advanced manufacturing systems design © 2000 john w. nazemetz lecture 10 topic : shop floor support...

Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design

© 2000 © 2000 John W. NazemetzJohn W. Nazemetz

Lecture 10 Topic :Lecture 10 Topic : Shop Floor Shop Floor Support SystemsSupport Systems

Segment A Topic:Segment A Topic: Automatic Guided Automatic Guided Vehicles - ConceptsVehicles - Concepts

Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 2

ADVANCED ADVANCED MANUFACTURING MANUFACTURING SYSTEMS DESIGNSYSTEMS DESIGN

Shop Floor SupportShop Floor Support

Automated Guided Vehicles - Automated Guided Vehicles - ConceptsConcepts


OverviewOverview

• Overview of Material Handling Overview of Material Handling SystemsSystems

• Automated Guided VehiclesAutomated Guided Vehicles– Components– Types– Guidance– Routing and Control– System Design


Material Handling Material Handling Overview (1) Overview (1)

• ConceptConcept– Best Material Handling is No Material

Handling• Except for Delivery to Customer, Material

Handling Adds No Value to Product• Can be 10 to 80% of Cost of Product

• GoalGoal– Least Cost Delivery of Undamaged

Material in a Timely Manner



• In–Plant MovementIn–Plant Movement– On Machines/Equipment (NC)– Within and/or Between Cells/Machines

• Fixed Path (Conveyors, Robots)• Variable Path (AGVs, Forktrucks)• Interface of Handling System and Equipment• Location Information and Control System• Hoists/Assists

– Between Floor and Storage (WIP, Finished)• Location Information, Status, and Control



• Outside of Plant MovementOutside of Plant Movement– Between Suppliers, Subcontractors

• Generally Longer Distances• Unit Loads for Efficiency• Time Delays, Variance in Receipt Time

– Between Plant and Customer• Generally Longer Distances• Multiple Destinations, Amounts to Move• Multiple Modes (Truck, Rail, Air, …)


Material Handling and Material Handling and Storage Principles (1) Storage Principles (1)

• Orientation PrincipleOrientation Principle– Facilitate Next Operation

• Planning PrinciplePlanning Principle– Establish Plan, Contingencies

• Systems PrincipleSystems Principle– Integrate into Rational System

• Unit Load PrincipleUnit Load Principle– Always transport is Largest Load

Possible



• Space Utilization PrincipleSpace Utilization Principle– Use All (Cubic) Space

• Standardization PrincipleStandardization Principle– Maximize Similarity of Solutions

• Ergonomic PrincipleErgonomic Principle– Make Human Compatible

• Energy PrincipleEnergy Principle– Minimize Energy (Potential/Kinetic)



• Ecology PrincipleEcology Principle– Minimize Environmental Impact

• Mechanization PrincipleMechanization Principle– Mechanize Wherever Possible

• FlexibilityFlexibility– Use Equipment Across Part Families

• Simplification PrincipleSimplification Principle– Eliminate/Simplify/Reduce



• Gravity PrincipleGravity Principle– Use Gravity (Cheap!) Whenever

Possible

• Safety PrincipleSafety Principle– Meet Codes, Capture Experience

• Computerization PrincipleComputerization Principle– Use Automation Wherever Applicable

• System Flow PrincipleSystem Flow Principle– Integrate Data and Material Flow



• Layout PrincipleLayout Principle– Synchronize Processing and Layout

• Cost PrincipleCost Principle– Investigate Alternatives

• Maintenance PrincipleMaintenance Principle– Ability/Cost to Service and Maintain

• Obsolescence PrincipleObsolescence Principle– Long Range Life Cycle Plan


Automatic Guided Automatic Guided Vehicles (AGV’s) Vehicles (AGV’s)

• ConceptsConcepts– Utilization

• Idle Labor = Problem (Wait for Delivery or Wait to Deliver)

• Idle Equipment = Cost• Equipment Cost -> Spread over Multiple

Shifts

– Control -- Sequence/Discipline– Automatic “Knowledge” of Location– Conveying with Less Bulk/Blockage


AGV’s - ComponentsAGV’s - Components• Components (Same as All Mat’l Components (Same as All Mat’l

Handl.)Handl.)– The Vehicle

• Device and Power System

– The Path• Routing and Alternatives

– Control Unit• Monitor and Control Vehicle and Path• Collision Avoidance/Reroute

– The Computer/Info System Interface• Link to Rest of Production System/World


AGV’s – Types/GuidanceAGV’s – Types/Guidance

• TypesTypes– Towing– Unit Load– Pallet Truck– Fork Truck– Light Load– Assembly Line

• GuidanceGuidance– Wire– Optical– Inertial– Infrared– Laser– Teaching


AGV’s – System AGV’s – System Analysis Analysis (1)(1)

• Vehicle Design and SelectionVehicle Design and Selection– Size/Cost/Maintenance– Height/Load/Width/– Maneuverability/ Interface/Off-Path

• Path/Vehicle Design ConsiderationsPath/Vehicle Design Considerations– Unidirectional, Bi-directional, Branches– Loading/Unloading, Variety of Load– Safety/Clearances


AGV’s – System AGV’s – System AnalysisAnalysis (2) (2)

• Number of VehiclesNumber of Vehicles– Analytical (p. 274 Singh)

• Single Cycle (Empty, Loaded Travel Percentage)

• Multiple Cycle (Probabilistic)

– Simulation– Breakdown/Replacement


AGV’s – Analysis (1)AGV’s – Analysis (1)

• PathPath– Routing/Flow of Product– Type of Guidepath/Vehicle– Location of Pickup/Dropoff Points– Storage/Buffer Locations


AGV’s – Analysis (2)AGV’s – Analysis (2)• Number of VehiclesNumber of Vehicles

– Distances Between Points– To/From Volume Between Points

• Recycling/Returns• Alternate Branches

– Required Deliveries/Hour– Loading and Unloading Time– Vehicle Travel Speed– Traffic Factor– Operation concept (Single/Bi-

Directional – One Cart per Path Segment)


AGV’s – ExampleAGV’s – Example

• Will Show Next SegmentWill Show Next Segment




Segment A Topic:Segment A Topic: Automated Guided Automated Guided Vehicles - ConceptsVehicles - Concepts

END OF SEGMENT END OF SEGMENT




Segment B Topic:Segment B Topic: Automated Guided Automated Guided Vehicles – Example, ASRS Vehicles – Example, ASRS

SystemsSystems




Automated Guided Vehicles – Automated Guided Vehicles – ExampleExample

Automated Storage and Automated Storage and RetrievalRetrieval


OverviewOverview• AGV Design ExampleAGV Design Example

• Automated Storage and Retrieval Automated Storage and Retrieval SystemsSystems– Principles and Concepts– Design and Analysis

• AGV and ASRS RationalizationAGV and ASRS Rationalization


AGV’s – Example Def’nAGV’s – Example Def’n

• Primarily “Straight Line” Flow with Primarily “Straight Line” Flow with Rework ReturnsRework Returns

• RoutingRouting– Whse -> A -> B -> C -> D -> Whse– A and B are Machining– C and D are Assembly

• LoadLoad– 100 Units Per Hour


AGV’s – Example LayoutAGV’s – Example Layout

Warehouse

AB

C

D


AGV’s – Example Flows AGV’s – Example Flows (1)(1)

Warehouse

AB

C

D

100

10

100100

8

50150

12

150

100


AGV’s – Example AGV’s – Example VolumesVolumes

. To. To

From From ..

AA BB CC DD WhseWhse

WhseWhse 100100 5050 100100

AA -- 100100

BB 1010 -- 100100

CC 88 -- 150150

DD 1212 -- 150150


AGV’s – Assumed PathAGV’s – Assumed Path

Warehouse

A

B

C

D

100100


AGV’s – Path Volumes AGV’s – Path Volumes (Unidirectional)(Unidirectional)

. . ToTo

From From . .


WhseWhse 100100 5050 100100

AA -- 100100

BB 1010 -- 100100

CC 88 -- 150150

DD 1212 -- 150150W -> AW -> A (110)+8+(50+12)+(100)=2(110)+8+(50+12)+(100)=2

808000

A -> BA -> B 0+108+62+100=2720+108+62+100=272 88

B -> CB -> C 10+0+162+100 = 27210+0+162+100 = 272 88

C -> DC -> D 10+8+(100+150) = 26810+8+(100+150) = 268 1212

D -> WD -> W 10+8+12+150 = 18010+8+12+150 = 180 100100


AGV’s – Path VolumesAGV’s – Path Volumes (Bi-directional) (Bi-directional)

. . ToTo

From From . .


WhseWhse 100100 5050 100100

AA -- 100100

BB 1010 -- 100100

CC 88 -- 150150

DD 1212 -- 150150W <-> AW <-> A (100)+ (0) + (50) + (100) = 250 (100)+ (0) + (50) + (100) = 250

+12+12

A <-> BA <-> B 10+ (100) + (50) + (100) = 260 +10 10+ (100) + (50) + (100) = 260 +10 + + 22

B <-> CB <-> C 0 + 8+ (50+100) + (100) = 258 + 8 0 + 8+ (50+100) + (100) = 258 + 8 + + 44

C <-> DC <-> D 0 + 0 + 12+ (100+150 ) = 262 +12 *0 + 0 + 12+ (100+150 ) = 262 +12 *

D <-> WD <-> W 0+0+0+0+ 0+0+0+0+ 150 150 = 150 = 150 + + 112112


AGV’s – AnalysisAGV’s – Analysis• Measure of PerformanceMeasure of Performance

– Number of Vehicles Needed

vD

TvD

TN

N

eh

d

f

hourdeliveriesvehicles

60

/


AGV’s – SensitivityAGV’s – Sensitivity• Different PathsDifferent Paths

– Dedicated Loops– Different Equipment Positions– Different Vehicles

• Loads/Speeds

– Different Traffic Factors • Higher for Bi-directional, Larger Segments

– Breakdowns


Automatic Storage And Automatic Storage And Retrieval Systems (1)Retrieval Systems (1)

• ConceptsConcepts– Space Efficiency – Utility Savings (Lights, Heat, ...)– Knowledge of Location– Safety (Elimination of Labor)– Zoned Storage– Distributed/Multiple Locations of Items

• Breakdown of System• Rsponse Time

– Less Breakage, Pilferage



• TerminologyTerminology– Storage Volume/Cube

• Space of Warehouse

– Bay• Vertical Column of Storage Locations

– Row• Series of Bays (One Side of Aisle)

– Aisle• Space Between Rows



• TerminologyTerminology– Storage Racks

• Structure comprising storage locations, bays, and rows

– Storage/Retrieval Unit• Machine capable of storing/retrieving items

from storage locations

– Input Output Stations• Area/Equipment at end of aisles that

interfaces with factory floor distribution and receiving system



• TerminologyTerminology– Storage Modules/Bins

• Media for holding parts in a storage location

– Pick-up and Delivery Stations• Same as Input-Output Stations

– Transfer Stations• End of Aisle Equipment Used to effect

transfer of parts between rows (Same as Pick-up and Delivery/Input-Output Stations)



• Why Use ?Why Use ?– Space Efficiency (Height/Cube)

• No Need to Allocate Space so Human can Remember Location/Find

– Improved Inventory Management• Accuracy of Counts• Knowledge of Location(s)• Aging/Security

– Quick Storage/Retrieval– Eliminate Manual Operations– Interface with Other Automated

Systems



• TypesTypes– Unit Load– Mini-Load

• Location Precision• Must be in Trays, Standard Containers

– Person on Board• Kitting• Small Items

– Deep Lane– Automated Item



• Design, Modeling, and AnalysisDesign, Modeling, and Analysis– Minimize Number of Spaces

• Dedicated Storage– Contamination/Special Requirements

• “Random” Storage– Rules applied so not Totally random

– Maximize Throughput/$• Single Cycle• Dual Cycle• Number of Aisles vs. Response Time


ASRS Design (1)ASRS Design (1)

• Determine Load/Storage Bin SizesDetermine Load/Storage Bin Sizes– Distribution of Sizes (Unit Multiples)

• Determine Number of Each Size Determine Number of Each Size NeededNeeded– Dedicated

• Sum of Maximum Needed in Any Period

– Random• Maximum Aggregate, Any Period



• Determine Number of Determine Number of Store/Retrieve Needed per HourStore/Retrieve Needed per Hour

• Determine Number/Length of Rows Determine Number/Length of Rows and Baysand Bays– Base on Random or Dedicated Storage– Available Footprint Restrictions– Common Sense

• Maximum Practical Length– Cycle Time– Available Height



• Determine Cycle TimesDetermine Cycle Times– Dependant on

• Aisle Length/Height, Ratio• Size/Number of Storage Locations• S/R Speed

– Single Cycle• Only Stores or Only Retrieves per cycle

– Dual Cycle• Stores and Retrieves (after store) each cycle



• Determine Cycle TimesDetermine Cycle Times

heightspacestorageofnumberm

baysofnumbern

where

chmH

clnL

/___

__

)(

)(

1

2




VelocityVerticalV

VelocityHorizontalV

where

VHt

VLt

v

h

vv

hh

_

_

/

/




DepositorPickupforTimeTpd

TtTtQ

ttT

Where

TQ

TT

vh

vh

pdsc

____

)/,/min(

),max(

2)13(

2




DepositorPickupforTimeTpd

TtTtQ

ttT

Where

TQQT

T

vh

vh

pddc

____

)/,/min(

),max(

4)1540(30

32



• Assess AlternativesAssess Alternatives– Vary Length/Height– Vary Single/Dual Command

Cycles/Ratio– Calculate System Cost for Various

Configurations– Select “Best”

• Expandability• Match to Other Automated Systems




Segment B Topic:Segment B Topic: AGV Example and AGV Example and ASRSASRS

END OF SEGMENTEND OF SEGMENT




Segment C Topic:Segment C Topic: Quality Assurance Quality Assurance




Quality Assurance/EngineeringQuality Assurance/Engineering


OverviewOverview• Defining QualityDefining Quality

– Meaning– Dimensions– Costs

• Taguchi Loss FunctionTaguchi Loss Function• Failure Mode and AnalysisFailure Mode and Analysis• Control ChartsControl Charts• Anticipatory Quality ControlAnticipatory Quality Control


Defining QualityDefining Quality

• ““The totality of features and The totality of features and characteristics of a product or characteristics of a product or service that bear on its ability to service that bear on its ability to satisfy a given need”satisfy a given need”

ANSI/ASQC Standard A3-1987


Dimensions of Quality Dimensions of Quality (1)(1)

• Dimensions (All Products Subsets Dimensions (All Products Subsets of)of)– Performance

• Job it Does

– Features• Secondary Characteristics

– Time• Time to Receive/Time to Use

– Reliability• Meant Time to Failure



• Dimensions (All Products Subsets of)Dimensions (All Products Subsets of)– Durability

• Amount of (Ab)Use to Maintenance or Repair

– Uniformity• Variation between Instances

– Consistency/Accuracy• Specifications Conformance

– Serviceability• Response to Complaints/Ability for Owner

Service



• Dimensions (All Products Subsets Dimensions (All Products Subsets of)of)– Aesthetics

• Psychological/Sensual Appeal

– Personal Interface• People to People Interaction Quality

– Harmlessness• To User, To Environment

– Perceived Quality• Purchaser Perception/Inference


Costs of Quality (1)Costs of Quality (1)• Prevention CostsPrevention Costs

– Avoiding Costs of Failure/Degraded Performance

• Appraisal CostsAppraisal Costs– Cost of Measurement/Testing to Assure

Quality

• Internal Failure CostsInternal Failure Costs– Cost of Scrapping/Repairing Defects

prior to Customer Receipt of Product


Costs of Quality (2)Costs of Quality (2)External Failure CostsExternal Failure Costs

– Cost of Repairing/Replacing Defects after Customer Receipt of Produc t

– Suits for Damages as a Result of Lack of Merchantability

• Life Cycle CostsLife Cycle Costs– Designing Quality In Products, Processes– Quality Production– Quality Maintenance/Repair– Disposal


Taguchi Loss Function Taguchi Loss Function (1)(1)

• ConceptConcept– Loss increases with deviation from

Target Value (Quadratically)– Nominal is Best:

valuetT

productofsticscharacteriqualityy

tcoefficienLossqualityk

Where

TykyL

_targe

___

__

)()( 2




Target Value (Quadratically)– Smaller is Better:

valuetT



Where

ykyL

_targe

___

__

)()( 2




Target Value (Quadratically)– Larger is Better:

valuetT



Where

ykyL

_targe

___

__

)1()(

2



• ConceptConcept– Average Loss can be Determined Based

on Target, Functional Limits, and Variation

– Based on Average Loss• Different Processes can be Evaluated• Different Definitions of Functional Limits

can be Explored

– Controllable, Uncontrollable, Noise Factors


Failure Mode AnalysisFailure Mode Analysis

• ConceptConcept– Recognize and evaluate potential

failure modes and effects• Mode -- Occurrence/Severity/Detection

– Identify actions that can eliminate or reduce the chance of potential failure occurring

– Document the process


Control Charts (1)Control Charts (1)

• AttributesAttributes– X bar and R– P charts

• Use to Identify Unlikely EventsUse to Identify Unlikely Events– Presume Process Has Changed


Control Charts (2)Control Charts (2)

• Record Out-of-Control Record Out-of-Control Events/CausesEvents/Causes– Histograms– Pareto Charts– Cause and Effect Diagrams– Scatter Diagram


Anticipatory Quality Anticipatory Quality ControlControl

• ““Look Ahead Control Charts”Look Ahead Control Charts”– Results not Random, Autocorrelated

UCL

LCL

Mean

x x x xx

x x x xx

x x x xx

x x x xx




Segment C Topic:Segment C Topic: Quality Assurance Quality Assurance

END OF SEGMENT END OF SEGMENT

advanced manufacturing systems design © 2000 john w. nazemetz lecture 10 topic : shop floor support...

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