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INTRODUCTION TO AUTOMATION (AUTOMATED MANUFACTURING SYSTEMS (1. Fixed…
INTRODUCTION TO
AUTOMATION
PRODUCTION SYSTEMS
Definition
A collection of people, equipment, and
procedures organized to accomplish the
manufacturing operations of a company.
2 Categories
Facilities
The factory and equipment in the facility and
the way the facility is organized (plant layout)
Manufacturing Support Systems
Set of procedures used by a company
To manage production
To solve technical and logistics problems in
ordering materials, moving work through the
factory, and ensuring that products meet quality
standards
Facilities
Include the factory, production machines
and tooling, material handling equipment,
inspection equipment, and computer systems
that control the manufacturing operations
Plant Layout
The way the equipment is physically arranged in the factory
Manufacturing Systems
Logical groupings of equipment
and workers in the factory
i. Production line
ii. Stand-alone workstation and worker
3 Categories (human participation)
Manual work systems
Worker-machine systems
Automated systems
Cycle of information-processing
activities
Business Functions
Sales and marketing, order entry,
cost accounting, customer billing.
Product Design
Research and development, design
engineering, prototype shop
Manufacturing Planning
Process planning, production planning,
MRP, capacity planning
Manufacturing Control
Shop floor control, inventory control, quality control
AUTOMATION IN
PRODUCTION SYSTEMS
2 Categories
Computerization of the manufacturing support systems
Automation of manufacturing systems in the factory
2 Categories overlap because
MSS connected to MS (CIM)
Automation
Definition
The technology by which a process or procedure is accomplished without human assistance
Elements of
Automated System
i. Power. To accomplish the process and
operate the automated system.
ii. Program of instructions. To direct the process.
iii. Control system – to actuate the instructions
MANUAL LABOR IN
PRODUCTION SYSTEMS
2 Aspects
Manual labor in factory operations
The long term trend is toward greater use of
automated systems to substitute for manual labor.
When is Manual
Labor Justified?
Some countries have very low labor
rates and automation cannot be justified
Task is too technologically difficult to automate
Short product life cycle
Customized product requires human flexibility
To cope with ups and downs in demand
To reduce risk of product failure
Labor in manufacturing support systems
Product designers who bring creativity to the design task
Manufacturing engineers who:
Design the production equipment and tooling
And plan the production methods and routings
Equipment maintenance
Programming and computer operation
Engineering project work
Plant management
AUTOMATION PRINCIPLES
AND STRATEGIES
Ten Strategies for Automation
and Process Improvement
Specialization of operations
Combined operations
Simultaneous operations
Integration of operations
Increased flexibility
Improved material handling and storage
On-line inspection
Process control and optimization
Plant operations control
Computer-integrated manufacturing
AUTOMATED
MANUFACTURING
SYSTEMS
1. Fixed Automation
A manufacturing system in which
the sequence of processing (or assembly)
operations is fixed by the equipment
configuration
Typical Features
High production rates
Suited to high production quantities
Relatively inflexible in accommodating product variety
High initial investment for custom-engineered equipment
3. Programmable Automation
A manufacturing system designed with
the capability to change the sequence of
operations to accommodate different product
configurations
Typical Features
Most suitable for batch production
Lower production rates than fixed automation
High investment in general purpose equipment
Flexibility to deal with variations and changes in product configuration
Physical setup and part program must be changed between jobs (batches)
2. Flexible Automation
An extension of programmable automation
in which the system is capable of changing over
from one job to the next with no lost time
between jobs
Typical Features
Medium production rates
Flexibility to deal with soft product variety
High investment for custom-engineered system
Continuous production of variable mixes of products
Reasons for Automating
To reduce labor cost
To improve worker safety
To improve product quality
To increase labor productivity
To reduce manufacturing lead time
To mitigate the effects of labor shortages
To avoid the high cost of not automating
To accomplish what cannot be done manually
To reduce or remove routine manual and clerical task