Ch 14

Single-Station Manufacturing Cells

Sections:
1. Single-Station Manned Workstations
2. Single-Station Automated Cells
3. Applications of Single-Station Cells
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4. Analysis of Single-Station Cells
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 Classification of
Single-Station Manufacturing Cells

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 Single-Station Manufacturing Cells

 Most common manufacturing system in industry

 Operation is independent of other stations
 Perform either processing or assembly operations
 Can be designed for:
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 Batch production
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 Mixedofmodel
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 Single-Station Manned Cell

“One worker tending one production machine (most

common model)”
 Most widely used production method, especially in
job shop and batch production
 Reasons
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timematerial is protected under all copyright laws
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least capital investment
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 Easiest to install and operate
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 Typically,
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the book
 MostProduction
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4
 Single-Station Manned Cell Examples
 Worker operating a standard machine tool
 Worker loads & unloads parts, operates machine
 Machine is manually operated
 Worker operating semi-automatic machine
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 Worker attention not required continuously during
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entirewithout
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 Worker
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5
 Variations of
Single-Station Manned Cell
 Two (or more) workers required to operate machine
 Two workers required to manipulate heavy forging at
forge press
 Welder and fitter in arc welding work cell
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plus support All
equipment
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 Single-Station Automated Cell

“Fully automated production machine capable of

operating unattended for longer than one work cycle”
 Worker not required except for periodic tending
 Reasons why it is important:
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 Labor cost is reduced
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Easiest exist.
and least expensive automated system to
No portionimplement
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 Production
any means, rates usually
without permission higherfrom
in writing thanthe
manned cellFor
publisher.
the exclusive
 First use
stepofinadopters of the book
implementing an integrated multi-station
Automation, Production
automated Systems, and Computer-Integrated
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7
 Enablers for
Unattended Cell Operation
 For single model and batch model production:
 Programmed operation for all steps in work cycle
 Parts storage subsystem
 Automatic loading, unloading, and transfer between
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and machine
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 Periodic This material is protected
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finished work
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currently exist. of starting work units, and other
resupply
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tending
any means, without permission in writing from the publisher. For
 Built-in safeguards to avoid self-destructive operation or
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8
 Enablers for
Unattended Cell Operation
 For mixed model production:
 All of the preceding enablers, plus:
 Work unit identification:
 Automatic identification (e.g., bar codes) or
sensors
©2008 Pearson that recognize
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NJ. All
starting
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material is protected under all copyright laws
 If starting
as they currently exist. units are the same, work unit
No portion ofidentification
this materialismay
unnecessary
be reproduced, in any form or by
 Capability
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without permission programs
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from each work unit
publisher. For
styleuse
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 Capability
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9
 Parts Storage Subsystem and
Automatic Parts Transfer
 Are necessary conditions for unattended operation
 Given a capacity = np parts in the storage subsystem, the
cell can theoretically operate for a time
UT = npTc
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 In reality, unattended time will be less than UT because
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 Parts Storage Capacity

 Typical objectives in defining the desired parts storage

capacity np:
 Make npTc = a fixed time interval that allows one worker
to tend multiple machines
 Make npTc = time between scheduled tool changes
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 Make n T = one complete shift
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 Make
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currently = one overnight (“lights-out operation”)
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The time
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without operation
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in writing fromdirectly with storage
the publisher. For
capacity, so there is an advantage to designing the storage
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subsystem with sufficient capacity to satisfy the plant’s operational
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 Storage Capacity of One Part

 Example: two-position automatic pallet changer (APC)

 With no pallet changer, work cycle elements of
loading/unloading and processing would have to be
performed sequentially
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copyright
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 they
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pallet changer,
Noperformed
portion of this material may be reproduced, in any form or by
simultaneously
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 CNC Machining Center with Automatic
Pallet Changer - Stores One Part

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 Storage Capacities Greater Than One

 Machining centers:
 Various designs of parts storage unit interfaced to
automatic pallet changer (or other automated
transfer mechanism)
 Turning centers:
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Plastic molding
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 Starting
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Production is sheet
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 Storage Capacities Greater Than One

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rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
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Machining center and automatic pallet changer with pallet holders
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arranged radially; parts storage capacity = 5
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 Storage Capacities Greater Than One

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
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Machining
the exclusivecenter
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book
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Automation, Production Systems, and Computer-Integrated
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 Storage Capacities Greater Than One

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
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 Storage Capacities Greater Than One

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
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theMachining
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Automation, storage capacity = 12 and Computer-Integrated
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18
 Applications of Single Station
Manned Cells
 CNC machining center (MC) with worker to load/unload
 CNC turning center (TC) with worker to load/unload
 Cluster of two CNC turning centers with time sharing of
one worker to load/unload
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All
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as they
One currently
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electronics subassembly workstation
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this material into
may PCB
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 Stamping presspermission
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19
 Applications of Single Station
Automated Cells
 CNC MC with APC and parts storage subsystem
 CNC TC with robot and parts storage carousel
 Cluster of ten CNC TCs, each with robot and parts
storage carousel, and time sharing of one worker to
load/unload
©2008 the carousels
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rights reserved.
 Plastic This molding
injection material is
onprotected
automatic under all with
cycle copyright
robotlaws
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armcurrently
to unloadexist.
molding, sprue, and runner
No portion of this
 Electronics material may
assembly be reproduced,
station in anyinsertion
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anymachine
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 Stamping press stamps parts from long coil
Automation, Production Systems, and Computer-Integrated
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20
 CNC Machining Center

“Machine tool capable of performing multiple operations

that use rotating tools on a workpart in one setup under
NC control”
 Typical operations: milling, drilling, and related operations
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Typical features to reduce nonproductive time:
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
as theyAutomatic tool changer
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 Automatic
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Automatic permission
pallet changerin writing from the publisher. For
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 CNC Horizontal Machining Center

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 CNC Turning Center

“Machine tool capable of performing multiple operations on

a rotating workpart in one setup under NC control”
 Typical operations:
 Turning and related operations, e.g., contour turning
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All
 Drilling
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This operations
material along
is protected workpart
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 CNC Turning Center

©2008 Pearson Education, Inc., Upper Saddle River, NJ. All

rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
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 Automated Stamping Press

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rights reserved. This material is protected under all copyright laws
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No portion of this material may be reproduced, in any form or by
anyStamping
means, without
press onpermission in writing
automatic cycle fromstampings
producing the publisher. For
from sheet
themetal
exclusive
coil use of adopters of the book
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25
 CNC Mill-Turn Center

“Machine tool capable of performing multiple operations

either with single point turning tools or rotating cutters in
one setup under NC control”
 Typical operations:
 Turning,
©2008 Pearsonmilling, drilling
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 Enabling This material is protected under all copyright laws
feature:
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 Capability to control position of c-axis in addition to x-
No portion of this control
and z-axis material(turning
may be reproduced, in anytoform
center is limited or byz-
x- and
any means, without permission in writing from the publisher. For
axis control)
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 Part with Mill-Turn Features

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Automation,Example part with
Production turned, and
Systems, milled, and drilled features
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27
 Sequence of Operations of a
Mill-Turn Center for Example Part

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rights reserved. This material is protected under all copyright laws
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No(1)portion of thisdiameter,
Turn smaller material(2)
maymillbe
flatreproduced, in any formangular
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positions, without permission
positions for squarein cross
writing from (3)
section; thedrill
publisher.
hole withFor
thepart in programmed
exclusive angular position,
use of adopters and (4) cutoff of the machined
of the book
piece
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