Automation and FMS
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AUTOMATION
Coined at Ford Motor Company in 1945 to describe
“ a logical development ” in technical progress where automatic handling between machines is combined with continuous processing at machines.
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Automation:
Few Workers Involved Computer gives the instruction to the
machine for the repetitive works Robots , CMC and CAM has
revolutionalized the automation
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In the past, automation meant the replacement of human effort with machine effort, to save labor costs.
Today, automation means integrating a full range of advanced information and engineering discoveries into operations processes for strategic purposes.
Today, automation is applied not only for labor cost savings, but also for: Improved quality Faster production and delivery of
products/services
AUTOMATIONAUTOMATIONAUTOMATIONAUTOMATION
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Purposes of Automation
Reduction in direct labour costs Uniform quality with machines Safety Improves Shop efficiency Use of standard tools
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Basic Principle in automation
Design of the part and the design of the process should be related as closely as
possible
- to avoid excessive costs
- to ensure maximum processing efficiency
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Types of Manufacturing Automation
Numerically Controlled (N/C) Machines Robotics Automated Quality Control Inspection Automatic Identification Systems (AIS) Flexible Manufacturing Systems (FMS) Automated Storage & Retrieval Systems (ASRS) Computer Based Systems. ( CAD/CAM, CIM,
ERP)
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Numerical Control (NC)
Definition:– The use of coded numerical information in the automatic control of equipment positioning
Principle : - Machine is controlled by the preset values loaded in punch tape and values will be referring physical
quantities like height, width etc.
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Numerically Controlled (N/C) Machines Have a control system that receives/reads
instructions and translates them into machine operations
The standards set for NC is usually theElectronic Industries Association (EIA)
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An NC Machine.
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Hardware for NC Machining
Machine Control Unit (MCU) - Data Processing Unit (DPU) - Control Loop Unit (CLU)
Data Processing Unit (DPU) - Reads a part program - Decomposes instructions into CLU
commands - Passes CLU commands to CLU
Control loop unit (CLU) - Receives the CLU commands - Translates into control signals for machine
drive mechanisms
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Data Processing Unit (DPU)
In the past, could be- Mechanical tape punch reader
- Mechanical card reader - Magnetic tape reader - Had no memory storage ability at all Today, - Has memory storage for program
storage - Some graphical preview display
capability - PLC (Programmable Logic Controller) or
PC based
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Control Loop Unit (CLU)
- Still very much the same as when NC first began
- Electronic hardware, sending analog signals to
motors - One major innovation: CLU are now usually packaged integrally with DPU - Motor types
Stepper Servo
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PART PROGRAM
DPU
CLU
NC Machine
Schematics of NC MachineSchematics of NC Machine
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Part Programming
The part program is created to control - The tool path - The machine operating parameters Creation of part program requires knowledge
of: 1. part geometry. 2. path taken by cutting tool. 3.machine tool and control system. 4.part identification, tool tolerances,
etc.
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NC machines have evolved:NC machines have evolved:
CNC – computer numerically controlledCNC – computer numerically controlled
DNC – direct numerically controlled DNC – direct numerically controlled (several machines controlled by a single (several machines controlled by a single computer)computer)
Examples:Examples:
Grinding MachineGrinding Machine
LatheLathe
Evolution of NC Controlled Machines
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Computer Numerical Control(CNC)
Primary difference between CNC and NC– NC cannot store the program; CNC can
CNC is so prevalent now that it is difficult to separate from NC
CNC has ability to create programs on station, ie parallel programming.
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DNC
A data communications system connecting a group of numerically controlled machines to a common computer
Requirements: Substantial memory for the storage of numerous
numeric control (NC) part programs Provision for on-demand distribution
(downloading) of NC Programs to the machines. Additional provision for the management, display
and editing of NC part programs.
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System Control
Direct Numerical Control (DNC) – A single computer controls several
machines directly. – Prominent in era of expensive computers. Distributed Numerical Control (DNC) – Central (or network host) computer
connected to satellites for program download and control
– Satellite computers (or “nodes”) are co-located at individual cutting machines for CNC
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Robotics and Robots
What is Robotics?
- Robotics is the science of designing , building, and applying robots.
What is a Robot?
- It means Slave in Czech.
- A reprogrammable, multifunctional manipulator designed to move material, parts, tools, or specialized devices through various programmed motions for the performance of variety of tasks.
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Why Robots are Needed?
To increase the productivity. To improve product quality. To decrease product cost. To work under hazardous and monotonous
jobs.
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Classification of Robots
Cartesian Robots Cylindrical Robots
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Classification of Robots
Spherical polar Robots Articulated Robots
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Applications of Robots in Manufacturing
Arc Welding Process Spot Welding Process
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Applications of Robots in Manufacturing
Spray Painting Process Drilling Operation
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Applications of Robots in Manufacturing
Material Handling Process Loading – Unloading Process
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Types of Manufacturing Automation
Automated Quality Control Inspection Take physical dimensions of parts Compare measurements to standards Determine if parts conform to specifications Also check performance (ex. - electronic
circuits) Making 100% inspection economically
feasible
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Types of Manufacturing Automation
Automatic Identification Systems (AIS) Sense and input data into computers Use bar codes, radio frequencies, magnetic
stripes, optical character recognition, machine vision
Data read from products, documents, parts, and containers
Used in warehouses, factory floors, retailing, wholesaling
Example – scanner at grocery store checkout
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Types of Manufacturing Automation
Automated Process Controls Use sensors to obtain measures of
performance Compare measures to standards Might use “expert system” to determine
if/what process adjustment is necessary If necessary, change settings of process Long used in chemical processing,
petroleum refining, paper production
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Automated Production Systems Automated Flow Lines
In-line, automated processing machines linked by automated material transfer
Perform without need for human attendance
Used to produce an entire component Also called fixed automation or hard
automation Used when product demand is high and
stable
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Automated Production Systems Automated Assembly Systems
Automated assembly machines linked by automated material transfer
Operations are component insertion and joining
Produce major assemblies or complete products
Often use standard (lower cost) robots Product design appropriate for assembly by
humans is not fitting for automated assembly
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COMPUTER AIDED QUALITY CONTROL
Objectives
To improve product quality To increase productivity in inspection
process To increase productivity and reduce
lead times in manufacturing
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COMPUTER AIDED QUALITY CONTROL
ADVANTAGES: 100% Inspection Integration with the manufacturing
process resulting in time savings Automatic adjustment of process
variables Cost-effective Quality improvement
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COMPUTER AIDED QUALITY CONTROL Quality Assurance QA Activities which maximise the profitability
that the product and its components will be manufactured within design specifications.
Quality Control QC Activities related to inspection of product
and component quality,detection of poor quality and corrective action necessary to eliminate it.
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WHEN ?
Incoming raw materials At various stages during manufacturing At completion of processing Before shipping the final assembled
product to the customer
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COMPUTER AIDED QUALITY CONTROL
Methods of Inspection
Contact Inspection : Parts or hardware such as rubber, silicon or thin wall parts that cannot be inspected with touch trigger probe technology are inspected with Non-Contact Inspection methods.
Non-Contact Inspection : If products or aspects of the product are too small or too soft, Non-Contact Inspection is the appropriate alternative over contact inspection techniques
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CONTACT INSPECTION
Qualitative Inspection Go/No-go gauges :refers to an inspection tool
used to check a workpiece against its allowed tolerances. Its name derives from its use. A Go NoGo gauge is a measuring tool that does not return a size in the conventional sense, but instead returns a state.
Quantitative Inspection Vernier Pressure Gauge CMM etc.
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NON-CONTACT INSPECTION
Optical Techniques Machine vision Scanning laser beam devices Photogrammetry etc.
Non-Optical Techniques Electric field techniques Radiation techniques Ultrasonics
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SCANNING LASER BEAM DEVICE
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NON-CONTACT INSPECTION
ADVANTAGES Eliminates need to reposition the work
part Faster than contact-inspection Eliminates mechanical wear Reduces potential danger to people Reduction of possibility surface damage
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Automated Production Systems Automated Storage & Retrieval Systems
(ASRS) Receive orders for materials from anywhere in
operations Collect the materials from locations in warehouse Deliver the materials to workstations in
operations Three major elements of ASRS are:
Computers and communication systems Automated materials handling/delivery systems Storage and retrieval systems in warehouse
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Automated Production Systems Automated Storage & Retrieval Systems
(ASRS) Main benefits of ASRS are:
Increased storage capacity Increased system throughput Reduced labor costs Improved product quality
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Computer Control System.
Composed of a Microprocessor.
Ability to be programmed by Human operator.
A Display device to display geometry of the product.
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Economic Objective.
To achieve efficiency of mass production for batch production.
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Automation in Services
Example Airlines – air traffic control, passenger
reservation Banks – ATMs, computerized bank statements Gas Stations – automated payment (pay-at-the-
pump) Health Care – MRI system, AGVS for waste
disposal Grocery Store – self-service checkout stations Real Estate – web based house-for-sale tour
video
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Degree of Customer Contact in Servicesand the Use of Automated Equipment
Degree of Degree of Customer ContactCustomer Contact
CapitalCapitalIntensityIntensity
HighHigh
HighHigh
LowLow
LowLow
Manual OperationsManual Operations
Mechanized OperationsMechanized Operations
AutomatedAutomatedOperationsOperations
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Automation Questions
What level of automation is appropriate? How would automation affect the
flexibility of an operation system? How can automation projects be
justified? How should technological change be
managed? What are some of the consequences of
implementing an automation project?
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Flexible Manufacturing System
A manufacturing system in which there is some amount of flexibility that allows the system to react in the case of changes, whether predicted or unpredicted.
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Flexibility in FMS
Machine Flexibility Ability to produce new product types Ability to change the order of operations
executed Routing Flexibility
Ability to use multiple machines to perform the same operation
Ability to absorb large-scale changes, such as in volume, capacity, or capability
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FMS System
Work Machine Material Handling System Control Computer System Human Labor
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Flexible Manufacturing System (FMS)
Machine 1Machine 1
ToolsTools
X X
Machine 2Machine 2
ToolsTools
X X
Machine 3Machine 3
ToolsTools
X X
ComputerComputer
WorkerWorker
X
X
X
X
X
X
X
UnloadUnloadLoadLoad
PalletPalletTransferTransferSystemSystem
PartsParts
Pallet withPallet withworkpieceworkpieceattachedattached
WorkpieceWorkpiecein queuein queue
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Work Machine
Performs processing, inspection and testing or assembly tasks
The processing could be: cheap removal, casting, plastic molding, forging, sheet metal processing, heat treating, welding, painting, flame cutting, washing, etc.
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Work Machine Tools and related equipment
Standard CNC machine tools Industrial Robots Special purpose machine tools Tools for maintenance of machines Special Inspection Probes used with the
machine tools
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Material Handling System
Consists of: Raw Material Parts in different stages of processing Tools
which have to be stored, transferred and handled
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Material Handling Equipment Transferring:
Roller Conveyor Towline Cart Automated Guided Vehicle (AGV)
Handling: Robots
Storage Automatic Storage and Retrieval System
(AS/RS)
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Computer Control System
Coordinates between Work Machine & Material Handling System
Controls & Supervise FMS Responsible for both Flexibility &
Automation in FMS
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Computer Control System
Machine Control Direct Numerical Control Production Control Traffic Control Shuttle Control Work Handling System Monitoring Tool Control System performance monitoring and
reporting
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Human Labor in FMS
System Manager Electrical technician Mechanic/Hydraulic technician Tool setter Fixture setup and lead man Load/unload man Rover operator
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Challenges
Rapid Programming Ability to set up tools and parts offline Technological problems of exact
component positioning and precise timing necessary to process a component
Expensive, costing millions of dollars
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Types of Manufacturing Systems
Productivity
Flexibility
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Benefits of FMS
Increased machine utilization Reduced direct and indirect labor Reduced manufacturing lead time Lower in-process inventory Scheduling flexibility
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THANK YOU