Unit 5
Automated Manufacturing
Automated Manufacturing
Automation is the use of control systems such as numerical
control, programmable logic control, and other industrial
control systems and information technology including
computer-aided technologies, to control industrial machinery
and processes, reducing the need for human intervention
Reasons for Automation in the
Factory Include
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Reduced labor costs
Sales growth
Better quality
Reduced inventory
Increased worker productivity
Two Types of Automation
• Fixed systems and
• Flexible systems
Current Factory Technology Includes:
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Computer networks including ERP
Data collection and reporting
Automated material handling
Cells and work centers
Automated inspection and testing
The paperless factory
Robots
Chapter 11
Production Support Machines and Systems
Industrial Robots
• A robot is an automatically controlled,
programmable, multipurpose, manipulating
machine with several programmable axes,
which may be either fixed in place or
mobile for use in industrial automation
applications.
• Key words are reprogrammable and
multipurpose
Industrial Robot at Work
Industrial Robots
• The basic robot system consists of manipulator,
power supply, controller, end effectors,
interfacing or required equipment such as
devices and sensors and any communications
interface that is operating and monitoring the
robot, equipment and sensors
• The mechanical arm is driven by electric motors,
pneumatic devices, or hydraulic actuators
• Six motions are identified: Arm sweep, shoulder
swivel, elbow extension, pitch, yaw, and roll.
Industrial Robots
• Robotic arm geometry classification includes the
following: Cartesian geometry, cylindrical geometry,
spherical geometry, and articulated geometry.
• End effector or end-of-arm tooling must be provided for
robots to have production capability
• The controller is a special-purpose computer with a
central processing unit which controls the robot’s arm
and the work cell in which it is operating.
• Robots are programmed by keying in or selecting menu
commands in the controller language, moving the robot
arm to the desired position in the work cell, and
recording the position in the program often with a teach
pendant.
Industrial Robots
• Programming methods include:
– Active robot teaching (teach pendant)
– Passive robot teaching (lead-through)
– Off-line robot programming
• Robot applications include: Material processing, material
handling, and assembly and fabrication.
• Selecting and justifying robot application requires a
detailed design process and cost analysis.
• Justifying a robotic system is performed using this
model: [P = I/(S-E)], where:
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P = # of years for pay back
I = Investment in robot
S = Savings in robot
E = Cost of servicing the robot
Automated Material Handling
• Material-handling process for parts and raw
materials should be automated only after every
unnecessary inch of material transport distance
has been removed from the production process.
• The work simplification and analysis process
that precedes the design and selection of
material-handling automation starts with a
diagram of the production flow, using process
flow analysis symbol shown on page 461.
Automated Material Handling
• The transfer mechanism used to move parts between
work cells and stations serves two main functions:
– Move the part in the most appropriate manner between
production machines, and
– Orient and position the part with sufficient accuracy at the
machine to maximize productivity and quality.
• Automated transfer systems include:
– Continuous transfer such as overhead monorail
– Intermittent or synchronized transfer such as the walking beam
transfer system
– Asynchronous transfer or power-and-free systems as in
conveyor and pallet system.
Integrated Material Handling Systems
Automatic guided vehicles (AGV)
An AGV is a vehicle equipped with
automatic guidance equipment capable of
following prescribed guide paths and may
be equipped for vehicle programming and
stop selection, blocking, and any other
special function required by the system.
Automatic guided vehicles (AGV)
• AGV types include: Towing vehicles, unit load
vehicles, pallet truck vehicles, fork lift vehicles,
light load vehicles, and assembly line vehicles.
• AGV systems must perform five functions,
namely: Guidance, routing, traffic management,
load transfer, and system management.
• AGV systems must be justified based on the
current and future material-handling
requirements.
AGV
Typical AGV Route
AGVs
Automated Storage and Retrieval
Systems (AS/RS)
• Materials to be stored and retrieved include: 1) raw
materials, 2) unsold finished products, 3) production
parts, 4) purchased parts and subassemblies used in the
assembly of products, 5) rework and scrap that result
from production operations, 6) spare parts for repair of
production machines and facilities, and 7) general office
supplies including tools and instruments.
• AS/RS is a combination of equipment and controls that
handles, stores, and retrieves materials with precision,
accuracy, and speed under a defined degree of
automation.
Automated Machine Tools and
Tooling
• Includes different machines and tooling
systems…:
– Machine tools
– Auxiliary equipment (MHS, robots etc)
– Tools
– Tooling
Conventional and CNC Lathes
CNC Milling Machines
Drilling Machines
Sawing Machines
Surface Grinder
Fold and Shear Coiline
Automated Punching Machine
Hydraulic CNC Folder
Plastic injection molding machine
Extrusion Machine
Gas Furnace
Column Press and Straight Side Press
Forging Machine
PalletShuttle
Chapter 13
Quality and Human Resource Issues in
Manufacturing
SPC and the Normal Curve
Review
• Deming’s 14 points for management
• Total quality management (TQM)
• Quality tools and processes (for quiz 3)
Bringing it all Together
Programmable Logic Controllers (PLC)
Components of Flexible Manufacturing
System
• FMS workstations:
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FMS for prismatic parts
FMS for rotational parts
Robots
Fixtures and pallets
Tooling
Operators
Inspection system
Coolant and chip handling systems
Cleaning stations
FMS off-line operations
Control station
Components of Flexible Manufacturing
System
• Material handling system:
– Parts delivery:
• Material handling outside the FMS
• Material handling inside the FMS
• Conveyor systems
• Cutting tool delivery
– Load/unload stations:
• Handling equipment
• Operator control
– Buffer storage
FMS Benefits
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Producing a family of parts
Random launching of parts
Reduced manufacturing lead time
Reduced work-in-process
Reduced operator requirements
Expandability
Increased machine utilization
Reduced capital equipment costs
Responsiveness to change
Ability to maintain production
Product quality improvement
Reduced labor costs
Better management control
Enterprise Resource Planning (ERP)