Unit 5 Automated Manufacturing. Automation is the use of control systems such as numerical control,...

Unit 5

Automated Manufacturing

Automation is the use of control systems such as numerical control, programmable logic control, and other industrial control systems and information technology including computer-aided technologies, to control industrial machinery and processes, reducing the need for human intervention

Automated Manufacturing

Reasons for Automation in the Factory Include

• Reduced labor costs

• Sales growth

• Better quality

• Reduced inventory

• Increased worker productivity

Two Types of Automation

• Fixed systems and

• Flexible systems

Current Factory Technology Includes:

• Computer networks including ERP

• Data collection and reporting

• Automated material handling

• Cells and work centers

• Automated inspection and testing

• The paperless factory

• Robots

Chapter 11

Production Support Machines and Systems

Industrial Robots

• A robot is an automatically controlled, programmable, multipurpose, manipulating machine with several programmable axes, which may be either fixed in place or mobile for use in industrial automation applications.

• Key words are reprogrammable and multipurpose

Industrial Robot at Work

Industrial Robots

• The basic robot system consists of manipulator, power supply, controller, end effectors, interfacing or required equipment such as devices and sensors and any communications interface that is operating and monitoring the robot, equipment and sensors

• The mechanical arm is driven by electric motors, pneumatic devices, or hydraulic actuators

• Six motions are identified: Arm sweep, shoulder swivel, elbow extension, pitch, yaw, and roll.

Industrial Robots

• Robotic arm geometry classification includes the following: Cartesian geometry, cylindrical geometry, spherical geometry, and articulated geometry.

• End effector or end-of-arm tooling must be provided for robots to have production capability

• The controller is a special-purpose computer with a central processing unit which controls the robot’s arm and the work cell in which it is operating.

• Robots are programmed by keying in or selecting menu commands in the controller language, moving the robot arm to the desired position in the work cell, and recording the position in the program often with a teach pendant.

Industrial Robots

• Programming methods include:– Active robot teaching (teach pendant)– Passive robot teaching (lead-through)– Off-line robot programming

• Robot applications include: Material processing, material handling, and assembly and fabrication.

• Selecting and justifying robot application requires a detailed design process and cost analysis.

• Justifying a robotic system is performed using this model: [P = I/(S-E)], where:– P = # of years for pay back– I = Investment in robot– S = Savings in robot– E = Cost of servicing the robot

Automated Material Handling

• Material-handling process for parts and raw materials should be automated only after every unnecessary inch of material transport distance has been removed from the production process.

• The work simplification and analysis process that precedes the design and selection of material-handling automation starts with a diagram of the production flow, using process flow analysis symbol shown on page 461.

Automated Material Handling

• The transfer mechanism used to move parts between work cells and stations serves two main functions: – Move the part in the most appropriate manner between

production machines, and – Orient and position the part with sufficient accuracy at the

machine to maximize productivity and quality.

• Automated transfer systems include:– Continuous transfer such as overhead monorail– Intermittent or synchronized transfer such as the walking beam

transfer system– Asynchronous transfer or power-and-free systems as in

conveyor and pallet system.

Integrated Material Handling Systems

Automatic guided vehicles (AGV)

An AGV is a vehicle equipped with automatic guidance equipment capable of following prescribed guide paths and may be equipped for vehicle programming and

stop selection, blocking, and any other special function required by the system.

Automatic guided vehicles (AGV)

• AGV types include: Towing vehicles, unit load vehicles, pallet truck vehicles, fork lift vehicles, light load vehicles, and assembly line vehicles.

• AGV systems must perform five functions, namely: Guidance, routing, traffic management, load transfer, and system management.

• AGV systems must be justified based on the current and future material-handling requirements.

AGV

Typical AGV Route

AGVs

Automated Storage and Retrieval Systems (AS/RS)

• Materials to be stored and retrieved include: 1) raw materials, 2) unsold finished products, 3) production parts, 4) purchased parts and subassemblies used in the assembly of products, 5) rework and scrap that result from production operations, 6) spare parts for repair of production machines and facilities, and 7) general office supplies including tools and instruments.

• AS/RS is a combination of equipment and controls that handles, stores, and retrieves materials with precision, accuracy, and speed under a defined degree of automation.

Automated Machine Tools and Tooling

• Includes different machines and tooling systems…:– Machine tools– Auxiliary equipment (MHS, robots etc)– Tools– Tooling

Conventional and CNC Lathes

CNC Milling Machines

Drilling Machines

Sawing Machines

Surface Grinder

Fold and Shear Coiline

Automated Punching Machine

Hydraulic CNC Folder

Plastic injection molding machine

Extrusion Machine

Gas Furnace

Column Press and Straight Side Press

Forging Machine

PalletShuttle

Chapter 13

Quality and Human Resource Issues in Manufacturing

SPC and the Normal Curve

Review

• Deming’s 14 points for management

• Total quality management (TQM)

• Quality tools and processes (for quiz 3)

Programmable Logic Controllers (PLC)

Bringing it all Together

Components of Flexible Manufacturing System

• FMS workstations:– FMS for prismatic parts– FMS for rotational parts– Robots– Fixtures and pallets– Tooling– Operators– Inspection system– Coolant and chip handling systems– Cleaning stations– FMS off-line operations– Control station

Components of Flexible Manufacturing System

• Material handling system:– Parts delivery:

• Material handling outside the FMS• Material handling inside the FMS• Conveyor systems• Cutting tool delivery

– Load/unload stations:• Handling equipment• Operator control

– Buffer storage

FMS Benefits• Producing a family of parts• Random launching of parts• Reduced manufacturing lead time• Reduced work-in-process• Reduced operator requirements• Expandability• Increased machine utilization• Reduced capital equipment costs• Responsiveness to change• Ability to maintain production• Product quality improvement• Reduced labor costs• Better management control

Enterprise Resource Planning (ERP)