IAT 0932 Chapter1 Rev2

7/28/2019 IAT 0932 Chapter1 Rev2

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CHAPTER 1:Introduction to

Automationand

Manufacturing

Rev: 2_Jan2011


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Reference Book

Automation, Production System and CIM


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Automation Definition

Automation technology concern with theapplication of mechanical, electronic and

computer-based systems to operate and control

production


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Example :* Automatic Machine tools to process

parts (eg.CNC machine)

* Automatic Assembly Machines (eg.Packaging machine)

* Industrial Robotics

* Automatic Material Handling & StorageSystem (eg. Positioning unit)

* Automatic Inspection System forQuality Control (eg. Vision system)

Technology concern with Automation


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Types of Automation

1. Fixed Automation (Hard Automation)

- a system in which the sequence of processing (or

assembly) operations is fixed by the equipmentconfiguration

- Operations in the sequence are simple

- It is Integration/ Coordination of many such operations

into one piece of equipment that makes the systemcomplex


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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 demandrates and volume

- High initial cost of equipment can be spread over a largenumber of unit

- Cost attractive

- Example: ~ Mechanized Assembly Lines (conveyor)

~ Machining Transfer Lines

~ Stamping Machine

~ Forging Machine


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Example of Stamping Machine


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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


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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 settingwill be taking times

- Example: CNC Machine, Robotics


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Example of CNC Machine


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3. Flexible Automation

- capable of producing a variety of products withvirtually no time lost for changeover from one productto the next

- no time lost while reprogramming the system andalternating the physical setup

- the system can produce various combinations andschedules of products instead of requiring that they bemade in separate batches

- Feature:

* High investment for a custom engineered system

* Continuous production of variable mixtures ofproducts

* Medium production rates

* Flexibility to deal with product design variations


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Flexible Automation (continue).

- Essential features that distinguish flexible automation fromprogrammable automation:

* Capacity to change part programs with no lost production

time

* Capability to change over the physical setup again withno 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


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- The use of pallet fixtures that hold the parts and transferinto position at the workplace is one way of implementingthis 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 itinto place simultaneously with the part

Flexible Automation (continue)


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Example of Flexible Manufacturing System


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Produc

tVariety

High

Medium

Low

Low Medium High

Parts per year

Type of Automation as a function Volume and Product Variety

PROGRAMMABLE

AUTOMATION

FLEXIBLE

AUTOMATION

MANUAL

METHOD FIXEDAUTOMATION


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Reason for Automating

1. Increase Productivity

- Higher production rates (Output/hour) are achievedcompared to manual operations

2. High Cost of Labor

- Machine can produce at higher rates of output resultinglower cost per unit labor

3. Labor shortages- Labor shortages stimulate the development of automation asa substitute for labor

4. Trend of labor toward the service sector

- the growth of government employment at federal, state andlocal levels has consumed a certain share of the labor market

- There has been a tendency for people to view factory workas tedious, demeaning and dirty. This view has cause them toseek employment in the service sector


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5. Safety

- By automating the operation and transferring the operator from

an active participation to a supervisory role, work is made safer

6. High cost of raw material

- Greater efficiency in using raw material is need7. Improve Product Quality

- Automation produced parts with greater consistency and

conformity to qualify specifications

8. 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

Reason for Automating (continue)..


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9. Reduction of in-process inventory

- Automation tends to accomplish this goal by reducing the time a

work parts spends in the factory

10. High cost of not automating

- The benefits of automation such as improved quality, highersales, better labor relation will bring up company image

Reason for Automating (continue)..


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Manufacturing


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1. Basic Producer

- Take the natural resources and transform iron ore into

steel ingots

Three categories to classify company :

~ in the transformation of natural resources and

basic raw materials into goods

Steel Ingot


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2. Converter

- Take the output of the basic producer and transform theraw 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 physicalform, product are not assembled item


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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


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Types of Production

Another way of classifying production activity is

according to the quantity of product made

1. 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


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Example of Aircraft Production


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2. Batch Production

- manufacture of medium size lots of the same item or

product- the lot maybe produced only once, or produced atregular intervals

- purpose : to satisfy continuous customer demand

- capability of production rate to exceeds the demandrate build up inventory

- than it changes over to another model

- when the inventory stock is depleted production isrepeated to build up inventory again

- manufacturing equipment used is general purpose butdesigned for higher rates

- eg: furniture, textbook, components part for assembleconsumer product, machine shop etc


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Example of Batch

Production Products


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3. Mass Production

- continuous specialized manufacture of identical

products- very high production rates

- equipmentdedicated to manufacture particularproduct at very high demand rates

- the entire plan is designed for the exclusive purposefor 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


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(a.) Quantity Production

- involves the mass production of single parts on standardmachine tools

- eg: injection moulding machine, automatic screw machineetc.

- the production is devoted full time to satisfy very largedemand 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 operationby 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


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Screw Production Machine

(a. Quantity Production)

Manual Production Line

(b. Flow Production)


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Types of Production

Job Shop

Batch

Production

Mass

Production

Production Quantity

Production Rate

Labor Skill LevelEquipment

Special Tooling

Plant Layout

SpecialGeneral

Product FlowProcess


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Manufacturing firms must organize themselves toaccomplish the 5 functions describe above

1. Business Function

2. Product Design

3. Manufacturing Planning

4. Manufacturing Control

5. Factory operation

Manufacturing Activities


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Manufacturing Activities

Factory

Operation

2. Product Design

1. Business

Function

3. Manufacturing

Planning

4. ManufacturingControl

Marketing

Sales

Order entry

Customer billing

Product Development

Engineering Drawing

Bill of Material

Process planning

Master Schedule

Requirement Planning

Capacity Planning

Shop floor control

Quality control

Inventory control


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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


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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 bedelivered and in what quantities

- the individual components and subassemblies that

make up each product must be planned


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(c.) Required Planning

- All items (such as raw material, purchase part fromsupplier) must be planned so that they are available

when needed

(d.) Capacity Planning

- concerned with planning the manpower and machine

resources of the firm


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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 toolitter inventory/ stock

- Quality Control : to ensure that the quality of the product and

its component meet the standards specified by the product

designer


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5. Factory Operation

(in manufacturing floor)

1. Processing

2. Assembly

3. Material Handling

4. Inspection & Testing

RawMaterial FinishedProduct

Add

Value

5. Control

Receiving Shipping

Documents

IAT 0932 Chapter1 Rev2