ISAT 331
Automation in Manufacturing
How does ISAT331 fit in the curriculum?
211, 330
211,330
Factory Operations
211
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
Computerization
Manufacturing
System
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
MH automated
Changeover (set up)Time
Product Variety
Job Shop
Sof
t
Low
Mid Variety
Mid Production
(Most Difficult)
Mass Production
100
10,000
Production Quantity
1M
Hig
h
Fig 1.3
Types of Production Plant (facilities) and Layout
Product Variety
Har
d
Sof
t
Low
•Fixed Position (Large)
•Process
•Process (Batch)
•Cellular (GT families)
•FMS (GT families- automated MH)
Job Shop
•Product (Flow line)
•Process (Quantity)
Mid Variety
Mid Production
(Apply GT)
Mass Production
100
10,000
Production Quantity
1M
Hig
h
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
Product Variety
Har
d
Sof
t
Low
100
10,000
Production Quantity
1M
Hig
h
Fig 1.1 Automation/Production Volume/Product Variety
Programmable Automation
Har
d
Flexible Automation
Product Variety
Job Shop
Sof
t
Low
Mid Variety
MidAutomation
Production
(Most Difficult)
Fixed Automation
Mass Production
Manual
100
10,000
Production Quantity
1M
Hig
h
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