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What is one reason why some countries may not justify automation?
What is one reason why some countries may not justify automation?
Which of the following tasks is typically associated with manufacturing engineers?
Which of the following tasks is typically associated with manufacturing engineers?
What is the first step in the U.S.A Principle for automation?
What is the first step in the U.S.A Principle for automation?
Which of the following strategies aims at reducing nonproductive time related to material handling?
Which of the following strategies aims at reducing nonproductive time related to material handling?
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What is one characteristic of Phase 1 in the Automation Migration Strategy?
What is one characteristic of Phase 1 in the Automation Migration Strategy?
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Which strategy involves using several workstations linked by automated work handling devices?
Which strategy involves using several workstations linked by automated work handling devices?
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What is a primary goal of online inspection in manufacturing?
What is a primary goal of online inspection in manufacturing?
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What aspect does the strategy of computer-integrated manufacturing (CIM) primarily improve?
What aspect does the strategy of computer-integrated manufacturing (CIM) primarily improve?
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What are the two main categories of a production system?
What are the two main categories of a production system?
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Which of the following is included in production system facilities?
Which of the following is included in production system facilities?
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What type of manufacturing system involves a worker operating powered equipment?
What type of manufacturing system involves a worker operating powered equipment?
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Which activity is NOT part of the manufacturing support functions?
Which activity is NOT part of the manufacturing support functions?
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What does plant layout refer to in a production system?
What does plant layout refer to in a production system?
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In a manual work system, how does a worker perform tasks?
In a manual work system, how does a worker perform tasks?
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Which of the following best describes an automated system in manufacturing?
Which of the following best describes an automated system in manufacturing?
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What role do manufacturing support systems play in production?
What role do manufacturing support systems play in production?
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What is the primary feature of fixed automation?
What is the primary feature of fixed automation?
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Which of the following is an example of automated manufacturing systems?
Which of the following is an example of automated manufacturing systems?
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What distinguishes programmable automation from fixed automation?
What distinguishes programmable automation from fixed automation?
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Which of these statements about the overlap between manufacturing systems and support systems is true?
Which of these statements about the overlap between manufacturing systems and support systems is true?
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Which type of automation is best suited for high production quantities?
Which type of automation is best suited for high production quantities?
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What type of system falls under the category of automated material handling?
What type of system falls under the category of automated material handling?
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What is a common characteristic of programmable automation?
What is a common characteristic of programmable automation?
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Which of these is NOT a feature of fixed automation?
Which of these is NOT a feature of fixed automation?
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What is a main characteristic of typical automation in batch production?
What is a main characteristic of typical automation in batch production?
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Which of the following is true regarding flexible automation?
Which of the following is true regarding flexible automation?
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What is one of the objectives of automating manufacturing support systems?
What is one of the objectives of automating manufacturing support systems?
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Which of the following is NOT a reason for automating manufacturing processes?
Which of the following is NOT a reason for automating manufacturing processes?
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What is a primary benefit of computer-integrated manufacturing (CIM)?
What is a primary benefit of computer-integrated manufacturing (CIM)?
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How does flexible automation differ from programmable automation?
How does flexible automation differ from programmable automation?
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When is manual labor justified in a modern production system?
When is manual labor justified in a modern production system?
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What potential advantage might high investment in a custom-engineered system provide?
What potential advantage might high investment in a custom-engineered system provide?
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Study Notes
Reasons Against Automation
- Low labor wages mean that automation might not be financially viable.
- Task complexity makes automation impossible.
- Short product life cycles make investment in automation unwise.
- Customized products require human flexibility in production.
- Manual labor is necessary to respond to fluctuations in demand.
- Manual labor reduces the risk of product failure at the early stages of production.
Labor in Manufacturing Support
- Product designers are responsible for creative design.
- Manufacturing engineers:
- Design production equipment and tooling
- Plan production methods and routes
- Other manual tasks include:
- Equipment maintenance
- Programming and computer operation
- Engineering project work
- Plant management
USA Principle
- Understanding the existing process:
- Input/output analysis
- Value chain analysis
- Charting techniques and mathematical modeling
- Process simplification:
- Reduce unnecessary steps and movements
- Process automation:
- Ten strategies for automation and production systems
- Automation migration strategy
Ten Strategies for Automation and Process Improvement
- Specialization of operations: Using specialized equipment for specific tasks.
- Combined operations: Combining multiple operations in a sequence at a single workstation.
- Simultaneous operations: Performing multiple combined operations simultaneously at a single workstation.
- Integration of operations: Linking several workstations together with automated material handling devices.
- Increased flexibility: Maximizing machine utilization in job shops to accommodate different product designs.
- Improved material handling and storage: Reduce non-productive time spent on material handling and storage.
- On-line inspection: Reduce scrap rates through automated inspection.
- Process control and optimization: Reduce individual process times through automated process control and optimization.
- Plant operations control: Utilizing computer networks within the factory to control plant-wide operations.
- Computer-integrated manufacturing (CIM): A comprehensive approach to integrate all aspects of manufacturing, from design to production, using computer technology.
Automation Migration Strategy For New Products
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Phase 1 – Manual production:
- Single-station manned cells working independently
- Advantages: quick to set up, low-cost tooling
-
Phase 2 – Semi-Automated Production:
- Utilizing automated equipment with human operators
- Advantages: Increased production rate, improved product quality
-
Phase 3 – Fully Automated Production:
- Utilizing fully automated systems with minimal human intervention
- Advantages: Increased production efficiency, reduced labor costs
Production Systems
- Production Systems Definition: A collection of people, equipment, and procedures organized to accomplish a company's manufacturing operations.
- Production System Categories:
- Facilities: The physical factory, equipment, and plant layout.
- Manufacturing Support Systems: Procedures for production management, technical problem solving, materials sourcing, production flow management and quality control.
Production System Facilities
- Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations.
- Plant layout: The physical arrangement of equipment in the factory.
- Manufacturing systems: Logical groupings of equipment and workers in the factory, including:
- Production lines: A sequential flow of workstations where each station performs specific operations.
- Stand-alone workstation: An individual workstation performing a specific operation.
Manufacturing Systems
- 3 Categories of Manufacturing Systems based on human participation:
- Manual Work System: A worker performs tasks without powered tools, using hand tools.
- Worker-Machine System: A worker operates powered equipment.
- Automated System: A machine performs the process without direct human interaction.
Manufacturing Support Systems
- Manufacturing support involves a sequence of activities consisting of four core functions:
- Business Functions: Sales and marketing, order entry, cost accounting, customer billing.
- Product Design: Research and development, design engineering, prototype shop.
- Manufacturing Planning: Process planning, production planning, Material Requirements Planning (MRP), capacity planning.
- Manufacturing Control: Shop floor control, inventory control, quality control.
Automation in Production Systems
- Two main categories of automation in production systems:
- Automation of manufacturing systems in the factory.
- Computerization of manufacturing support systems.
- These two categories often overlap as manufacturing support systems are connected to factory manufacturing systems.
- Computer-Integrated Manufacturing (CIM) integrates both categories.
Computer-Integrated Manufacturing (CIM)
- CIM uses computer systems to integrate all aspects of manufacturing, including design, production planning, production control, and business functions. This enables seamless data flow and real-time decision-making.
Automated Manufacturing Systems
- Common examples of automated manufacturing systems include:
- Automated machine tools
- Transfer lines
- Automated assembly systems
- Industrial robots for processing or assembly operations
- Automated material handling and storage systems
- Automatic inspection systems for quality control.
Types of Automated Manufacturing Systems
- Three primary types of automated manufacturing systems:
- Fixed automation
- Programmable automation
- Flexible automation
Fixed Automation
- Fixed automation refers to manufacturing systems where the sequence of operations is determined by the equipment configuration.
- Fixed automation is suitable for high production quantities and offers higher production rates than programmable or flexible automation.
- However, it is relatively inflexible in accommodating product variety.
Programmable Automation
- Programmable automation allows the manufacturing system to change the sequence of operations to accommodate different product configurations.
- It requires a significant investment in general-purpose equipment, leading to lower production rates compared to fixed automation.
- Programmable automation is suitable for batch production, but setup changes are necessary between production runs.
Flexible Automation
- Flexible automation is an extension of programmable automation that enables the system to quickly change over from one job to another with no lost time between jobs.
- It allows for continuous production of variable mixes of products, with medium production rates, and is highly adaptable to handle changes in product design.
- Flexible automation requires a significant investment in custom-engineered systems.
Product Variety and Production Quantity for Different Automation Types
- Fixed automation is well-suited for high-volume production of a single product.
- Programmable automation is suitable for producing a variety of products in lower volumes.
- Flexible automation allows for high-volume production of a wide variety of products.
Computerized Manufacturing Support Systems
- The objectives of computerizing manufacturing support systems are:
- To reduce manual and clerical tasks in product design, manufacturing planning and control, and business functions.
- To integrate Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) (CAD/CAM).
- To implement Computer-Integrated Manufacturing (CIM), including both CAD/CAM and business functions.
Reasons for Automating Manufacturing Processes
- Key benefits of automating manufacturing processes include:
- Increased labor productivity
- Reduced labor cost
- Mitigation of labor shortages
- Reduced manual and clerical tasks
- Improved worker safety
- Improved product quality
- Reduced manufacturing lead time
- Accomplished tasks that cannot be done manually.
- Preventing high costs associated with not automating.
Manual Labor in Production Systems
- Manual labor still has a place in modern production systems.
- Two areas where manual labor plays a role:
- Manual labor in factory operations.
- Labor in manufacturing support systems.
Manual Labor in Factory Operations
- The long-term trend is toward greater automation to replace manual labor.
- While automation continues to grow, manual labor remains justified in certain situations, such as:
- Handling complex tasks that are too difficult or expensive to automate.
- Responding to unforeseen challenges during production.
- Supporting highly customized products.
- Responding to rapidly changing market demands.
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Description
This quiz explores the reasons against automation in manufacturing, discussing the roles of human labor and the importance of creativity within production processes. It also highlights key responsibilities in manufacturing support and principles for process analysis. Test your understanding of these concepts and their implications in modern manufacturing.
