Lecture 7: Fundamentals of Advanced Manufacturing Technology PDF

Lecture 7 Fundamentals of Advanced Manufacturing Technology  Industrial Revolutions 1. First - Industry 1.0 18th century in England, the use of steam in production (trains, printing, factories) 2. Second - Industry 2.0 19th / 20th century in Europe use of oil and electricit...

Lecture 7 Fundamentals of Advanced Manufacturing Technology  Industrial Revolutions 1. First - Industry 1.0 18th century in England, the use of steam in production (trains, printing, factories) 2. Second - Industry 2.0 19th / 20th century in Europe use of oil and electricity in production, telephone, radio, television, and later assembly line 3. Third - Industry 3.0 1970s 2008 (?) in the USA and the West use of new energies and ICT in production. 4. Fourth - Industry 4.0 Today, digital revolution, biotechnologies, nanotechnologies, 3D printing Industrial Revolutions  Advanced Manufacturing Technology Advanced Manufacturing Technology (AMT) can be defined as adopting various hard and soft technologies that have been developed to improve manufacturing capabilities. AMT can be described in detail according to specific classifications regarding the objective technology is used to accomplish. There are different types of AMT used for various manufacturing purposes and defined functional-wise. With the different classifications of AMT comes the need to understand the technology and how to utilize it to the optimal level. Rapidly changing technology provides a valuable opportunity for a flourishing industry, but it is also risky if not adopted and implemented correctly.  Advanced Manufacturing Technology A more straightforward classification of AMTs is using the product itself as a reference to categorize different AMTs as follows: Direct AMT: technology used on the factory floor to cut, join, reshape, transport, store, or modify materials, for example, CNC, DNC, robotics, FMS, AS/RS, AMHS, AGV, RP, etc. Indirect AMT: technology used to design products and schedule production, for example, CAD, MRP, SPC, BC, MRP II, etc. Administrative AMT: technology used to give administrative support to the factory and integrate its operations with the rest of the organization, for example, ERP, ABC, OA, etc. Advanced Manufacturing Technology  Computer Numerical Control (CNC) First implemented in the early 1950s, this is a method of controlling the movements of machine components by direct insertion of coded instructions in the form of numerical data.  Adaptive Control (AC) The processing parameters in an operation are automatically adjusted to optimize the production rate and product quality and to minimize manufacturing costs. For example, in machining, forces, temperature, surface finish, and dimensions of the part are constantly monitored. If they move outside the specified range, the system automatically adjusts the relevant variables until all the parameters are within the specified range.  Industrial Robots Introduced in the early 1960s, industrial robots have rapidly been replacing humans, especially in operations that are repetitive, dangerous, and boring. Robots are particularly effective in assembly operations; intelligent robots have been developed with sensory perception capabilities and movements that simulate those of humans. Recent innovations involve cobots, which are designed to work and interact with humans.  Automated Assembly Systems. These systems have been developed to replace assembly by human operators, although humans still have to perform some of the operations. Depending on the type of product, assembly costs can be high; thus, products must be designed such that they can be assembled more easily and faster by automated machinery.  Group Technology (GT) The concept behind group technology is that numerous parts can be grouped and produced by classifying them into families according to similarities in (a) design and (b) the manufacturing processes employed to produce them. In this way, part designs and processing plans can be standardized, and new parts, based on similar parts made previously, can be produced efficiently and economically.  Cellular Manufacturing (CM) This system utilizes workstations that consist of several manufacturing cells, each containing various production machines, all controlled by a central robot, with each machine performing a specific operation on the part, including inspection  Flexible Manufacturing Systems (FMS). These systems integrate manufacturing cells into a large production facility, in which all cells are interfaced with a central computer. Although very costly, flexible manufacturing systems can produce parts efficiently and of quickly changing manufacturing sequences required for making different types of parts. Flexibility enables these systems to meet rapid changes in market demand for all types of products.  Expert systems (ES) Consisting basically of complex computer programs, these systems have the capability of performing a variety of tasks and solving difficult real-life problems (much as human experts would), including expediting the traditional iterative process.  Additive Manufacturing Commonly known as 3D printing, is the process of creating a three-dimensional object by building it one thin layer at a time. It is called "additive" - unlike traditional manufacturing methods that remove material from a solid block (subtractive), additive manufacturing adds material to create the desired shape. It can work with various materials, including plastics, metals, concrete, and even living cells.  Artificial Neural Networks (ANN). These networks are designed to simulate the thought processes of the human brain, with such capabilities as modeling and simulating production facilities, monitoring and controlling manufacturing operations, diagnosing problems in machine performance, and conducting financial planning and managing a company’s manufacturing strategy.