Our Lady & St John Catholic College
Edexcel BTEC Level 3 Nationals specification in Engineering
Unit 31 – Computer Aided Manufacturing
Assignment 3 :- Industrial Robots and Flexible
Manufacturing Systems In
Engineering
The following assignment covers the assessment criteria for:-
P5 – Describe the applications, advantages and limitations of industrial
robots
P6 - Explain why a flexible manufacturing system will produce
productivity gains for a business deploying a range of processing
machines, loading and unloading systems and coordinated work
schedules [IE4]
M3 - Explain the use and operation of robots to move parts between
workstations in a flexible machining system
Scenario of the Assignment
You are asked by an employer to produce a report on the benefits and limitations of
using industrial robots and the use of flexible manufacturing systems. Complete the
tasks as described below to review the application of industrial robots and to explain
why a flexible manufacturing system can produce gains for a business
P5 – Describe the applications, advantages and limitations of industrial
robots
This task is about the application of robot devices and the selection of a particular
type of robot to carry out a specific task. Do not look at the detailed operating
principles of this type of equipment
You must include applications of an industrial robot in your report. These need to
be carefully chosen so that a range is considered (a pick-and place system for
assembling components onto a jig/fixture, loading of raw material into a machine
tool, moving components between stations in a cell).
Some of the evidence should be taken from your case study based on a visit to
local industry including photos and explanations of the equipment / methods used
to ensure the robots are used in a safe and correct manner.
1. Sectors of Manufacturing
For each of the sectors of Manufacturing Industry identify some of the
stages where an industrial robot may be used
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
Automotive
Aerospace
Space
Biotechnology
Chemical
Electrical and Electronics
Food and Drink processing
Metals/minerals/materials
Marine, Nuclear
Oil & Gas
Pharmaceutical
2. Applications of industrial robots
Show using annotated diagrams and photographs examples of the ways
that industrial robots could be used for the following applications in any
of the manufacturing sectors.
a)
b)
c)
d)
e)
f)
g)
h)
Pick and place systems for assembling components onto a jig/fixture
Joining parts together (riveting, welding, soldering)
Product packaging
Loading of raw material into a machine tool
Moving components between stations in a manufacturing cell
Robotic spraying of paint on an assembly line
Material removal (Drilling of holes, machining)
Inspection of parts / assemblies
3. Safe operation
What are the Codes of practice that should be adhered to when
installing and operating an industrial robot?
You should make reference to :a) Health and Safety Executive HSG43
b) Provision and Use of Work Equipment Regulations
For each of the 3 separate applications
4. Advantages
What are the advantages of using industrial robots in manufacturing?
Make reference to the following points:a) Consistency of performance,
b) 24/7 continuous working,
c) Reduced cycle times;
d) Reduced amount of operator errors
e) Improved quality of product
5. Limitations
What are the limitations of using industrial robots in manufacturing?
Make reference to the following points:a)
b)
c)
d)
e)
f)
High standard of maintenance required
Precise programming needed (time, training, specialist knowledge)
How computer systems failure will cause breakdown
New products require complete reprogramming
Certain processes still need a skilled operator
Complex and expensive equipment to buy and install
P6 - Explain why a flexible manufacturing system will produce
productivity gains for a business deploying a range of processing
machines, loading and unloading systems and coordinated work
schedules
1. Explain how Flexible Manufacturing Systems can produce
productivity gains for the following families of parts.
a) By Assembly (to make a single assembly)
b) By Type (similar products)
c) By size and similar operations (allows product mix and volume changes)
2. Use your knowledge of an industrial visit and explain how it is
important for that business to design their manufacturing system to
be flexible.
You may wish to Include photographs or diagrams of the business to help
explain the flow of manufacture through the plant.
M3 - Explain the use and operation of robots to move parts between
workstations in a flexible machining system
In your answer you should provide a range of annotated examples and explore into
a) Material handling
b) Automated Guided Vehicles (AGV)
Websites
http://www.prospects.ac.uk/engineering_manufacturing_sector_overview.htm
Manufacturing Sectors
http://en.wikipedia.org/wiki/Industrial_robot
Industrial Robots
http://en.wikipedia.org/wiki/Flexible_manufacturing_system
FMS Systems
http://www.osha.gov/dts/osta/otm/otm_iv/otm_iv_4.html
INDUSTRIAL ROBOTS AND ROBOT SYSTEM SAFETY
Textbooks
Amiriouche F M – Principles of Computer Aided Design and Manufacturing
(Prentice Hall, 2004)
ISBN 0130646318
Colestock H – Industrial Robotics: Selection, Design and Maintenance (TAB
Books Inc, 2004)
ISBN 0071440526
Hill T - Manufacturing Strategy
ISBN 0-333-57648-9
Manufacturing Flexibility: a literature review. By A. de Toni and S. Tonchia.
International Journal of Production Research, 1998, vol. 36, no. 6, 1587-617.
Computer Control of Manufacturing Systems. By Y. Korem. McGraw Hill, Inc. 1983,
287 pp, ISBN 0-07-035341-7
Manufacturing Systems – Theory and Practice. By G. Chryssolouris. New York, NY:
Springer Verlag, 2005. 2nd edition.
Design of Flexible Production Systems – Methodologies and Tools. By T. Tolio.
Berlin: Springer, 2009. ISBN 978-3-540-85413-5