ISAT 331

Automation in Manufacturing

How does ISAT331 fit in the curriculum?

211, 330
Factory Operations 211

211,330

211, 330 211, 330

ISAT 211 & 330

331

331

331

331

ISAT 331

References
1. Groover, M.P Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall 2001 2. Bedworth, D.D.,Henderson, M.R., and Wolfe P.M., ComputerIntegrated Design and Manufacturing, McGraw-Hill, 1991. 3. Chang,T., Wysk,R..A, Wang, H. Computer Aided Manufacturing, Prentice Hall, 2nd Ed, 1991

Module 1 Introduction 1/10/05

Production Systems Facilities Automation in Production Systems Manual Labor in Production Systems Automation Principles and Strategies CAD, CAM and CIM

ISAT330
Manufacturing Support Activities

ISAT331
Manufacturing System

Computerization

CIM
Automation

Terminologies

Computers in Manufacturing
Automate physical system and information system in manufacturing
Automation is more related to automating the factory operations Computerization is more related to automating information cycle

CIM is more related to automating of both factory operations and information cycle

Product Variety vs Production Quantity

Har d Job Shop Product Variety MH automated Changeover (set up)Time

Mid Variety Mid Production (Most Difficult)

Mass Production 100 10,000 1M Hig h

Sof t
Low

Production Quantity

Fig 1.3

Types of Production Plant (facilities) and Layout

Har d Fixed Position (Large) Process Process (Batch) Cellular (GT families) FMS (GT families- automated MH) Job Shop

Product Variety

Mid Variety Mid Production (Apply GT)

Product (Flow line) Process (Quantity)

Mass Production

Sof t
Low

100

10,000

1M Hig h

Production Quantity

Characteristics of Production Plants

Job Shop has processes that cope with low volume and high number of products - Uses Process or Fixed position layout - Make to order. - Production Rate = Demand Rate

Batch, cellular, and FMS Production has processes that cope with medium volume and medium variety in products -Cellular deals with harder variety products than FMS - FMS is highly automated (MH) when compared to cellular - Repeated set up-a major disadvantage. - Production rate > Demand rate. - Make to Stock.

Characteristics of Production Plants

Mass Production has processes that cope with high volume and limited number of products - Process or cellular layout is used for quantity production (single station equipment) - Product layout Flow Line when multiple stations are required (single- or mixed model lines) - Demand Rate ~ Production Rate

Automation of Production Plant

Definition of Automation Why to Automate? Arguments for Automation Arguments against Automation Examples Types of Automated Manufacturing Systems

Categorized based on sequence of operations Justified based on production volume and variety of products a) Fixed Automation b) Programmable Automation c) Flexible Automation

Manual vs Automation
Har d

Sof t
Low

Product Variety

100

10,000

1M Hig h

Production Quantity

Fig 1.1 Automation/Production Volume/Product Variety

Programmable Automation
Har d Job Shop Product Variety Flexible Automation

Mid Variety Mid Production Automation (Most Difficult) Manual

100 10,000

Fixed Automation

Mass Production 1M Hig h

Sof t
Low

Production Quantity

Programmable Automation
MOST FLEXIBLE Sequence of operations can be changed (variety of products that are made by similar processes) High investment (general purpose equipment)

Low Medium production rate (relatively longer time lost for changeovers of programming and set-up) Automation of operations (processes or workstations)
is emphasized (not MH)

Fixed Automation
MOST EFFICIENT Sequence of operation is fixed (fixed configurations)

Many simple ( reliability) operations (complex system)

Initial investment is high (custom-engineered equipment) Production rates are high (mass production-Examples) Automated Operations (processes or workstations) and Material handling

Flexible Automation
Extension of Programmable Automation with
Lower time lost on changeovers (continuous production of a group of parts GT family- that accommodate part variations within the family) Mid volume/variety range

Higher investment (custom-engineered devices (e.g fixtures and Jigs) for changeover)

Automation Strategies & Migration

Automation is not the answer (Robotics application?) Main principle Understand (charting?), Simplify, and Automate Strategies? Automation Migration Strategy

Fig 1.9

Manufacturing Support Activities

Manufacturing System

Back to our Conceptual Model

Factory Operations
(Fig 2.2) Processing advance to completion (Basic, Secondary, Property Enhancement, Finishing) Assembly Material handling&Storage Inspection (specifications)and Testing (function) Control on shop floor (process control, quality control)

SAP system?

Manufacturing Support Activities

(Fig 2.4) Business functions (type of orders?) Product Design (source of specifications?) Manufacturing Planning (process planning and route sheet?) Manufacturing Control (management) implement plans(type of controls?), performance of processes # rejects, machine rate, etc, performance of plant operating cost, meeting schedule, etc)

Manual Labor in Production System

Factory Operations Supporting Activities

Fig 24.7 Scope of CAD, CAM and CIM

Fig 24.8

Definitions
CAD is any design activity that involves the effective use of computer technology to create,modify, or document an engineering design (part or system) CAM is the effective use of computer technology in the planning, management, and control of the manufacturing function CAD/CAM integration of the design and manufacturing activities. That is to automate the transition from design to manufacturing (e.g NC and process plan and Rapid Prototyping)

Home Work#1
Due Wednesday 1/18/2006

1) Explain and contrast the characteristics of the basic production systems 2) Explain and contrast the characteristics of the basic automated production systems 3) Discuss TWO situations in which humans are preferred over automation in Factory Operations (blue collar tasks) 4) Discuss TWO situations in which humans are preferred over automation in Manufacturing Support Systems (white collar tasks) 5) Explain THREE strategies for automating production systems

Unused Slides