CHAPTER 1: Introduction to Automation and Manufacturing

Rev: 2_Jan2011

Reference Book
Automation, Production System and CIM

Automation Definition
Automation technology concern with the application of mechanical, electronic and computer-based systems to operate and control production

Technology concern with Automation

Example : * Automatic Machine tools to process parts (eg.CNC machine) * Automatic Assembly Machines (eg. Packaging machine) * Industrial Robotics * Automatic Material Handling & Storage System (eg. Positioning unit) * Automatic Inspection System for Quality Control (eg. Vision system)

Types of Automation
1. Fixed Automation (Hard Automation)
- a system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration - Operations in the sequence are simple - It is Integration/ Coordination of many such operations into one piece of equipment that makes the system complex

Fixed Automation (continue)

- Typical features : * High initial investment for custom-engineered equipment * High production rates * Inflexible in accommodating product changes - Economic justification : Product with very high demand rates and volume - High initial cost of equipment can be spread over a large number of unit - Cost attractive - Example: ~ Mechanized Assembly Lines (conveyor) ~ Machining Transfer Lines ~ Stamping Machine ~ Forging Machine

Example of Stamping Machine

2. Programmable Automation
- the production equipment is designed with the capability to change the sequence of operations to accommodate different product configuration - the operation sequence is controlled by a program which is a set of instructions coded so that the sys. Can read and interpret them - New program can be prepared and entered into the equipment to produce new products

Programmable Automation (continue)

- Features : * High investment in general purpose equipment * Low production rates relative to Fixed Automation * Flexibility to deal with changes in product configuration * Most suitable for batch production - Used in low and medium volume production - The changeover process like reprogram, physical setup, tools & fixture replacement and required machine setting will be taking times - Example: CNC Machine, Robotics

Example of CNC Machine

3. Flexible Automation
- capable of producing a variety of products with virtually no time lost for changeover from one product to the next - no time lost while reprogramming the system and alternating the physical setup - the system can produce various combinations and schedules of products instead of requiring that they be made in separate batches - Feature: * High investment for a custom engineered system * Continuous production of variable mixtures of products * Medium production rates * Flexibility to deal with product design variations

Flexible Automation (continue).

- Essential features that distinguish flexible automation from programmable automation: * Capacity to change part programs with no lost production time * Capability to change over the physical setup again with no lost production time - These features allow the automated production sys. To continue production without the downtime between batches - Changing the part programs is generally accomplished by preparing the programs off line on a computer system and electronically transmitting the programs to automated production system

Flexible Automation (continue)

- The use of pallet fixtures that hold the parts and transfer into position at the workplace is one way of implementing this approach - Therefore the variety of part is more limited compared to programmable automation - Example: Flexible Manufacturing System for performing machining operations

- Changing the physical setup is accomplished by making the changeover off-line and then moving it into place simultaneously with the part

Example of Flexible Manufacturing System

Product Variety

Type of Automation as a function Volume and Product Variety

High

PROGRAMMABLE AUTOMATION

Medium

FLEXIBLE AUTOMATION

MANUAL METHOD FIXED AUTOMATION

Low Low Medium High

Parts per year

Reason for Automating

1. Increase Productivity - Higher production rates (Output/hour) are achieved compared to manual operations High Cost of Labor - Machine can produce at higher rates of output resulting lower cost per unit labor Labor shortages - Labor shortages stimulate the development of automation as a substitute for labor Trend of labor toward the service sector - the growth of government employment at federal, state and local levels has consumed a certain share of the labor market - There has been a tendency for people to view factory work as tedious, demeaning and dirty. This view has cause them to seek employment in the service sector

2.

3.

4.

Reason for Automating (continue)..

5. Safety - By automating the operation and transferring the operator from an active participation to a supervisory role, work is made safer High cost of raw material - Greater efficiency in using raw material is need Improve Product Quality - Automation produced parts with greater consistency and conformity to qualify specifications Reduce Manufacturing Lead Time - Automation allows the manufacturer to reduce the time between customer order and product delivery. This gives the manufacturer a competitive advantage in promoting good customer service

6. 7.

8.

Reason for Automating (continue)..

9. Reduction of in-process inventory - Automation tends to accomplish this goal by reducing the time a work parts spends in the factory High cost of not automating - The benefits of automation such as improved quality, higher sales, better labor relation will bring up company image

10.

Manufacturing

Three categories to classify company :

~ in the transformation of natural resources and basic raw materials into goods 1. Basic Producer - Take the natural resources and transform iron ore into steel ingots

Steel Ingot

2.

Converter - Take the output of the basic producer and transform the raw materials into various industrial products and some consumer items -eg: Steel ingot is converted into bar stock or sheet metal - characteristic : products are uncomplicated in physical form, product are not assembled item

3.

Fabricator -Fabricate and assemble final products * bar stock and sheet metal are tramsform into machined engine components and automobile body panel * plastic are moulded into various shape - include both the firms that produce the components and those which assemble the components into consumer item

Types of Production
Another way of classifying production activity is according to the quantity of product made Job Shop Production - Low Volume, Manufacturing lot size are small - Use to meet specific requirement - Variety in the type of work in the plant - The equipment must be flexible and general purpose for variety of work - skill level of worker must be high - eg: Aircraft, Machine tools

1.

Example of Aircraft Production

2.

Batch Production - manufacture of medium size lots of the same item or product - the lot maybe produced only once, or produced at regular intervals - purpose : to satisfy continuous customer demand - capability of production rate to exceeds the demand rate build up inventory - than it changes over to another model - when the inventory stock is depleted production is repeated to build up inventory again - manufacturing equipment used is general purpose but designed for higher rates - eg: furniture, textbook, components part for assemble consumer product, machine shop etc

Example of Batch Production Products

3.

Mass Production - continuous specialized manufacture of identical products - very high production rates - equipment dedicated to manufacture particular product at very high demand rates - the entire plan is designed for the exclusive purpose for particular product - special purpose equipment - investment machines and special tooling is high - skill of labor is low due to transferring to machine - two category of mass production: (a.) Quantity Production (b.) Flow Production

(a.) Quantity Production - involves the mass production of single parts on standard machine tools - eg: injection moulding machine, automatic screw machine etc. - the production is devoted full time to satisfy very large demand rate - eg of items: components for assemble products (screw, bolts, nuts, nails etc) (b.) Flow Production - the items are made to flow through a sequence of operation by material handling devices (conveyor, moving belts, transfer devices etc) - eg: * automated transfer for the production of complex discrete parts * manual assembly lines for assembly of complex products * automotive engine block

Screw Production Machine

(a. Quantity Production)

Manual Production Line (b. Flow Production)

Types of Production
Mass Production Batch Production Job Shop Production Quantity Production Rate Labor Skill Level General Equipment Special Tooling Process Plant Layout Product Flow Special

Manufacturing Activities
Manufacturing firms must organize themselves to accomplish the 5 functions describe above 1. Business Function 2. Product Design 3. Manufacturing Planning 4. Manufacturing Control 5. Factory operation

Manufacturing Activities
2. Product Design

Product Development
Engineering Drawing Bill of Material 1. Business Function Marketing Sales Order entry Customer billing 4. Manufacturing Control Shop floor control

3. Manufacturing Planning

Factory Operation

Process planning

Master Schedule
Requirement Planning Capacity Planning

Quality control
Inventory control

1. Business Function
- Principle means of communicating with the customer - The beginning and the end of information processing cycle - An order to produce product will typically originate from the sales and marketing department

2. Product Design
- The design will have been provided by the customer - The cycle of events that initiates a new product design often originates in the sales and marketing department - The product design is documented by means of component drawing, specifications, Bill of Material (BOM) etc - Prototype built for testing and demo - Upon completion of the design and fabrication of prototype, management is invited in for a show & tell presentation

3. Manufacturing Planning
- Information & documentation from design flow into the manufacturing planning function - Including manufacturing engineering, industrial engineering and production planning & control - The information processing activities in manufacturing planning include: (a.) Process Planning - determining the sequence of the individual processing and assy. Operations needed to produce part (b.) Master Schedule - listing of the products to be made, when they are to be delivered and in what quantities - the individual components and subassemblies that make up each product must be planned

(c.) Required Planning - All items (such as raw material, purchase part from supplier) must be planned so that they are available when needed (d.) Capacity Planning - concerned with planning the manpower and machine resources of the firm

4. Manufacturing Control
- Concerned with managing and controlling physical operations in the factory to implement the manufacturing plan - Production Scheduling : concerned with assigning start dates and due dates to the various part - Inventory Control : attempts to balance up too much or too litter inventory/ stock - Quality Control : to ensure that the quality of the product and its component meet the standards specified by the product designer

5. Factory Operation (in manufacturing floor)

1. Processing Raw Material 2. Assembly Add Value Finished Product

3. Material Handling
4. Inspection & Testing

Receiving 5. Control

Shipping