cam 1 unit palanivendhan manufacturin systems
DESCRIPTION
PALANIVENDHAN MANUFACTUING SYSTEMS PFA GROUP TECHNOLOGYTRANSCRIPT
![Page 1: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/1.jpg)
Computer Aided Manufacturing
M.PALANIVENDHAN
Department of Automobile Engineering
SRM University, kattankulathur campus
![Page 2: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/2.jpg)
Computer Aided Manufacturing
• What is Manufacturing
• It is the process of converting the raw material into product.
• It encompasses
– Design of the product
– The selection of raw material
– The sequence of processes through which the product will be manufactured.
Difference between production and manufacturing
![Page 3: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/3.jpg)
Need of
Manufacturing
• Globalization
• International outsourcing
• Local outsourcing
• Contract manufacturing
• Quality expectation
• Operational efficiency
![Page 4: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/4.jpg)
Manufacturing
Process
Starting material
(Raw material)
Machinery
Tools
Power
Labor
Completed part
(Product)
Scrap
![Page 5: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/5.jpg)
Changes in manufacturing
![Page 6: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/6.jpg)
Manufacturing engineers are required to achieve the
following objectives to be competitive in a global context.
• ‘edu tio i i e to
• Lo e the ost of the p odu t • ‘edu e aste
• I p o e ualit
• I ease fle i ilit i a ufa tu i g to a hie e immediate and rapid response to: – Product changes
– Production changes
– Process change
– Equipment change
– Change of personnel
![Page 7: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/7.jpg)
7
![Page 8: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/8.jpg)
Manufacturing systems approaches
• Automation (Low labor high prod.)
• Material handling technologies(scm)
• Manufacturing systems (integration of automated or manual )
• Flexible manufacturing (low volume and high mix product)
• Quality programs (6sigma)
• CIM (CAD CAM)
• Lean production (more work fewer resources)
![Page 9: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/9.jpg)
Manufacturing System – Definition
• A set of operations performed on materials
which bring them closer to the desired final
form.
![Page 10: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/10.jpg)
Production systems
• A production system is a collection of people,
equipment and procedures.
– Facilities (factory and the equipment)
– Manufacturing support systems(manage production
and to solve the technical and logistics problems
encountered in ordering materials)
blue collar workers, white collar workers
![Page 11: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/11.jpg)
The Facilities
• Factory, production machine,tooling,material
handling equipment,inspection equipment,
computer systems
• Manual work systems
– Without aid of powered tools, only of hand tool
• Worker –machine systems
– (human worker +machine tool)
• Automated systems
– without participation of a human worker
– 1.semi automated 2. Fully automated
![Page 12: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/12.jpg)
Manufacturing Support Systems • To operate the production facilities efficiency to design the
processes and control the production and satisfy the product
quality
![Page 13: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/13.jpg)
![Page 14: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/14.jpg)
• Business Functions
– Comm to customer,sales,marketing
• Product Design
– Product development
• Manufacturing Planning
– Process planning, logistics issues, master
production schedule
• Manufacturing control
– Shop floor,inventory and quality control
![Page 15: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/15.jpg)
Types of production
• Continuous process
• Mass production
• Batch production
![Page 16: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/16.jpg)
Continuous Process
• In this type of industry, the
production process generally
follows a specific sequence.
• These industries can be easily
automated and computers are
widely used for process
monitoring, control and
optimization.
• Oil refineries, chemical plants,
food processing industries, etc
are examples of continuous
process industries.
![Page 17: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/17.jpg)
Mass production
• Industries manufacturing
fasteners (nuts, bolts etc.),
integrated chips,
automobiles, entertainment
electronic products,
bicycles, bearings etc.
• which are all mass produced
can be classified as mass
production industries.
• Production lines are
specially designed and
optimized to ensure
automatic and cost effective
operation.
![Page 18: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/18.jpg)
Batch Production
• The largest percentage of
manufacturing industries can
be classified as batch
production industries.
• The distinguishing features of
this type of manufacture are
the small to medium size of
the batch, and varieties of
such products to be taken up
in a single shop.
• Due to the variety of
components handled, work
centers should have broader
specifications.
• Another important fact is that
small batch size involves loss
of production time associated
with product changeover.
![Page 19: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/19.jpg)
![Page 20: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/20.jpg)
TYPES OF LAYOUT
• 1.FIXED POSITION LAYOUT
• 2.PROCESS LAYOUT
• 3.PRODUCT FLOW LAYOUT
• 4.GROUP TECHNOLOGY(CELLULAR) LAYOUT
![Page 21: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/21.jpg)
1.Fixed position
part” stationary
workstations move
![Page 22: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/22.jpg)
7/24/2014
• Fixed position layout – Product must remain stationary throughout production
sequence
– Machines are brought to the product
– Higher expense due to robustness and accuracy of
equipment
![Page 23: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/23.jpg)
2.Process Layout
– organized by machine type
![Page 24: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/24.jpg)
3.Product flow layout
-Assembly/flow/transfer line
![Page 25: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/25.jpg)
• Product flow layout – Suited for high volume production
– Advantages: minimized material handling, easy to
automate material handling, less WIP, easier to
control
– Disadvantages: inefficient to alter the sequence of
operations, breakdown on one machine can stop
the entire line
![Page 26: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/26.jpg)
What is Manufacturing
• It is the process of converting the raw material
into product.
• It encompasses
– Design of the product
– The selection of raw material
– The sequence of processes through which the
product will be manufactured.
![Page 27: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/27.jpg)
Manufacturing can be defined as the
application of physical and chemical processes
to alter the geometry, properties, and/or
appearance of a given starting material to
make part or products
![Page 28: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/28.jpg)
Manufacturing
Process
Starting material
(Raw material)
Machinery
Tools
Power
Labor
Completed part
(Product)
Scrap
![Page 29: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/29.jpg)
Changes in manufacturing
![Page 30: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/30.jpg)
Manufacturing engineers are required to achieve the
following objectives to be competitive in a global context.
• ‘edu tio i i e to
• Lo e the ost of the p odu t • ‘edu e aste
• I p o e ualit
• I ease fle i ilit i a ufa tu i g to a hie e immediate and rapid response to: – Product changes
– Production changes
– Process change
– Equipment change
– Change of personnel
![Page 31: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/31.jpg)
TYPES OF MANUFACTURING
• Continuous process
• Mass production
• Batch production
![Page 32: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/32.jpg)
Continuous Process
• In this type of industry, the production process
generally follows a specific sequence.
• These industries can be easily automated and
computers are widely used for process
monitoring, control and optimization.
• Oil refineries, chemical plants, food processing
industries, etc are examples of continuous
process industries.
![Page 33: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/33.jpg)
![Page 34: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/34.jpg)
Mass production
• Industries manufacturing fasteners (nuts, bolts
etc.), integrated chips, automobiles,
entertainment electronic products, bicycles,
bearings etc.
• which are all mass produced can be classified as
mass production industries.
• Production lines are specially designed and
optimized to ensure automatic and cost effective
operation.
• Automation can be either fixed type or flexible.
![Page 35: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/35.jpg)
![Page 36: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/36.jpg)
Batch Production
• The largest percentage of manufacturing industries can be classified as batch production industries.
• The distinguishing features of this type of manufacture are the small to medium size of the batch, and varieties of such products to be taken up in a single shop.
• Due to the variety of components handled, work centers should have broader specifications.
• Another important fact is that small batch size involves loss of production time associated with product changeover.
![Page 37: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/37.jpg)
![Page 38: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/38.jpg)
Volume
![Page 39: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/39.jpg)
Manufacturing systems
• Agile manufacturing
• Flexible manufacturing
• Just-in-time manufacturing
• Lean manufacturing
• Mass production
• Ownership
• Prefabrication
• Rapid manufacturing
![Page 40: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/40.jpg)
CIM WHEEL
![Page 41: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/41.jpg)
![Page 42: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/42.jpg)
Current trends in manufacturing • Group Technology
• Design for manufacturing
• Computer Aided Process Planning (CAPP)
• Total Quality Approach
• Concurrent engineering
• Rapid prototyping
• Computer Integrated manufacturing (CIM)
• Digital Manufacturing
• Green Manufacturing
• Lean Manufacturing
• Agile manufacturing
![Page 43: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/43.jpg)
![Page 44: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/44.jpg)
Automation in Manufacturing
• Automation are now perform operation
such as processing, assembly, inspection,
material handling, in some cases
accomplishing more than one of these
operations.
![Page 45: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/45.jpg)
Classification of Automated
manufacturing system
• Fixed Automation
• Programmable Automation
• Flexible Automation
![Page 46: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/46.jpg)
Fixed Automation
• Fixed automation is a system in
which sequence of processing
operation is fixed by the equipment
configuration.
![Page 47: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/47.jpg)
Features of fixed automation
• High initial investments
• High production rates
• Relatively inflexible in accommodating
product variety
![Page 48: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/48.jpg)
Examples of fixed automation
• Machining transfer lines
• Automation assembly machines.
![Page 49: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/49.jpg)
Programmable Automation
• In Programmable Automation systems the
production equipments is designed with the
capability to change the sequence of
operation to accommodate different product
configuration.
![Page 50: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/50.jpg)
Features of Programmable Automation
• High investment in general purpose
equipment
• Flower production rate than fixed automation
• Flexible to deal with variations and changes in
product configuration.
• More suitable for batch production
![Page 51: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/51.jpg)
Examples of Programmable
Automation
• Numerical controlled machine tool
• Industrial robots
• Programmable logic controllers
![Page 52: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/52.jpg)
Flexible Automation
• Flexible automation is capable of producing a
variety of parts with virtually no time lost for
changeover from one part style to the next.
![Page 53: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/53.jpg)
• Continuous production of various mixtures of
products
• Medium production rate
• Flexibility to deal with product design
variations
Features of Flexible Automation
![Page 54: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/54.jpg)
Fixed
Automation
Flexible
Automation
Programmable
Automation
Pro
duct va
rie
ty
Production quantity
100 10,000 1,000,000
Manual
Production
![Page 55: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/55.jpg)
Factory
Operation
Design
Mfg.
Planning
Mfg.
Control
Business
Functions
![Page 56: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/56.jpg)
![Page 57: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/57.jpg)
GROUP TECHNOLOGY
![Page 58: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/58.jpg)
GROUP TECHNOLOGY
• GT is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in manufacturing and design.
• Similar parts are arranged into part families.
– eg. A factory manufacturing 10000 different parts may be categorized into 50 families.
• Each family will have some common characteristics feature or parameters.
![Page 59: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/59.jpg)
PART FAMILY
• A part family is a collection of parts which are similar either because of geometric shape and size or because similar processing steps are required in their manufacture.
• Three methods of identifying part family:
1.Visual inspection
2.Part classification and coding schemes
3.Production flow analysis (PFA Chart)
![Page 60: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/60.jpg)
Grouping according to geometric similarities
Grouping according to manufacturing similarities
![Page 61: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/61.jpg)
Plant Layout
& Group
Technology
Process type
Layout
GT
(Cellular)
Layou
![Page 62: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/62.jpg)
FUNCTIONAL LAYOUTS ARE INEFFICIENT
PROCESS-TYPE LAYOUT
Lathe Milling Drilling
Grinding
Assembly
Receiving and
Shipping
L
L L
L
L
L
L
L M
M M
M M
M
A A
A A
D
D D
D
G
G
G
G G
G
![Page 63: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/63.jpg)
Process Layout Characteristics
• Advantages
– Deep knowledge of the process
– Common tooling and fixtures
– Most Flexible -- can produce many different part types
• Disadvantages
– Spaghetti flow -- everything gets all tangled up
– Lots of in-process materials
– Hard to control inter-department activities
– Can be difficult to automate
![Page 64: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/64.jpg)
PRODUCT LAYOUT
Shipping
L L M D
L M D
G
L M G G
A A
Receiving
Part #1
Part #3
Part #2
![Page 65: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/65.jpg)
Product Layout Characteristics
• Advantages
– Easy to control -- input control
– Minimum material handling -- frequently linked to the next process
– Minimal in-process materials
– Can be more easily automated
• Disadvantages
– Inflexible -- can only produce one or two parts
– Large setup
– Duplicate tooling is required for all cells
![Page 66: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/66.jpg)
Cell #2
Cell #3
Cell #1
D D M I
D M L L I
D
M
L M
I
CELLULAR LAYOUT
![Page 67: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/67.jpg)
Cellular Layout Characteristics
• Advantages
– Control is simplified
– Common tooling and fixtures
– Flexible -- can produce many different part types - a part
family
• Disadvantages
– More Setup time required
– Need to know about many different processes
![Page 68: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/68.jpg)
TRANSFER
LINE
SPECIAL
SYSTEM FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY
VO
LU
ME
HIGH
VARIETY
LOW HIGH
![Page 69: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/69.jpg)
![Page 70: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/70.jpg)
Advantages of Group Technology
• Standardization of part design and minimization of design duplication • New parts can be developed using previous similar designs. • Data reflecting the experience of the part designer and manufacturing process planner are stored in a database. • Process plans are also standardized and scheduled more
efficiently. • Setup times are reduced and parts are produced more efficiently. • Similar tools, clamps, jigs, fixtures and machinery are shared. • Needs to be implemented CIM, CAD/CAM and cellular manufacturing. Potential savings 5 to 75 %.
![Page 71: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/71.jpg)
Classification and Coding of Parts
• Design Attributes: • External and internal shapes and dimensions • Aspect ratio • Tolerances specified • Surface finish specified • Part function
• Manufacturing Attributes: • Primary processes • Secondary and finishing processes • Tolerances and Surface finish • Sequence of operations • Tools, dies, fixtures and machinery • Production quantity and production rate
![Page 72: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/72.jpg)
• Part Classification and Coding System
• • Classification means to sort similar parts into
predetermined groups based on appropriate
attributes (shape,manufacturing process, material,
etc.)
• • A code is a combination of letters and numbers
that are assigned to parts for information
processing
![Page 73: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/73.jpg)
Coding Systems
• Types of Coding:
• Hierarchical coding (monocode)
• Polycoding (chain type)
• Decision-tree Coding (hybrid code)
• Major Industrial Coding Systems:
• Opitz System
• Multiclass System
• KK-3 system
![Page 74: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/74.jpg)
Coding schemes
• Hierarchical
1
2 3
1 2
3 1 2
3
1 2
3
![Page 75: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/75.jpg)
• Chain
1
2
3
.
.
1
2
3
.
.
![Page 76: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/76.jpg)
Decision Tree Classification
![Page 77: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/77.jpg)
OPITZ SYSTEM
• 12345 6789 ABCD
- Basic code consist of first 9 digits. This convey
both design and manufacturing data.
-Fi st digit alled fo ode
- Ne t digit alled supple e ta ode
- Ne t digit ABCD alled se o da ode
![Page 78: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/78.jpg)
![Page 79: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/79.jpg)
![Page 80: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/80.jpg)
A Simple Rotaional Part
![Page 81: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/81.jpg)
![Page 82: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/82.jpg)
Given the part design shown define the "form
code" using the Opitz system
![Page 83: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/83.jpg)
![Page 84: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/84.jpg)
![Page 85: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/85.jpg)
![Page 86: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/86.jpg)
MULTI CLASS SYSTEM
• This developed by the organization for
industrial research.
• This is relatively flexible.
• This used for variety of diff types of mfg
product.
• It uses a hierarchical or decision tree coding
structure.
• Coding structure up to 30 digits.
![Page 87: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/87.jpg)
MULTI CLASS SYSTEM
Digit Function
0 – code system prefix
1 – main shape category
2,3 – external and internal configuration
4 - machined secondary elements
5,6 –Functional description
7-12 – Dimensional data (length,diameter)
13-Tolerances
14,15 – Material chemistry
16 – Raw material shape
17- production quantity
18- machined element orientation
![Page 88: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/88.jpg)
![Page 89: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/89.jpg)
PRODUCTION FLOW ANALYSIS(PFA)
• It does not use part classification and coding system.
• It does not use part drawing
• It used to analyze the operation sequence and machine routing.
• PFA uses manufacturing data rather than design data.
• Dis adv: It provides no mechanism for rationalizing the manufacturing routings.
![Page 90: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/90.jpg)
PFA PROCEDURE
• 1.DATA COLLECTION
• 2. SORTING OF PROCESS ROUTINGS.
• 3.PFA CHART
• 4. ANALYSIS
![Page 91: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/91.jpg)
• Part Family & Manufacturing Cell
Formation: General Procedure • 1. Define the scope of the study including system boundaries
• 2. Identify the similarity attributes of interest
• 3. Simplify:
• Group obviously similar parts into representative part-type
• G oup pie es of e uip e t that ust sta togethe i to
representative machine-type
• 4. Find process plans using part-types and machine types
found in the previous step
• 5. Determine the Part-Machine Incidence Matrix
based on the process plans found in the previous step
• 6. Find the best Product Families and Machine Cells using
clustering methods.
![Page 92: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/92.jpg)
![Page 93: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/93.jpg)
EXAMPLE:
Consider a problem of 4 machines and 6 parts. Try
to group them.
Machines 1 2 3 4 5 6
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1
93
Components
![Page 94: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/94.jpg)
Machines 2 4 6 1 3 5
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1
94
Components
![Page 95: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/95.jpg)
Rank Order Clustering Algorithm:
Rank Order Clustering Algorithm is a simple
algorithm used to form machine-part groups.
95
![Page 96: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/96.jpg)
Step 1: Assign binary weight and calculate a
decimal weight for each row and column using the
following formulas:
96
Decimal we
Decimal we bpjn p
ight for row i = b
ight for column j =
ipm-p
p=1
m
p=1
n
2
2
![Page 97: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/97.jpg)
Step 2: Rank the rows in order of decreasing
decimal weight values.
Step 3: Repeat steps 1 and 2 for each column.
Step 4: Continue preceding steps until there is
no change in the position of each element in
the row and the column.
97
![Page 98: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/98.jpg)
EXAMPLE:
Consider a problem of 5 machines and 10 parts. Try to group
them by using Rank Order Clustering Algorithm.
Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1
98
Components
Table 1
![Page 99: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/99.jpg)
Machines 1 2 3 4 5 6 7 8 9 10 Decimal
equivalent
M1 1 1 1 1 1 1 1 1 1 1007
M2 1 1 1 1 1 451
M3 1 1 1 1 568
M4 1 1 1 1 1 1 455
M5 1 1 1 1 1 1 1 1 1020
29 28 27 26 25 24 23 22 21 20
99
Binary weight
Components
Table 2
![Page 100: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/100.jpg)
Binary
weight Machines 1 2 3 4 5 6 7 8 9 10
24 M5 1 1 1 1 1 1 1 1
23 M1 1 1 1 1 1 1 1 1 1
22 M3 1 1 1 1
21 M4 1 1 1 1 1 1
20 M2 1 1 1 1 1 Decimal
equivalent 28 27 27 27 28 20 28 26 11 11
29 28 27 26 25 24 23 22 21 20
100
Binary weight
Components
Table 3
![Page 101: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/101.jpg)
Binary
weight
Machines 1 5 7 2 3 4 8 6 9 10 Decimal
equivalent
24 M5 1 1 1 1 1 1 1 1 1020
23 M1 1 1 1 1 1 1 1 1 1 1019
22 M3 1 1 1 1 900
21 M4 1 1 1 1 1 1 123
20 M2 1 1 1 1 1 115 Decimal
equivalent 28 28 28 27 27 27 26 20 11 11
29 28 27 26 25 24 23 22 21 20
101
Binary weight
Components
Table 4
![Page 102: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/102.jpg)
Manufacturing Cell Layout
• Once machine clusters are identified, one needs to
decide the best machine layout to
implement.
• For a good cell layout one must consider:
• -Technological considerations
• -Streamlined material flow
• Hollier methods specifies the machine layout that
maximizes the proportion of in-sequence
moves within the cell.
![Page 103: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/103.jpg)
Hollier Method • 1. Develop the From-To Chart
• 2. Determine the From/To ratio for each a hi e di idi g the F o -su the To-
su fo ea h a hi e
• 3. Arrange the machines in order of decreasing From/To ratios
• • Ma hi es ith high atios a e pla ed at the beginning of the flow.
• • I the ase of ties, pla e a hi es ith highe F o alues fi st.
![Page 104: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/104.jpg)
Solve the problem using Hollier
Method 1:
2 3 1 4 From
2 - - 62 145 207
3 167 167
1 12 12
4 140 140
167 0 202 157
Step 1
17
![Page 105: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/105.jpg)
Solve the problem using Hollier
Method :
2 3 1 4 From
2 - - 62 145 207
3 167 167
1 12 12
4 140 140
167 0 202 157
Step 1 Step 2
17
2 3 1 4 From
2 - - 62 145 207
3 167 167
1 12 12
4 140 140
167 0 202 157
Machine 3
first
![Page 106: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/106.jpg)
Solve the problem using Hollier
Method :
2 1 4 From
2 - 62 145 207
1 12 12
4 140 140
To 0 202 157
Step 1 Step 2
17
2 1 4 From
2 - 62 145 207
1 12 12
4 140 140
To 0 202 157
Machine 2
next
![Page 107: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/107.jpg)
Solve the problem using Hollier
Method1 :
1 4 From
1 12 12
4 140 140
To 140 12
Step 1 Step 2
17
1 4 From
1 12 12
4 140 140
To 140 12
3 2 4 1
The flow diagram
40
167 145 140
12
17
62
190
Machine 4 next
![Page 108: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/108.jpg)
Solve the problem using Hollier
Method 2:
2 3 1 4 From
2 - - 62 145 207
3 167 167
1 12 12
4 140 140
167 0 202 157
From to From
to ratio
order
2 207 167 124 2
3 167 0 infinity 1
1 12 202 0.06 4
4 140 157 0.89 3
Step 1 Step 2
3 2 4 1
The flow diagram
167
40
167 145 140
12
17
62
190
![Page 109: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/109.jpg)
![Page 110: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/110.jpg)
Flexible Manufacturing System
• A highly automated GT machine cell,
consisting of a group of processing stations
(usually CNC machine tools), interconnected
by an automated material handling and
storage system, and controlled by an
integrated computer system
![Page 111: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/111.jpg)
Five Types of FMS Layouts
• 1.In-line
• 2.Loop
• 3.Ladder
• 4.Open field
• 5.Robot-centered cell
![Page 112: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/112.jpg)
In-line FMS Layouts
![Page 113: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/113.jpg)
Loop FMS Layouts
![Page 114: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/114.jpg)
Ladder FMS Layouts
![Page 115: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/115.jpg)
Open field FMS Layouts
![Page 116: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/116.jpg)
Robot-centered cell FMS Layouts
![Page 117: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/117.jpg)
FMS Components • Hardware components
– Workstations - CNC machines in a machining type system
– Material handling system - means by which parts are moved between stations
– Central control computer - to coordinate the activities of the components so as to achieve a
– smooth overall operation of the system
• Software and control functions
• Human labor
![Page 118: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/118.jpg)
Computer Functions in a FMS
• NC part programming - development of NC
programs for new parts introduced into the
system
• Production control - product mix, machine
scheduling, and other planning functions
• NC program download - part program commands
must be downloaded to individual stations
• Machine control - individual workstations require
controls, usually CNC
![Page 119: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/119.jpg)
Computer Functions in a FMS • Work part control - monitor status of each work part in
the system, status of pallet fixtures, orders on loading/unloading pallet fixtures
• Tool management - tool inventory control, tool status relative to expected tool life, tool changing and resharpening, and transport to and from tool grinding
• Transport control - scheduling and control of work handling system
• System management - compiles management reports on performance (utilization, piece counts, production rates, etc.)
![Page 120: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/120.jpg)
Duties Performed by Human Labor
• Loading and unloading parts from the system
• Changing and setting cutting tools
• Maintenance and repair of equipment
• NC part programming
• Programming and operating the computer
system
• Overall management of the system
![Page 121: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/121.jpg)
FMS Applications
• Machining –most
common application of
FMS technology
• Assembly
• Inspection
• Sheet metal processing
(punching, shearing,
bending, and forming)
• Forging
![Page 122: Cam 1 unit palanivendhan manufacturin systems](https://reader033.vdocuments.us/reader033/viewer/2022052618/554a0a45b4c905557a8b594a/html5/thumbnails/122.jpg)
FMS Benefits
• Higher machine utilization than a
conventional machine shop due to better
work handling, off-line setups, and improved
scheduling
• Reduced work-in-process due to continuous
production rather than batch production
• Lower manufacturing lead times
• Greater flexibility in production scheduling