MT308 Industrial Automation PDF

MT308 Industrial Automation Mechatronics Engineering Department Faculty of Engineering Sana’a University Dr. Khalil A. Al-Hatab  Brief Course Contents Week # Module Name Lecture # & Heading...

MT308 Industrial Automation Mechatronics Engineering Department Faculty of Engineering Sana’a University Dr. Khalil A. Al-Hatab  Brief Course Contents Week # Module Name Lecture # & Heading Reading Sections Lecture 1: introduction & Basic Concept of Ch. 1 & Ch. 4 Automation Module 1: Introduction and Basic Concept Lecture 2: Components & Applications of Ch1* 1-3 of Automation Automation System Lecture 3: Overview of Manufacturing: Ch. 2 & Ch. 3 Operations, Metrics and Economics Lecture1: Mechanical System: Components, Ch3* Module 2: Mechanical System: Dynamics & Modeling 4 Components, Dynamics & Modeling 5 Module 3: Industrial Control Systems Lecture1: Industrial Control Systems Ch. 6 & Ch5* Lecture1-2: Automation Sensory Devices Ch. 6 & Ch5* Module 4: Hardware Components Lecture3-4: Control of Actuators in Automation Ch. 6 & Ch4* 6-10 for Automation Mechanisms Lecture5: Digital Data Acquisition (DDA) Ch. 6 Lecture1: Design an Example for Industrial Ch6* Automation System Lecture2-3: Numerical Control Ch. 7 10-14 Module 5: Industrial Automation Systems Lecture4: Material Handling & Identifications Ch. 10-Ch. 12 Lecture5: Single-Station Manufacturing Cells Ch. 13 & Ch. 14 15 Review for Final Exam 2 *: Industrial Automation: An Engineering Approach  Course Information ▪ Instructor ▪ Associate Professor Dr. Khalil Al-Hatab, (PhD) ▪ [email protected] ▪ Time and place ▪ Lecture: Monday 8-12, xxx Wed. 8-10d. 10-12 ▪ Lab (class & practicing): Lab 2 Wed. 12-2 ▪ Grading Policy ▪ Homework & Attendance: 10% ▪ Quizzes: 10% ▪ Labs: 10% ▪ Mid-term: 20% ▪ Mini-Projects 10% ▪ Final Exam: 40% ▪ Textbook 1. Mikel P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 4th ed., Pearson Higher Education, 2015. 2. Lecture Notes: Industrial Automation: An Engineering Approach, JM 608 INDUSTRIAL AUTOMATION, Politeknik Port Dickson, 2013 3  Module 1 - Lecture 1: Introduction To Automation In Production Systems ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 4  Module 1 - Lecture 1: Introduction To Automation In Production Systems Sections: ❑ Definitions & Overview of Industrial Automation ❑ Production Systems ❑ Automation in production systems ❑ Manual Labor in Production Systems ❑ Types of Automation ❑ Basic Elements of an Automated System ❑ Control System ❑ Advanced Automation Functions ❑ Reason for automated and not automated ❑ Automation Principles and Strategies ❑ Levels of Automation ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 5  Objectives: Upon completion of this course, students should be able to:- To explain the definition and classification of automation in industry of automation in industry Explain the basic concept of automation terminology To classify the element of automation function and level To define the reason of automation. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 6  Definition of industrial automation ❑ Automation as a technology that is concerned with use of mechanical, electronic and computer-based systems in the operation and control of production. ❑ Technology development process continuous improve until human started introduce the usage of NC machine tools and robotic, CAD/CAM, Flexible manufacturing system (FMS) and others technology to increase human quality of life and increase productivity in the industrial. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 7  Definition of industrial automation ❑ The word ‘Automation’ is derived from Greek words “Auto”(self) and “Matos” (moving). Automation therefore is the mechanism for systems that “move by itself”. However, apart from this original sense of the word, automated systems also achieve significantly superior performance than what is possible with manual systems, in terms of power, precision and speed of operation ❑ Automation is a set of technologies that results in operation of machines and systems without significant human intervention and achieves performance superior to manual operation ❑ Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. ❑ Automation is defined as “The creation & application of technology to monitor & control the production and delivery of products and services.” ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 8  Definition of industrial automation ❑ Automation can be defined as the technology by which a process or procedure is accomplished without human assistance. ❑ Industrial: In a general sense the term “Industry” is defined as follows: Systematic Economic Activity that could be related to Manufacture/Service/ Trade. In this course, we shall be concerned with Manufacturing Industries only ❑ Mechanization refers to the use of machinery (usually powered) to assist or replace human workers in performing physical tasks, but human workers are still required to accomplish the cognitive and sensory elements of the tasks. By contrast, automation refers to the use of mechanized equipment that performs the physical tasks without the need for oversight by a human worker. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 9  OVERVIEW OF INDUSTRIAL AUTOMATION ❑ How to improve PRODUCTIVITY? ▪ By MECHANIZATION: operation runs with the use of various mechanical, hydraulic, pneumatic, or electrical devices. ▪ But still operator have to control the process and check the machine’s performance, thus to IMPROVE THE EFFICIENCY of manufacturing process = AUTOMATION. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 10  OVERVIEW OF INDUSTRIAL AUTOMATION 1950s, manufacturing operations used traditional machinery: Lacked flexibility, Required high skilled labor, Have to retooled the machinery on each different product manufactured, The movement of materials have to be rearranged, Product with complex shapes required trial and error attempts by the operator in order to set the proper processing parameters on the machine, Time-consuming Labor cost and production cost increase. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 11  OVERVIEW OF INDUSTRIAL AUTOMATION ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 12  OVERVIEW OF INDUSTRIAL AUTOMATION ▪ An automated system is a collection of devices working together to accomplish tasks or produce a product or family of products. ▪ Industrial automated systems can be one machine or a group of machines called a cell. ▪ The term “programmable automation technology” actually refers to three individually distinct technologies that have a common thread: programmability. These technologies are computer numerical control (CNC) technology, robotics technology, and programmable logic control (PLC). ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 13  The Realities of Modern Manufacturing ▪ Globalization - Once underdeveloped countries (e.g., China, India, Mexico) are becoming major players in manufacturing ▪ International outsourcing - Parts and products once made in the United States by American companies are now being made offshore (overseas) or near-shore (in Mexico and Central America) ▪ Local outsourcing - Use of suppliers within the U.S. to provide parts and services ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 14  More Realities of Modern Manufacturing ▪ Contract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companies ▪ Trend -toward the service sector (economy) ▪ Quality expectations - Customers, both consumer and corporate, demand products of the highest quality ▪ Need for operational efficiency - manufacturers must be efficient in in their operations to overcome the labor cost advantage of international competitors ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 15  Modern Manufacturing Approaches and Technologies ▪ Automation - automated equipment instead of labor ▪ Material handling technologies - because manufacturing usually involves a sequence of activities ▪ Manufacturing systems - integration and coordination of multiple automated or manual workstations ▪ Flexible manufacturing - to compete in the low- volume/high-mix product categories ▪ Quality programs - to achieve the high quality expected by today's customers ▪ CIM - to integrate design, production, and logistics ▪ Lean production - more work with fewer resources ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 16  Manual Labor in Production Systems Is there a place for manual labor in the modern production system? ▪ Answer: YES ▪ Two aspects: 1. Manual labor in factory operations 2. Labor in manufacturing support systems ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 17  Manual Labor in Factory Operations ▪ The long term trend is toward greater use of automated systems to substitute for manual labor. ▪ When is manual labor justified? ▪ Some countries have very low labor rates and automation cannot be justified ▪ Task is too technologically difficult to automate ▪ Short product life cycle ▪ Customized product requires human flexibility ▪ To cope with ups and downs in demand ▪ To reduce risk of product failure ▪ Lack of capital. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 18  Labor in Manufacturing Support Systems ▪ Product designers: who bring creativity to the design task ▪ Manufacturing engineers: who ▪ Design the production equipment and tooling, and ▪ Plan the production methods and routings ▪ Equipment maintenance ▪ Programming and computer operation ▪ Engineering project work ▪ Plant management ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 19  Production System Defined ❑ Production System is a collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company ❑ Two categories: ▪ Facilities: the factory and equipment in the facility and the way the facility is organized (plant layout) ▪ Manufacturing support systems: the set of procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 20  The Production System Fig. 1.1 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 21  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 way the equipment is physically arranged in the factory ▪ Manufacturing systems – logical groupings of equipment and workers in the factory ▪ Production line: More complex manufacturing systems consist of collections of machines and workers. ▪ Stand-alone workstation and worker ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22  Manufacturing Systems ❑ Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work systems - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools (i.e. A quality control inspector using a micrometer to measure the diameter of a shaft) 2. Worker-machine systems - a worker operating powered equipment. A combinations of one or more workers and one or more pieces of equipment (i.e. A machinist operating an engine lathe to fabricate a part for a product) 3. Automated systems - a process performed by a machine without direct participation of a human. Automation is implemented using a program, control system & Power. Two levels of automation can ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. be identified: semiautomated and fully automated. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 23  Manual Work System Fig. 1.2 (a) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 24  Worker-Machine System Fig. 1.2 (b) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 25  Automated System Fig. 1.2. (c) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 26  Manufacturing Support Systems ❑ Involves a cycle of information-processing activities that consists of four functions: 1. Business functions - sales and marketing, order entry, cost accounting, customer billing 2. Product design - research and development, design engineering, prototype shop 3. Manufacturing planning - The information and documentation that constitute the product design flows into the manufacturing planning function. The information- processing activities in manufacturing planning include: process planning, master scheduling, material requirements planning, and capacity planning. 4. Manufacturing control - is concerned with managing and controlling the physical operations in the factory to implement the manufacturing plans. The flow of information is from planning to control. Included in this function are shop floor control, inventory control & quality control ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 27  Information Processing Cycle in Manufacturing Support Systems Fig. 1.3 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 28  Automation in Production Systems Examples of industries for automation: ❑ Manufacturing (e.g. on factory shop floors) ❑ Services (e.g. voice menus for banks) ❑ Transport (e.g. planes, ships, cars) ❑ Process control (e.g. nuclear/electrical power stations, chemical plants) ❑ Offices (e.g. word processing, spreadsheets, photocopying, email) Automation and robots are two closely related technologies. Both are connected with the use and control of production operations. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 29  Automation in Production Systems ❑ Example of this technology in Automated Manufacturing System includes: ▪ Transfer lines that perform a series of machining operation ▪ Mechanical assembly machines ▪ Feedback control systems ▪ Numerically controlled machine tools ▪ Logistic support tools ▪ Automated inspection system for quality control ▪ Automated material handling system and storage system to integrate manufacturing operation ▪ CAD/CAM system and robots- robots are mechatronic devices that assist industrial automation. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 30  Automation in Production Systems ▪ The automated elements of the production system can be separated into two categories: 1. Automation of manufacturing systems in the factory 2. Computerization of the manufacturing support systems ▪ In modern manufacturing systems, the two categories overlap because the automated manufacturing system operating on the factory floor are often implemented by computer systems; and connected to the computerized manufacturing support system and management information system operating plant and enterprise level. ▪ Computer-Integrated Manufacturing (CIM) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 31  Computer Integrated Manufacturing (CIM) Fig. 1.4 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 32  Objectives of Computerized Manufacturing Support Systems ▪ To reduce the amount of manual and clerical effort in product design, manufacturing planning and control, and the business functions. ▪ Computer technology is used to implement automation of the manufacturing systems in the factory. ▪ CIM (computer integrated manufacturing) denotes the pervasive use of computer system to design the products, plan the production, control the operations, and perform the various business-related functions in one system that operates throughout the enterprise. ▪ CIM includes CAD/CAM and the business functions of the firm ▪ Integrates computer-aided design (CAD) and computer-aided manufacturing (CAM) in CAD/CAM. CAD denotes the use of computer systems to support the product design function. CAM denotes the use of computer systems to perform function related to manufacturing engineering such as process planning and numerical control part programming. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 33  Automated Manufacturing Systems Three basic types: 1.Fixed automation 2.Programmable automation 3.Flexible automation ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 34  Fixed Automation ❑ Fixed Automation is a manufacturing system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration. The operation are usually simple, it used with high demand rates and inflexible product design. ❑ Typical features: ▪ Suited to high production quantities ▪ High initial investment for custom-engineered equipment ▪ High production rates. It is therefore appropriate to design specialized equipment to process products at high production rates and low cost (custom- engineered with special purpose equipment to automate a fixed sequence of operation ▪ Relatively inflexible in accommodating product variety ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 35  Fixed Automation A good example of fixed automation can be found in the automobile industry, where highly integrated transfer lines are used to perform machining operation on engine and transmission component. The economics of fixed automation is such that the cost of the special equipment can be divided over a large number of units produced, so that the resulting units cost can be lower relative to alternative method of production. The risk encountered with fixed automation is that the initial investment cost is high and if the volume of production turns out to lower than anticipated, then the unit costs become greater. Another problem with fixed automation is that the equipment is specially designed to produce only one product and after that product’s life cycle is finished, the equipment is likely to become obsolete. Therefore, for products with short life cycles, fixed automation is not economical. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 36  Programmable Automation ❑ A manufacturing system designed with the capability to change the sequence of operations to accommodate different product configurations. ❑ The operation sequence is controlled by a program which is a set of instructions coded so that they can be read and interpreted by the system. New programs can be prepared and entered into the equipment to produce new products. ❑ The physical setup of the machine must also be changed, tools must be loaded. Fixtures must be attached to the machine table and the required machine setting must be entered. This change over procedure takes time. ❑ Typical features: ▪ High investment in general purpose equipment. The production equipment is designed to be adaptable to variations in a product configuration. ▪ Lower production rates than fixed automation ▪ Flexibility to deal with variations and changes in product configuration ▪ Most suitable for batch production ▪ Physical setup and part program must be changed between jobs (batches) ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 37  Programmable Automation This adaptability feature is accomplished by operating the equipment under the control of a “program” of instructions that has been prepared especially for a given product.The program is read into the production equipment and the equipment performs that particular sequence of operations to make that product. The system must be reprogrammed with the set machine instructions that correspondent to the new product when a new batch of different product needs to produce. Physical setup of the machine must be changed: ▪ Tool must be loaded ▪ Fixtures must be attached to the machine table ▪ Required machine setting must be entered. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 38  Programmable Automation In terms of economics, the cost of the programmable equipment can be spread over a large number of products even though the products are different. Because of the programming feature and the resulting adaptability of the equipment, may different and unique products can be processed economically in small batches (batches production and medium volume). ▪ Example : SMT production line in PCBA manufacturing - SMT : Surface Mount Technology - PCBA : Printed Circuit Board Assembly ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 39  Flexible Automation ▪ Flexible Automation is an extension of programmable automation in which the system is capable of changing over from one job to the next with no lost time between jobs. There is no lost production time while reprogramming the system and altering the physical combination and schedules of parts or products instead of requiring that they be made in batches. It is designed to manufacture a variety of product or parts with low production rates, varying product design and demand. ▪ Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 40  Flexible Automation Most suitable for the mid-volume production range. Flexible automation possesses some of the features of both fixed and programmable automation. Other terms used for flexible automation include FMS and CIM. Flexible automation typically consists of a series of workstations that are interconnected by material-handling and storage equipment to process different product configurations at the same time on the same manufacturing system. A central computer is used to control the various activities that occur in the system, routing the various parts to the appropriate stations and controlling the programmed operations at the different stations. One of the features that distinguish programmable automation from flexible automation is that with programmable automation the products are made in batches. When one batch is completed, the equipment is reprogrammed to process the next batch. Flex. Auto can produce one of a kind, batches not required ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 41  Flexible Automation With flexible automation, different products can be made at the same time on the same system. This feature allows a level of versatility that is not available in pure programmable automation. This means that products can be produced on a flexible system in batches, if desirable, or that several products can mix on the same system. The computational power of the control computer is what makes this versatility possible. Flexible Automation advantages: 1. Increased speed and productivity. 2. Reduced manual labor. 3. Improved consistency. 4. Greater reliability. 5. Greater accuracy and consistency. 6. Reduced cost of assembly ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 42  Automation Comparison Automation When to consider Advantages Disadvantages Fixed - High demand - Maximum - Large initial volume, efficiency investment - Long product life - Low unit cost - Inflexibility cycles Programmable - Batch production, - Flexibility to deal -New products - Product with with changes in requires long setup different options. product. time. - Low unit cost for - High unit cost large batches. relative to fixed automation. Flexible - Low production - Flexibility to deal - Large initial rates. with designs investment. - Varying demand. variations. - High unit cost. - Short product life - Customized cycles. products. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 43  Product Variety and Production Quantity for Three Automation Types Fig. 1.5 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 44  Elements of an Automated System 1) Power 2) Program Instruction 3) Control System ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 45 Basic Elements of an Automated System 1) Power to accomplish the automated process An automated system is used to operate some process and power is required to drive the process as well as the controls. The principal source of power is electricity: ❑ Available at moderate cost. ❑ Can be readily converted to alternative energy forms (mechanical, thermal, light, acoustic, hydraulic and pneumatic). ❑ Low level power can be used to accomplish functions such as signal transmission, information processing and data storage and communication. ❑ Can be stored in long-life batteries for use in remote locations  Power a) Power for the Process  The term ‘process’ refers to the manufacturing operation that is performed on work unit as follows: Manufacturing process and their power requirements  Material handling functions: →Loading and unloading the work unit →Material transport between operations  Power b) Power for Automation ❖ Controller unit: →Need electrical power to read the program of instructions, calculations and execute the instructions by transmitting the proper commands to actuating devices. ❖ Power to actuate the control signals: →Controller sent the commands by means of low-voltage control signal to provide the proper power level for actuating device (motor). ❖ Data acquisition and information processing: → Keeping the records of process performance or product quality.  Program of instructions 2) Program of instructions ❑ The action performed by an automated process are defined by a program of instructions. Whether the manufacturing operation involves low, medium or high production, each part require one or more processing steps performed during the work cycle. ❑ The particular processing steps for the work cycle are specified in a work cycle program. ❑ Work cycle programs are called part programs in numerical control. ❑ Program is a set of commands that specify the sequence of steps in the work cycle and the details of each step.  Program of instructions ❑ Work cycle programs The simplest automated processes, the work cycle consists of 1 step (set point control). The more complicated systems consist of multiple steps. The set point is the value of the process parameter or desired value of the controlled variable in the process. The process parameter changes in each step. A process parameter is an input to the process, whereas a process variable is the corresponding output of the process. ❑ Decision making in the Programmed Work Cycle Each work cycle consists of the same steps and associated process changes with no variation from one cycle to the next. →Operator interaction →Different part or product styles are processed by the system → Variations in the starting work unit.  Work Cycle programs ▪ In the simplest automated processes, the work cycle consists of essentially one step, which is to maintain a single process parameter at a defined level. It is assumed that loading and unloading of the work units into and from the furnace is performed manually and is therefore not part of the automatic cycle. ▪ Process parameter : is an input to the process, such as the temperature dial setting. ▪ Process variable: is the corresponding output of the process, which is the actual temperature of the furnace ▪ During each step, there are one or more activities involving changes in one or more process parameters ▪ Examples of process parameters include: desired coordinate axis value in a positioning system, valve open or closed in a fluid flow system, and motor on or off. ▪ Examples of corresponding process variables include the actual position of the coordinate axis, flow rate of fluid in the pipe, and rotational speed of the motor. 51  Five Categories Of Work Cycle Programs ▪ Set-point control, in which the process parameter value is constant during the work cycle (as in the furnace example). ▪ Logic control, in which the process parameter value depends on the values of other variables in the process. ▪ Sequence control, in which the value of the process parameter changes as a function of time. The process parameter values can be either discrete (a sequence of step values) or continuously variable. ▪ Interactive program, in which interaction occurs between a human operator and the control system during the work cycle. ▪ Intelligent program, in which the control system exhibits aspects of human intelligence (e.g., logic, decision making, cognition, learning) as a result of the work cycle program. 52  Five Categories Of Work Cycle Programs ▪ A work cycle consisting of multiple steps that are repeated with no deviation from one cycle to the next. Most discrete part manufacturing operations are in this category. ▪ A typical sequence of steps (simplified) is the following: (1) load the part into the production machine, (2) perform the process, and (3) unload the part. ▪ During each step, there are one or more activities that involve changes in one or more process parameters. Example 4.1 An Automated Turning Operation Consider an automated turning operation that generates a cone-shaped product The system is automated and a robot loads and unloads the work units. The work cycle consists of the following steps: (1) load starting workpiece, (2) position cutting tool prior to turning, (3) turn, (4) reposition tool to a safe location at end of turning, and (5) unload finished workpiece. Identify the activities and process parameters for each step of the operation. 53  Example 4.1 An Automated Turning Operation step # Activities Process parameters (1) Robot reaching, lifting and positioning the axis values, gripper value (open or manipulator raw work part, then retreating to safe closed), chuck jaw value (open or position. closed). (2) cutting movement to a “ready” position. x- and z-axis position of the tool. tool (3) turning workpiece rotation, cutting tool feed & speed (rev/min), (mm/rev), radial operation position, cut the conical shape, distance (changed continuously at a finishing operation (multiple turning constant rate /revolution) passes). For a consistent finish on the surface, the rotational speed must be continuously adjusted to maintain a constant surface speed (m/min) 4 are the reverse of steps (2) and (1), process parameters are the same. 5 respectively ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 54/20  Features of a Work Cycle Program ▪ The two features of the work cycle were: (1) The number and sequence of processing steps and (2) The process parameter changes in each step. ▪ The following are examples of automated work cycles in which decision making is required: ▪ Operator interaction (input data) ▪ Automated teller machine ▪ Different part or product styles processed by the system ▪ Robot welding cycle for two-door vs. four door car models ▪ Variations in the starting work units ▪ Additional machining pass for oversized sand casting ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 55  Features of a Work Cycle Program The following summarizes the features of work cycle programs (part programs) used to direct the operations of an automated system: 1. Number of steps in the work cycle: A general sequence in discrete production operations is (1) load, (2), process, (3) unload, but the process may include multiple steps. 2. Manual participation in the work cycle (e.g., loading and unloading workparts) 3. Process parameters - How many process parameters must be controlled during each step? Are the process parameters continuous or discrete? Do they change during the step? 4. Operator interaction - does the operator enter processing data? 5. Variations in part or product styles 6. Variations in starting work units - some adjustments in process parameters may be required to compensate for differences in starting units 56  Control System – Two Types ▪ The control system causes the process to accomplish its defined function, which is to perform some manufacturing operation. ▪ The control element of the automated system executes the program of instructions. 1. Closed-loop (feedback) control system – a system in which the output variable is compared with an input parameter, and any difference between the two is used to drive the output into agreement with the input 2. Open-loop control system – operates without the feedback loop, so no comparison is made between the actual value of the output and the desired input parameter. ▪ Simpler and less expensive ▪ Risk that the actuator will not have the intended effect ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 57/75  Closed-loop (Feedback) Control System 1. The input parameter often referred to as the set point, represents the desired value of the output. 2. The process is the operation or function being controlled. 3. The output variable (process variable) that is being controlled in the loop, perhaps a critical performance measure in the process, such as temperature or force or flow rate. 4. A sensor is used to measure the output variable and close the loop between input and output. Sensors perform the feedback function in a closed-loop control system. 5. The controller compares the output with the input and makes the required adjustment in the process to reduce the difference between them. 6. Actuator: These are the hardware devices which perform the required job. The adjustment is accomplished using one or more actuators, which are the hardware devices that physically carry out the control actions, such as electric motors or flow valves. Figure 4.3 shows only one loop. Most industrial processes require multiple loops, one for each process variable that must be controlled 58/75  Open-Loop Control System ▪ In this case, the controls operate without measuring the output variable. ▪ The controller relies on an accurate model of the effect of its actuator on the process variable. ▪ With an open-loop system, there is always the risk that the actuator will not have the intended effect on the process, and that is the disadvantage of an open-loop system. Its advantage is that it is generally simpler and less expensive than a closed-loop system. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 59/75  Positioning System Using Feedback Control A one-axis position control system consisting of a leadscrew driven by a servomotor and using an optical encoder as the feedback sensor. For the open-loop case, the diagram for the positioning system would be similar to the preceding, except that no feedback loop is present and a stepper motor would be used in place of the dc servomotor. A stepper motor is designed to rotate a precise fraction of a turn for each pulse received from the controller. Since the motor shaft is connected to the leadscrew, and the leadscrew drives the worktable, each pulse converts into a small constant linear movement of the table. To move the table a desired distance, the number of pulses corresponding to that distance is sent to the motor. Given the proper application, whose characteristics match the preceding list of operating conditions, an open-loop positioning system works with high reliability. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 60/75  When to Use an Open-Loop Control System Open-loop systems are usually appropriate when the following conditions apply: ▪ Actions performed by the control system are simple ▪ Actuating function is very reliable ▪ Any reaction forces opposing the actuation are small enough as to have no effect on the actuation ▪ If these conditions do not apply, then a closed-loop control system should be used ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 61/75  Advanced Automation Functions ❑ In addition to executing work cycle programs, an automated system may be capable of executing advanced functions that are not specific to a particular work unit. Advanced automation functions include the following: (1) Safety monitoring, (2) Maintenance and repair diagnostics, and (3) Error detection and recovery, ❑ These functions are made possible by special subroutines included in the program of instructions. ❑ Safety Monitoring: is the use of sensors to track the system's operation and identify conditions that are unsafe or potentially unsafe. ▪ Reasons for safety monitoring: To protect workers and equipment ▪ Possible responses to hazards: ▪ Complete stoppage of the system ▪ Sounding an alarm ▪ Reducing operating speed of process ▪ Taking corrective action to recover from the safety violation 62  Advanced Automation Functions ❑ Safety Monitoring An automated system is often installed to perform a potentially dangerous operation that would otherwise be accomplished manually. Two reasons for providing an automated system with a safety monitoring capability: a) To protect human workers in the vicinity of the system b) To protect the equipment associated with the system ▪ Example: Emergency stop buttons, Limit switches, photoelectric sensors, temperature sensors, heat or smoke detectors, pressure-sensitive floor pads and machine vision systems. ❑ Maintenance and repair diagnostics: Three modes of operation are typical of a modern maintenance and repair diagnostics subsystem: 1) Status monitoring: To monitor and record the status of key sensors and parameter of the system during normal operation. 2) Failure diagnostics: The failure diagnostics mode is invoked when a malfunction or failure occurs. 3) Recommendation of repair procedure: The subsystem provides a recommendation procedure to the repair crew as to the steps that should be taken to effects repairs.  Status monitoring serves two important functions in machine diagnostics: (1) providing information for diagnosing a current failure and (2) providing data to predict a future malfunction or failure  Advanced Automation Functions 3) Error Detection and Recovery: ❑ Error detection – in analyzing a given production operation, the possible errors can be classified into one of three general categories: 1. Random errors, occur when the process is in statistical control. Large variations in part dimensions, even when the production process is in statistical control, can cause problems in downstream operations. 2. Systematic errors, are those that result from some assignable cause such as a change in raw material or drift in an equipment setting. 3. Aberrations errors that results from either an equipment failure or a human mistake ❑ Functions: ▪ Use the system’s available sensors to determine when a deviation or malfunction has occurred ▪ Correctly interpret the sensor signal ▪ Classify the error ❑ The two main design problems in error detection are (1) anticipating all of the possible errors that can occur in a given process, and (2) specifying the appropriate sensor systems and associated interpretive software so that the system is capable of recognizing each error  Advanced Automation Functions ❑ Error recovery: is concerned with applying the necessary corrective action to overcome the error and bring the system back to normal operation. ▪ Possible strategies: ▪ Make adjustments at end of work cycle ▪ Make adjustments during current work cycle ▪ Stop the process to invoke corrective action ▪ Stop the process and call for help ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 65  ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 66  ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 67  Reasons for Automating Companies undertake projects in automation and computer-integrated manufacturing for good reasons, some of which are the following: 1. To increase labor productivity 2. To reduce labor cost 3. To mitigate the effects of labor shortages 4. To reduce or remove routine manual and clerical tasks 5. To improve worker safety 6. To improve product quality 7. To reduce manufacturing lead time 8. To accomplish what cannot be done manually 9. To avoid the high cost of not automating ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 68  Reason for Automated and Not Automated REASON FOR AUTOMATED Improved product quality: Automation performs the manufacturing process with greater uniformity and conformity to quality specifications. Reduction of fraction defect rate is one of the chief benefits of automation. To accomplish processes that cannot be done manually: Certain operation cannot be accomplished without the aid of a machine. These processes have requirements for precision, miniaturization or complexity of geometry that cannot be achieved manually. Example: manufacturing process based on CAD models and rapid prototyping. Increased labor productivity: ✓ Value of output per person per hour increases ✓ Automating a manufacturing operation usually increases production rate and labor productivity.  Reduce labor cost: ✓ Higher investment in automation has become economically justifiable to replace manual operation. Machines are increasingly being substituted for human labor to reduce unit product cost. To reduce or eliminate routine manual and clerical tasks: ✓ An argument can be put forth that there is social value in automating operations that routine, boring, fatiguing and possibly irksome. Automating such tasks serves a purpose of improving the general level of working conditions. Lower costs: Reduce scrap, lower in-process inventory, superior quality, shorter lines. Reducing manufacturing lead time and reduces work-in- progress: Respond quickly to the customers’ needs and rapid response to changes in design. Improve worker safety: By automating a given operation and transferring the worker from activate participation in the process to a supervisory role, the work is made safer.  To avoid the high cost of not automating: The advantage of automating cannot easily be demonstrated on a company’s authorized from. The benefits of automation often show up in unexpected and intangible ways, such as improved quality, higher sales, better labor relationship and better company image. Companies that do not automate are likely to find themselves at a competitive disadvantage with their customers, their employees and the general public. Competition: Lower prices, better product, better image, better labor relation. New process technologies require automation: Example; Robot controlled thermal spray torch for coating engine blocks. Potential for mass customization and reduced inventory. High cost of raw materials  Reason for not automated Labor resistance Cost of upgraded labor : Example : Chrysler Detroit plant spend 1 million hours of retraining Initial investment Management of process improvement Intellectual assets versus technological assets Appropriate use of technology A system approach to automation is important Equipment incompatibilities  Automation Principles and Strategies 1. The USA Principle 2. Ten Strategies for Automation and Process Improvement 3. Automation Migration Strategy ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 73  U.S.A Principle 1. Understand the existing process: ▪ Input/output analysis: What are the inputs? What are the outputs? What exactly happens to the work unit between input and output? What is the function of the process? ▪ Value chain analysis: How does it add value to the product? What are the upstream and downstream operations in the production sequence, and can they be combined with the process under consideration? ▪ Charting techniques(such as the operation chart and the flow process chart) and mathematical modeling 2. Simplify the process: Reduce unnecessary steps and moves 3. Automate the process: ▪ Ten strategies for automation and production systems ▪ Automation migration strategy ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 74  Ten Strategies for Automation and Process Improvement If automation seems a feasible solution to improving productivity, quality, or other measure of performance, then the following ten strategies provide a road map to search for these improvements 1. Specialization of operations: use of special-purpose equipment 2. Combined operations: performing more than one operation at a given machine, thereby reducing the number of separate machines needed. 3. Simultaneous operations 4. Integration of operations 5. Increased flexibility 6. Improved material handling and storage 7. On-line inspection 8. Process control and optimization 9. Plant operations control 10.No portion Computer-integrated of this material may be reproduced, in anymanufacturing ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 75  Automation Migration Strategy For Introduction of New Products 1. Phase 1 – Manual production ▪ Single-station manned cells working independently ▪ Advantages: quick to set up, low-cost tooling 2. Phase 2 – Automated production ▪ Single-station automated cells operating independently ▪ As demand grows and automation can be justified 3. Phase 3 – Automated integrated production ▪ Multi-station system with serial operations and automated transfer of work units between stations ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 76 Automation Migration Strategy ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 77  Levels of Automation Enterprise level Plant level Cell or system level Machine level Device level  Levels of Automation 1) Device The lowest level and it includes the actuators, sensors and other hardware components that comprise machine level. The devices are combined into the individual control loops of the machine. Example: the feedback control loop for one axis of a CNC machine. 2) Machine Hardware at the device level is assembled into individual machines. Example: CNC machine tools and similar production equipment, industrial robot and AGV. Control function at this level includes performing the sequence of steps in the program of instructions in correct order and making sure that each step is properly executed. 3) Cell or system Manufacturing cell or system level, this cell operates under instructions from the plant level. It is a group of machines or workstations connected and supported by a material handling system, computers, and other equipment appropriate to the manufacturing process.  Levels of Automation 4) Plant level This is the factory or production systems level. It received instructions from the corporate information system and translates them into operational plans for production. The functions include: order processing, process planning, inventory control, purchasing, material requirement planning, shop floor control and quality control. 5) Enterprise level This is the highest level, consisting of the corporate information system. It concerned with all of the function necessary to manage the company: marketing and sales, accounting, design, research, aggregate planning and master production scheduling.  A manufacturing system is defined in this book as a collection of integrated equipment designed for some special mission, such as machining a defined part family or assembling a certain product. Manufacturing systems include people. The manufacturing systems in a factory are components of a larger production system,  Levels of Automation Fig. 4.6 Production system, which is defined as the people, equipment, and procedures that are organized for the combination of materials and processes that comprise a company’s manufacturing operations. Production systems are at level 4, the plant level, while manufacturing systems are at level 3 in the automation hierarchy. Production systems include not only the groups of machines and workstations in the factory but also the support procedures that make them work. Procedures include process planning, production control, inventory control & material ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. requirements This material is protected under all copyright laws asplanning, they currently exist. shop No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 81  Homework 1) A beverages plant plan to mass produce orange flavor drink for 4 different brands. All 4 brands using the same aluminium can size but different in printing label on the can. In your opinion what types of automated manufacturing system is most suitable to produce 10,000 can/day and each brand is different in quantity? 2) Identify the situations in which manual labor is preferred over automation? 3) Review questions: 1.1 to 1.16 & 4.1 to 4.10 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 82/20