve as the first step in implementing an
integrated multi-station automated system.
2. Enablers for Unattended Cell Operation:
o For single-model and batch production, the following factors enable unattended cell
operation:
 Programmed operation for all steps in the work cycle.
 Parts storage subsystem.
 Automatic loading, unloading, and transfer between parts storage subsystem and machine.
 Periodic attention from a worker for removal of finished work units, resupply of starting
work units, tool changes, and other machine tending.
 Built-in safeguards to avoid self-destructive operation or damage to work units or unsafe
conditions for workers.

1.2.2 Single – station manufacturing cell in shoe manufacturing

Let us see the concept of a Single-Station Manufacturing Cell and explore its relevance in
the context of shoe manufacturing.

Single-Station Manufacturing Cells

1. Overview:
o A Single-Station Manufacturing Cell is a fundamental system used in various industries,
including footwear manufacturing.
o These cells are designed to be efficient, flexible, and cost-effective.
2. Components:
o Workstation: The central element of the cell where the manufacturing process occurs.
o Equipment: Machinery, tools, and fixtures necessary for the specific operation.
o Material Handling System: Transfers raw materials, workpieces, and finished products to
and from the workstation.
o Control System: Manages the operation, monitoring, and coordination of the cell.
3. Types of Single-Station Cells:

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 Types of manufacturing systems

o Single-Station Manned Workstations:

 In this model, one worker tends to one production machine.
 Commonly used in job shops and batch production.
 Advantages: Quick implementation, low capital investment, ease of operation, and flexibility
for product changeovers.
o Single-Station Automated Cells:
 Fully automated production machines that operate unattended for extended work cycles.
 Labor costs are reduced, and production rates are higher.
 Often the first step toward implementing an integrated multi-station automated system.
4. Applications in Shoe Manufacturing:
o Sole Digitization: Involves scanning and capturing the shape and dimensions of shoe soles.
o Glue Dispensing: Precise application of adhesive for attaching components (e.g., outsoles,
insoles).
o Sole Manipulation: Handling and positioning shoe soles during assembly.
o Quality Control: Inspecting finished shoes for defects.
5. Benefits:
o Flexibility: Single-station cells adapt easily to different shoe models and production volumes.
o Cost-Effectiveness: Lower initial investment compared to complex multi-station systems.
o Quick Setup: Rapid deployment for new shoe designs.
o Improved Quality: Focused attention on each station ensures quality control.
6. Challenges:
o Limited Automation: While automated, these cells may still require periodic worker
attention.
o Space Constraints: Each cell occupies physical space, which can be a limitation in crowded
factories.

In summary, single-station cells play a crucial role in shoe manufacturing by combining

efficiency, flexibility, and targeted operations. Whether it’s digitizing soles, dispensing glue,
or handling components, these cells contribute to the production of comfortable and stylish
footwear.

1.2.3 How to implement a single station manufacturing cell in shoe

manufacturing

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 Types of manufacturing systems

Implementing a Single-Station Manufacturing Cell in shoe manufacturing involves several

steps. Let’s break it down:
1. Identify the Operation:
o Determine which specific operation or task you want to automate or streamline.
o Examples include sole digitization, glue dispensing, or quality control checks.
2. Select the Workstation:
o Choose a suitable workstation or station where the operation will take place.
o Ensure it is ergonomically designed for worker comfort and efficiency.
3. Equipment and Tools:
o Acquire the necessary machinery, tools, and fixtures for the chosen operation.
o For glue dispensing, you’ll need precision dispensers. For digitization, consider 3D scanners.
4. Material Handling System:
o Set up a system for transferring raw materials (shoe components) to the workstation.
o Designate areas for storing materials and finished products.
5. Automation Level:
o Decide on the level of automation:
 Manual: Worker-operated with minimal automation.
 Semi-Automated: Combines manual and automated steps.
 Fully Automated: Operates unattended for extended cycles.
6. Programming and Control:
o Program the equipment for the desired operation.
o Implement safety features and error handling.
o Integrate control systems for smooth operation.
7. Quality Assurance:
o Incorporate quality checks within the cell:
 Vision systems for defect detection.
 Weight measurements for consistency.
 Dimensional checks for accuracy.
8. Worker Training:
o Train operators on using the workstation, handling materials, and responding to alarms.
o Emphasize safety protocols.
9. Maintenance and Calibration:

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o Regularly maintain and calibrate equipment.

o Address any issues promptly to avoid downtime.
10. Testing and Optimization:
o Run test batches to ensure the cell operates as intended.
o Optimize cycle times, material flow, and quality.
11. Integration with Workflow:
o Integrate the single-station cell into your overall shoe manufacturing process.
o Plan material flow from preceding and subsequent stations.
12. Continuous Improvement:
o Monitor performance metrics (cycle time, defect rate, etc.).
o Seek opportunities for further efficiency gains.

Remember that the success of implementing a single-station cell lies in careful planning,
effective training, and ongoing evaluation.

1.2.4 The advantages of using Single-Station Manufacturing Cells in the

context of shoe manufacturing

1. Flexibility:
o Single-station cells are highly adaptable to different shoe models and production volumes.
o Shoe designs vary significantly, and these cells allow quick adjustments for new styles
without major reconfiguration.
o Manufacturers can efficiently switch between different shoe types, sizes, and materials.
2. Cost-Effectiveness:
o Implementing single-station cells requires lower initial investment compared to complex
multi-station systems.
o The focus is on a specific operation, reducing the need for extensive automation or elaborate
conveyor systems.
o For smaller shoe manufacturers or those with diverse product lines, this cost-effectiveness is
crucial.
3. Quick Setup and Changeovers:
o When introducing a new shoe design, single-station cells can be rapidly deployed.

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o Changeovers involve minimal downtime, allowing manufacturers to respond swiftly to

market demands.
o Adjustments to tooling, fixtures, and programming are straightforward.
4. Quality Control:
o Each station receives focused attention from workers or automated systems.
o Inspections and quality checks can be integrated directly into the cell.
o Defects are caught early, ensuring that only high-quality shoes proceed to the next stage.
5. Reduced Labor Costs:
o While some worker attention may be required, single-station cells still reduce labor costs.
o Automation handles repetitive tasks, freeing up workers for more skilled or supervisory roles.
o The balance between automation and human intervention optimizes efficiency.
6. Space Efficiency:
o These cells occupy less space compared to large multi-station assembly lines.
o In crowded factories or limited production areas, single-station cells maximize floor space
utilization.
o Manufacturers can create efficient layouts without compromising productivity.
7. Specialized Operations:
o Certain shoe manufacturing steps are best suited for single-station cells:
 Glue Dispensing: Precise application of adhesive for attaching components.
 Sole Digitization: Scanning and capturing sole shapes.
 Sole Manipulation: Handling and positioning shoe soles during assembly

1.3 A flexible manufacturing system

1.3.1 UNDERSTANDING OF FMS

A Flexible Manufacturing System (FMS) is a production method designed to adapt to

changes in product requirements without compromising quality. Let’s delve into what it
entails and how it relates to shoe manufacturing:
1. Definition of FMS:
o An FMS is all about adaptability. It enables manufacturers to respond swiftly to variations in
product specifications, production volumes, or the introduction of new products.

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o The system relies on computers and automated machines to handle critical manufacturing
processes, including machining, assembly, loading/unloading, and data processing.
o FMS can perform tasks like cutting and forming metal, welding, joining, assembling, testing,
inspecting, deburring, and applying finishing treatments to parts.

Most flexible manufacturing systems consist of three main systems:

1. The work machines which are often automated CNC machines are connected by
2. By a material handling system to optimize parts flow and
3. The central control computer controls material movements and machine flow.

The main advantage of a flexible manufacturing system is its high flexibility in managing
manufacturing resources like time and effort to manufacture a new product.
The best application of a flexible manufacturing system is found in the 'production of small
sets of products like those from mass production

2. Types of Flexible Manufacturing Systems:

o Sequential FMS: Similar to a small batch flexible transfer line, it produces one type of part
and then transitions to another type in a predetermined sequence.
o Random FMS: This system manufactures a mix of parts with varied configurations at any
given time. It can handle a random order of parts.
o Dedicated FMS: Less flexible than the random counterpart, it continuously produces a
limited mix of parts but maintains a higher production rate.
o Engineered FMS: Consistently produces the same parts.
o Modular FMS: Allows operators to switch between sequential, random, dedicated, and
engineered modes based on production needs.

1.3.2 Flexible Manufacturing Systems in Shoe Manufacturing

o In the context of shoe production, an FMS can streamline various processes:

 Cutting and shaping shoe components: Automated machines can precisely cut leather,
fabric, and other materials.
 Assembly: FMS can assemble shoe uppers, soles, and other components.
 Finishing treatments: It can apply coatings, stitching, and other finishing touches.
 Quality control: FMS can inspect shoes for defects.

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 Shoe manufacturers in industries like aerospace , medical,construction,and mining can

benefit FMS

1.3.3 Implementing a flexible manufacturing system in shoe manufacturing

Implementing a Flexible Manufacturing System (FMS) in shoe manufacturing involves

several steps. Let’s break it down:

1. Assessment and Planning:

o Evaluate Needs: Understand your shoe production requirements, including volume, variety,
and customization levels.
o Identify Processes: Analyze existing shoe manufacturing processes (cutting, stitching,
assembly, finishing) and determine where FMS can be most effective.
o Budget and Resources: Allocate funds for FMS implementation and ensure you have the
necessary resources (personnel, space, technology).
2. Technology Selection:
o Automated Machinery: Invest in CNC machines, robotic arms, and conveyor systems.
o Software Integration: Choose software for process control, scheduling, and data
management.
o Sensor Systems: Implement sensors for quality control and monitoring.
3. Design the FMS Layout:
o Cellular Layout: Organize workstations into cells, each handling specific tasks (e.g., cutting
cell, assembly cell).
o Material Flow: Plan how materials move within the system.
o Ergonomics: Ensure ease of operation and maintenance.
4. Training and Workforce Preparation:
o Train Operators: Familiarize employees with FMS components, software interfaces, and
safety protocols.
o Cross-Training: Develop a skilled workforce capable of handling multiple tasks within the
FMS.
5. Integration and Testing:
o Install Equipment: Set up CNC machines, robots, and conveyors according to the layout.
o Software Integration: Connect machines to the central control system.
o Test Run: Conduct trial runs to identify any issues and fine-tune the system.

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6. Production Transition:
o Gradual Implementation: Introduce FMS incrementally to avoid disrupting existing
production.
o Monitor Performance: Track productivity, quality, and efficiency during the transition.
7. Maintenance and Optimization:
o Scheduled Maintenance: Regularly service machines and update software.
o Continuous Improvement: Analyze data to identify bottlenecks and optimize processes.
o Adaptability: Be prepared to modify the FMS as production needs change.
8. Quality Assurance and Monitoring:
o Automated Inspection: Use sensors and cameras to check shoe components for defects.
o Data Analytics: Monitor production data to ensure consistent quality.
9. Safety Measures:
o Safety Protocols: Train operators on safe FMS operation.
o Emergency Procedures: Establish protocols for handling malfunctions or emergencies.
10. Feedback and Iteration:
o Feedback Loop: Gather input from operators and adjust the FMS based on their insights.
o Continuous Learning: Stay updated on FMS advancements and adapt accordingly.

Remember that FMS implementation is a journey, and collaboration between production

managers, engineers, and operators is crucial for success.

1.3.4 Advantages and disadvantages of FMS for shoe manufacturers

The advantages and disadvantages of implementing a Flexible Manufacturing System

(FMS) in a shoe company:

Advantages of FMS for Shoe Companies:

1. Increased Efficiency:
o FMS automates various production processes, leading to faster production cycles.
o Reduced manual labor results in higher throughput and shorter lead times.
2. Adaptability:
o FMS can swiftly adjust to changes in shoe designs, materials, or production volumes.
o Shoe companies can respond promptly to market demands and trends.

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3. Quality Control:
o Automated systems ensure consistent quality by minimizing human error.
o FMS can perform precise cutting, stitching, and assembly, resulting in better-finished
products.
4. Resource Optimization:
o FMS optimizes material usage, reducing waste.
o It minimizes energy consumption and labor costs.
5. Scalability:
o As shoe production scales up, FMS can handle increased workloads without major
modifications.
o Companies can expand production capacity seamlessly.

Disadvantages of FMS for Shoe Companies:

1. High Initial Investment:
o Implementing FMS requires substantial capital investment.
o Costs include purchasing automated machinery, software, and training personnel.
2. Complex Maintenance:
o FMS components need regular maintenance and calibration.
o Downtime during maintenance can disrupt production schedules.
3. Limited Customization:
o FMS excels at mass production but may struggle with highly customized or unique shoe
designs.
o Customization often requires manual intervention.
4. Dependency on Technology:
o If FMS malfunctions or experiences technical issues, production can come to a halt.
o Companies must have backup plans and skilled technicians.
5. Resistance to Change:
o Transitioning to FMS may face resistance from existing employees.
o Training and adapting to new processes can be challenging.

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1.4 A transfer manufacturing system

1.4.1 Understanding a transfer manufacturing system

A transfer line is a manufacturing system which consists of a predetermined sequence of

machines connected by an automated material handling system and designed for working on
a very small family of parts. Parts can be moved singularly because there’s no need for
batching when carrying parts between process stations (as opposed to a job shop for
example). The line can synchronous, meaning that all parts advance with the same speed, or
asynchronous, meaning buffers exist between stations where parts wait to be processed. Not
all transfer lines must geometrically be straight lines, for example circular solutions have
been developed which make use of rotary tables, however using buffers becomes almost
impossible.

A crucial problem for this production system is that of line balancing: a trade-off between
increasing productivity and minimizing cost conserving total processing time.

1.4.2 A transfer manufacturing system in shoe manufacturing

Transfer lines are a type of manufacturing system that can be relevant to shoe
manufacturing. Let’s explore how transfer lines apply to the footwear industry:
1. Traditional Shoe Manufacturing Challenges:
o Conventional shoe manufacturing involves various processes, many of which are labor-
intensive and require skilled workers.
o Workers often face loud noises and hazardous environments, leading to difficulties in
attracting and retaining manpower.
o Automation is essential to improve efficiency and reduce reliance on manual labor.
2. Robot-Based Automation for Shoe Manufacturing:

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o To address these challenges, robot-based automation is gaining traction in the footwear

industry.
o Robotic workcells can automate tasks such as sole digitization, glue dispensing, and sole
manipulation within the factory plant.
o The goal is to progress toward Shoe Industry 4.0, where automation and smart
manufacturing play a central role.
3. Upper Manufacturing Process:
o For upper manufacturing, a trajectory acquisition system with a digitizer and a shoe last
turning device is proposed.
o The system measures the gauge line on the upper and plans the robot’s tool path for roughing
and cementing using industrial robot manipulators.
o The method aims to replace manual processes and improve production efficiency.
4. Sole Manufacturing Process:
o In sole manufacturing, an industrial robot manipulator equipped with a 3D scanning system
and a cementing tool is used.
o A trajectory generation algorithm transforms 3D information of the sole into a 6D posture for
the robot.
o The robot can perform cementing on both the outer and inner sides of the sole.
5. Experimental Verification:
o These systems and algorithms are tested in an automated production testbed.
o The proposed methods achieve successful grasps for soles without heels made from materials
of low or medium flexibility
o In –summary , transfer lines , when combined with robotic automation, enhance shoe
manufacturing by streamlining processes , improving quality , and reducing reliance on
manual labour.

1.4.3 How to implement transfer lines in shoe manufacturing process

Implementing transfer lines in shoe manufacturing involves leveraging automation and

advanced technologies to streamline production processes. Here are some strategies for
integrating transfer lines into the footwear industry:

1. Automated Material Handling:

o Design a conveyor system or robotic transport system to move shoe components between
workstations.
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o Ensure smooth material flow, minimizing manual handling and reducing production time.
2. Robotic Workcells:
o Develop robotic workcells for specific tasks:
 Upper Manufacturing:
 Use robots for tasks like digitizing shoe uppers, applying glue, and stitching.
 Implement trajectory acquisition systems with digitizers and shoe last turning devices.
 Plan robot tool paths for roughing and cementing.
 Sole Manufacturing:
 Employ industrial robots equipped with 3D scanning systems and cementing tools.
 Generate trajectory algorithms for cementing both outer and inner sides of soles.
3. Industry 4.0 Technologies:
o Embrace smart manufacturing principles:
 IoT (Internet of Things): Connect machines, sensors, and devices to collect real-time data.
 Big Data Analytics: Analyze production data to optimize processes and identify bottlenecks.
 Digital Twins: Create virtual models of shoe production lines for simulation and
optimization.
 AI and Machine Learning: Predictive maintenance, quality control, and process
optimization.
4. Customization Lines:
o Dedicate production lines to customized shoe orders.
o Use transfer lines to efficiently produce personalized shoes with shorter lead times.
5. Collaborative Robots (Cobots):
o Integrate cobots alongside human workers.
o Cobots can handle repetitive tasks, allowing skilled workers to focus on craftsmanship.
6. Quality Control Stations:
o Implement quality checks at specific points along the transfer line.
o Use vision systems to inspect shoe components for defects.
7. Training and Upskilling:
o Train workers to operate and maintain automated systems.
o Upskill employees to work alongside robots effectively.
8. Maintenance and Reliability:
o Regularly maintain robots and transfer line equipment.

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o Address any failures promptly to prevent production disruptions.

9. Collaboration with Research Institutes:
o Collaborate with universities and research centers specializing in footwear technology.
o Stay informed about the latest advancements and innovations.
10. Continuous Improvement:
o Monitor production metrics and identify areas for improvement.
o Optimize transfer line layouts, cycle times, and material handling.

Remember that successful implementation requires a balance between automation and

craftsmanship. While transfer lines enhance efficiency, skilled workers remain essential for
maintaining quality and addressing unique shoe designs.

1.4.4 The advantages and disadvantages of transfer lines in shoe

manufacturing:

Advantages of Transfer Lines in Shoe Manufacturing:

1. Shorter Production Cycles for Higher Weight Parts:
o Transfer lines offer shorter production cycle times compared to traditional methods like
compression molding.
o Compound preparation and product finishing time are significantly reduced.
o Less cutting and flash result in more efficient production.
2. Tighter Dimensional Tolerance:
o Transfer lines allow for much tighter tolerances than processes like compression molding.
o This precision enables the production of more complex shoe parts.
3. Consistent Quality:
o Transfer lines minimize variability, leading to consistent and predictable quality.
o The absence of excess material spilling out of the cavity parting line ensures uniform results.
4. Ideal for Composite Seals and Inserts:
o Transfer molding is excellent for creating composite seals with insert molding.
o It allows for multi-component sealing solutions, reducing overall component count and
enhancing product resilience.

Disadvantages of Transfer Lines in Shoe Manufacturing:

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1. Lack of Flexibility:
o Transfer lines are designed for specific part families, making them less adaptable to changes.
o Introducing new shoe designs or modifying existing ones can be challenging.
2. Risk of Obsolescence:
o Rapid changes in shoe designs and materials may render transfer lines obsolete.
o Keeping up with evolving trends requires constant reconfiguration.
3. Vulnerability to Failures:
o A breakdown in one machine can halt the entire line, affecting production.
o Maintenance and reliability are critical to prevent disruptions.
4. High Initial Investment:
o Setting up transfer lines involves substantial capital expenditure.
o Smaller shoe manufacturers may find it cost-prohibitive.
5. Limited Variety:
o Transfer lines excel in high-volume production of a narrow range of parts.
o Handling diverse shoe styles or materials is not their strength.

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Reference
Transfer line - Wikipedia

Assembly line - Wikipedia

Flexible manufacturing system - Wikipedia

Microsoft PowerPoint - Single Station Manufacturing Lec 2 [Compatibility Mode] (uettaxila.edu.pk)

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