dr rabie 331s06 introd mod1

7/29/2019 Dr Rabie 331S06 Introd Mod1

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How does ISAT331 fit in the curriculum?

ISAT 331Automation in Manufacturing


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211, 330 211, 330

211,330211, 330

Factory Operations211

ISAT 211 & 330


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331

331331

331

ISAT 331


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References

1. Groover, M.P, Automation, Production Systems, and ComputerIntegrated Manufacturing, Prentice-Hall 2001

2. Bedworth, D.D.,Henderson, M.R., and Wolfe P.M., Computer-

Integrated Design and Manufacturing, McGraw-Hill, 1991.

3. Chang,T., Wysk,R..A, Wang, H. Computer Aided Manufacturing,

Prentice Hall, 2nd Ed, 1991


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Module 1

Introduction

1/10/05

Production Systems Facilities

Automation in Production SystemsManual Labor in Production Systems

Automation Principles and Strategies

CAD, CAM and CIM


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Manufacturing

System

Manufacturing

Support Activities

Automation

Computerization

CIM

ISAT331

ISAT330

Terminologies


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Computers in Manufacturing

Automatephysical system and information system in

manufacturing

Automation is more related to automating the factoryoperations

Computerization is more related to automating information

cycleCIM is more related to automating of both factory operations

and information cycle


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Production Quantity

P

roductVariety

100 10,000 1 M

Product Variety vs Production Quantity

Hard

Sof

t

Low High

Job Shop

Mass Production

Mid Variety

Mid Production

(Most Difficult)

Changeover (set up)Time

MH automated


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Fig 1.3


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Mass Production

Production Quantity

Pr

oductVariety

100 10,000 1 M

Types of Production Plant (facilities) and Layout

Hard

Sof

t

Low High

Fixed Position (Large)

Process

Product (Flow line)

Process (Quantity)

Process (Batch)

Cellular (GT families)

FMS (GT families- automated MH)

Job Shop

Mid Variety

Mid Production

(Apply GT)


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Job Shop has processes that cope with low volume and high numberof products

- Uses Process or Fixed position layout

- Make to order.

- Production Rate = Demand Rate

Batch, cellular, and FMS Production has processes that cope with

medium volume and medium variety in products

-Cellular deals with harder variety products than FMS

- FMS is highly automated (MH) when compared to cellular- Repeated set up-a major disadvantage.

- Production rate > Demand rate.

- Make to Stock.

Characteristics of Production Plants


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Mass Production has processes that cope with high volume and

limited number of products

- Process or cellular layout is used for quantity production

(single station equipment)

- Product layout Flow Linewhen multiple stations arerequired (single- or mixed model lines)

- Demand Rate ~ Production Rate

Characteristics of Production Plants


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Automation of Production Plant

Definition of Automation

Why to Automate? Arguments for Automation

Arguments against Automation

Examples

Types of Automated Manufacturing Systems

Categorized based on sequence of operations

Justified based onproduction volume and variety ofproducts

a) Fixed Automation

b) Programmable Automation

c) Flexible Automation


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Production Quantity

P

roductVariety

100 10,000 1 M

Manual vs Automation

Hard

Sof

t

Low Hig

h


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Production Quantity

P

roductVariety

100 10,000 1 M

Fig 1.1 Automation/Production Volume/Product Variety

Hard

Sof

t

Low Hig

h

Job Shop

Mass Production

Mid Variety

Mid Production

(Most Difficult)

Programmable Automation

Flexible Automation

Fixed Automation

Manual

Automation


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Programmable Automation

MOST FLEXIBLE

Sequence of operations can be changed (variety of

products that are made by similar processes)

High investment (general purpose equipment) LowMedium production rate (relatively longer

time lost for changeoversofprogramming and

set-up)

Automation of operations (processes or workstations)

is emphasized (not MH)


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Fixed Automation

MOST EFFICIENT

Sequence of operation is fixed (fixed configurations)

Many simple ( reliability) operations (complex system)

Initial investment is high (custom-engineeredequipment)

Production rates are high (mass production-Examples)

Automated Operations (processes or workstations)

and Material handling


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Flexible Automation

Extension of Programmable Automation with

Lower time lost on changeovers (continuous

production of a group of partsGT family- that

accommodate part variations within the family)

Mid volume/variety range

Higher investment (custom-engineered devices(e.g fixtures and Jigs) for changeover)


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Automation Strategies & Migration

Automation is not the answer (Robotics application?)

Main principle Understand (charting?), Simplify, and Automate

Strategies?

Automation Migration Strategy


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Fig 1.9


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Back to our Conceptual Model

Manufacturing

Support Activities

Manufacturing

System


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Factory Operations

(Fig 2.2)

Processing advance to completion

(Basic, Secondary, Property Enhancement, Finishing)

AssemblyMaterial handling&Storage

Inspection (specifications)and Testing (function)

Control on shop floor (process control, quality control)


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SAP system?


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Manufacturing Support Activities

(Fig 2.4)

Business functions (type of orders?)

Product Design (source of specifications?)Manufacturing Planning (process planning and route

sheet?)

Manufacturing Control (management) implement

plans(type of controls?),performance of processes #

rejects, machine rate, etc, performance of plantoperating cost, meeting schedule, etc)

M l L b i P d ti S t


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Manual Labor in Production System

Factory Operations

Supporting Activities


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Fig 24.7 Scope of CAD, CAM and CIM


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Fig 24.8


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Definitions

CAD is any design activity that involves the effective use of

computer technology to create,modify, or document anengineering design (part or system)

CAM is the effective use of computer technology in the

planning, management, and control of the manufacturing

function

CAD/CAM integration of the design and manufacturing

activities. That is to automate the transition from design to

manufacturing (e.g NC and process plan and Rapid

Prototyping)


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Home Work#1

Due Wednesday 1/18/2006

1) Explain and contrast the characteristics of the basic productionsystems

2) Explain and contrast the characteristics of the basic automated

production systems3) Discuss TWO situations in which humans are preferred over

automation in Factory Operations (blue collar tasks)

4) Discuss TWO situations in which humans are preferred overautomation in Manufacturing Support Systems (white collar tasks)

5) Explain THREE strategies for automating production systems


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