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UNIT-IV Shop Floor Control and Flexible Manufacturing

Systems

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Shop Floor Control• Shop floor control (or) Production Activity Control Manages the detailed

flow of materials inside the production facility

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Functions of Shop floor Control• Scheduling• Follow up• Dispatching

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Phases of Shop floor Control• Order Release• Order Scheduling• Order Progress

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Order Release • This phase provides the documentation needed to process a production

order through the factory• This collection of documents referred as the shop packet • Shop pocket consists of

• Route sheet- used to list the sequence of operations and tools required• Material requisitions- used to get necessary raw materials from inventory• Job cards- used to report the labour for each operation on the route sheet• Move tickets- used to move the parts between the work centres• Part lists- required for assembly jobs

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Order Scheduling • It executes the dispatching function in production planning and control

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Elements of Order Scheduling 1.Machine loading- Allocating orders to work centres2.Job sequencing- Determining priority in which the jobs should be proceedPriority Sequencing rules:• Shortest operating time• Earliest due date• Slack time remaining-(Time remaining before due date-Processing time

remaining)• First come, first served- orders are run in the order they arrive in dept.• Last come first, first served- orders arrive, they placed on top of the stock

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Order progress • Monitors the status of the various orders in the plant, work –in progress

and other progress in the shop floor Types of orders progress reports: • Work order status progress- indicate the current status of each shop• Progress reports- indicates the performance of each shop• Exception reports- indicate the deviations from production schedule

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Factory Data Collection System (FDC) • FDC consists of various paper documents , terminals and automated

devices throughout the plant for collecting data on shop floor operations and compile and process the collected data for reference.

Types of data collected by FDC• Number of Pieces completed at a certain work centre• Labour time spend on each order• List and no. of parts that are scrapped• List the no. of parts required rework• Time clocks used by employees to punch in and out of work

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Objectives of Factory Data Collection System (FDC)

• To supply status and performance data to shop floor control system• To provide up to date information• To enable the management to monitor and implementation of master

schedule

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Types of Data Collection System • Online data collection system• Offline data collection system

Online data collection system• The data are entered directly into the plant computer system and are

immediately available to the order progress module. It always kept the details in current status

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Types of Data Collection System Offline data collection system• The data are collected temporarily in a storage device (or) stand alone

computer system • Its easy to install and monitor• It cannot provide up to date information to the shop floor

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Data Input Techniques 1.Manual/Clerical input techniques

• Job traveler- long sheet that travels with the shop packet through the factory • Employee time sheets- daily time sheet is prepared for each worker• Operation tear strips- set of preprinted tear strips• Prepunched cards- Prepunched computer cards to each workers

Disadvantages:• Its depends on accuracy• Manual errors are highly possible• Delay on submitting the progress data• Delay on compiling data

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Data Input Techniques 2. Data collection terminals- Workers to input data relative to order progress using simple keyboards (or) conventional alphanumeric keyboardsEX: Push button keyboards, Workstation etc

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Automatic Identification methodsAutomatic data collection is essential for streaming the flow of information in CIM environmentsTypes of Automatic identification techniques:• Bar codes• Radio frequency systems• Magnetic stripe• Optical character recognition• Machine vision

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Bar code Technologyhttps://www.youtube.com/watch?v=CFubTQ5p4xk

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Bar codsCommonly used bar codes are,• Code 39• Interleaved two of five (ITF)• Universal Product Code• Code 93• Code 128• Postnet• Codabar• Plessey

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Bar cods

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Radio Frequency systems

https://www.youtube.com/watch?v=MAA9JpGraoU

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Automated data collection systems

1. Data acquisition systems2. Data logging systems3. Multilevel scanning

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Data Acquisition Systems (DAS)

DAS is a computer system used to automatically collect data from process (or) piece of equipment. These perform an analysis of data (or) transfer the data to another computer for further use

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Data Logging Systems (DAS)

Data logger is a device that automatically collects and stores data for off line analysis

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Multilevel Scanning

More than one level of scanning• Low level scan• High level scan

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Flexible Manufacturing System (FMS)

FMS is highly automate GT machine cell. A FMS is an individual machine (or) group of machines served by an automated materials handling system that is computer controlled and has a tool handling capability

(Or)Multiple Machines that are integrated by an automated material handling system, whose operation is managed by computerized control systemhttps://www.youtube.com/watch?v=BBC2oswnrt0

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Components/Elements of FMS

1.Workstations2.Material handling and Storage systems3.Computer control systems4.Human Resources

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1.FMS Workstations

1. Load/unload Stations2. Machining Stations3. Assembly workstations4. Inspection Stations5. Other processing stations

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Load/Unload stations

• Loading and unloading of parts-either manually or automatically• Data entry in system• Soft movement of parts

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Machining Stations

• Automatic tool changing and tool storage • Use of CNC• Use of palletized work parts

Machines • Turning modules• Milling modules• Head indexers

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Assembly Workstations

• Replace the manual labour for assembling the parts• In this workstations, products made of batches –(Robots are used)

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Inspection Workstations

• Inspection carried out for the assembly products

Tools used• Coordinate Measuring Machines(CMM)• Special inspection Probes, etc

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Other Processing Workstations

• Sheet metal processing workstations• Forging process stations,etc

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2.Material handling and storage system

• Part Transportation• Raw material and finished product transportation • Storage of Work pieces• Wastes• Empty pallets• Fixtures and tools

1.Functions of material handling system2.Types of FMS layout3.Types of handling equipment used in FMS

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Functions of material handling system• Random, independent movement of work parts between stations• Handle of variety of work part configurations• Temporary storage• Convenient access for loading and unloading work parts• Compatible with computer control

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FMS Layout

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FMS LayoutLadder layout

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Types of material handling equipment's• Conveyors• Cranes• Industrial trucks• Rail guided vehicles• Automated guided vehicles• Industrial robots

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Conveyors• https://www.youtube.com/watch?v=HvFqo_ZOrsU

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Craneshttps://www.youtube.com/watch?v=GwTsLysTtpQ

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Industrial truckshttps://www.youtube.com/watch?v=bmU2CtcGIyQ

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Rail guided vehicle https://www.youtube.com/watch?v=UdC_Jm7hDs8

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Automated guided vehicle systems(AGVS)

https://www.youtube.com/watch?v=7xvP645fVnI

https://www.youtube.com/watch?v=QKPIOny1AL4&index=4&list=PLQDv5X70diTwDaucbQ7AyEuzwhQ8Bws0s

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Industrial robotshttps://www.youtube.com/watch?v=DYoBUhADU5s