How does ISAT331 fit in the curriculum?

ISAT 331

Automation in Manufacturing

211, 330211, 330

211,330211, 330

Factory Operations211

ISAT 211 & 330

331

331331

331

ISAT 331

References

1. Groover, M.P, Automation, Production Systems, and Computer Integrated 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

Module 1

Introduction

1/10/05

•Production Systems Facilities

•Automation in Production Systems

•Manual Labor in Production Systems

•Automation Principles and Strategies

•CAD, CAM and CIM

Manufacturing System

Manufacturing Support Activities

Automation

Computerization

Production System

CIM

ISAT331

ISAT330

Terminologies

Computers in Manufacturing

• Automate physical system and information system in manufacturing

•Automation is more related to automating the factory operations

•Computerization is more related to automating information cycle

•CIM is more related to automating of both factory operations and information cycle

Production Quantity

Pro

duct

Var

iety

100 10,000 1 M

Product Variety vs Production Quantity

Hard

Soft

Low High

Job Shop

Mass Production

Mid VarietyMid Production(Most Difficult)

Changeover (set up)Time

MH automated

Fig 1.3

Mass Production

Production Quantity

Pro

duct

Var

iety

100 10,000 1 M

Types of Production Plant (facilities) and Layout

Hard

Soft

Low High

•Fixed Position (Large)•Process

•Product (Flow line)•Process (Quantity)

•Process (Batch)•Cellular (GT families)•FMS (GT families- automated MH)

Job Shop

Mid VarietyMid Production

(Apply GT)

Efficiency

Flexibility

Job Shop has processes that cope with low volume and high number of 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

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 Line’ when multiple stations are

required (single- or mixed model lines) - Demand Rate ~ Production Rate

Characteristics of Production Plants

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 on production volume and variety of

productsa) Fixed Automationb) Programmable Automationc) Flexible Automation

Production Quantity

Pro

duct

Var

iety

100 10,000 1 M

Manual vs Automation

Hard

Soft

Low High

Production Quantity

Pro

duct

Var

iety

100 10,000 1 M

Fig 1.1 Automation/Production Volume/Product Variety

Hard

Soft

Low High

Job Shop

Mass Production

Mid VarietyMid Production(Most Difficult)

Programmable Automation

Flexible Automation

Fixed Automation

Manual

Automation

Change Over (Set-up) Time

Programmable Automation

MOST FLEXIBLE

• Sequence of operations can be changed (variety of products that are made by similar processes)

• High investment (general purpose equipment)

• Low – Medium production rate (relatively longer time lost for changeovers of programming and set-up)

• Automation of operations (processes or workstations)

is emphasized (not MH)

Fixed Automation

MOST EFFICIENT

• Sequence of operation is fixed (fixed configurations)

• Many simple ( reliability) operations (complex system)

• Initial investment is high (custom-engineered equipment)

• Production rates are high (mass production-Examples)

• Automated Operations (processes or workstations)

and Material handling

Flexible Automation

Extension of Programmable Automation with

• Lower time lost on changeovers (continuous production of a group of parts – GT family- that accommodate part variations within the

family)

• Mid volume/variety range

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

Automation Strategies & Migration

•Automation is not the answer (Robotics application?)

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

• Strategies?

• Automation Migration Strategy

Fig 1.9

Back to our Conceptual Model

Manufacturing Support Activities

Manufacturing System

Factory Operations

• (Fig 2.2)Processing ‘advance to completion’ (Basic, Secondary, Property Enhancement, Finishing)Assembly Material handling&StorageInspection (specifications)and Testing (function)Control on shop floor (process control, quality control)

SAP system?

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 plant “operating cost, meeting schedule”, etc)

Manual Labor in Production System

•Factory Operations

•Supporting Activities

Fig 24.7 Scope of CAD, CAM and CIM

Fig 24.8

Definitions•CAD is any design activity that involves the effective use of computer technology to create,modify, or document an engineering 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)

Home Work#1

Due Wednesday 1/18/2006

1) Explain and contrast the characteristics of the basic production systems

2) Explain and contrast the characteristics of the basic automated production systems

3) 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 over automation in Manufacturing Support Systems (white collar tasks)

5) Explain THREE strategies for automating production systems

Unused Slides