COMPUTER INTEGRATED

MANUFACTURING

SAJID ALI

14-ME-IND-02

LEARNING OBJECTIVES

• Automated Guided Vehicles (A.V.G)

• Group Technology (G.T)

• Just in Time (J.I.T)

AUTOMATED GUIDED VEHICLES

CONTENTS :

• Introduction

• History of AGV’S

• What is AGV?

• Types of AGV’s

• Why consider AGV’s

• Types of navigations in AGV’s

• Applications of AGV’s

INTRODUCTION

• AGVs increase efficiency and reduce costs by helping to automate a manufacturing facility or warehouse.

• AGVs can carry loads or drag objects behind them in trailers. The trailers can be used to move raw materials or finished product.

• The AGV can also store objects on a bed. some AGVs use fork lifts to lift objects for storage.

• AGVs are employed in nearly every industry, including, paper, metals, newspaper and general manufacturing.

Continue ….

• AGVs are available in a variety of models and can be used to move products on an assembly line, transport goods throughout a plant or warehouse.

• An AGV can also be called as a Laser Guided Vehicle (LGV) or Self-Guided Vehicle (SGV) .

History of AGV’S

The first AGV was brought to market in the 1950s, by

Barrett Electronics of Northbrook, and at the time it

was simply a tow truck that followed a wire in the floor

instead of a rail. over the years the technology has

become more sophisticated and today automated

vehicles are mainly Laser navigated ex: LGV.

In an automated process, LGVs are programmed to

communicate with other robots to ensure product is

moved smoothly through the warehouse, whether it is

being stored for future use or sent directly to shipping

areas. Today the AGV plays an important role in the

design of new factories and warehouses.

What is AGV?

AGV is a material handling system that uses independently operated, self-propelled vehicles guided along defined pathways.

Types of AGV’s

1. Driverless Trains

2. AGV’s Pallet Trucks

3. Unit load Carriers

1. DRIVERLESS TRAINS

• It consists of a towing vehicle that pulls one or more trailers to form a train.

• This type is applicable in moving heavy pay loads over large distance in warehouses or factories with or without intermediate pickup and drop off points along the route.

• It consists of 5-10 trailers and is an efficienttransport system.

• The towing capacity is up to 60,000 pounds

2. AGV PALLET TRUCKS

• Pallet trucks are used to move palletized loads along predetermined routes.

• The capacity of an AGV pallet truck ranges up to several thousand kilograms and some are capable of handling two pallets.

• It is achieved for vertical movement to reach loads on racks and shelves.

3. UNIT LOAD CARRIERS

• These are used to move unit loads from one station to another.

• It is also used for automatic loading and unloading of pallets by means of rollers.

• Load capacity ranges up to 250 kg or less.

• Especially these vehicles are designed to move small loads.

WHY CONSIDER AGV’S?

• Reduces the labor cost.

• Flexible.

• Intelligent.

• Time consuming.

• Can significantly reduce production & warehouse costs.

• Transforming the materials handling industry.

TYPES OF NAVIGATION IN AGV’S

• Wired navigation

• Guide tape navigation

• Laser target navigation

APPLICATIONS OF AGV’S

• Automated Guided Vehicles can be used in a wide variety of applications to transport many different types of material including pallets, rolls, racks, carts, and containers.

• Raw Material Handling:-

AGVs are commonly used to transport raw materialssuch as paper, steel, rubber, metal, and plastic.This includes transporting materials from receiving tothe warehouse, and delivering materials directly toproduction lines.

Applications ….

• Work-in-Process Movement:-

Work-in-Process movement is one of the first applications where automated guided vehicles were used, and includes the repetitive movement of materials throughout the manufacturing process.

• Pallet Handling:-

Pallet handling is an extremely popular application for AGVs as repetitive movement of pallets is very common in manufacturing and distribution facilities.

Applications….

• Finished Product Handling:-

Moving finished goods from manufacturing to storage or shipping is the final movement of materials before they are delivered to customers. These movements often require the gentlest material handling because the products are complete and subject to damage from rough handling.

GROUP TECHNOLOGY

Learning Objectives …

• Introduction

• Brief history

• Designing a Group Technology

• Basic Approaches of Group Technology

GROUP TECHNOLOGY

• Group technology (GT) is a manufacturing philosophy that seeks to improve productivity by grouping parts and products with similar characteristics into families and forming production cells with a group of dissimilar machines and processes.

• It is management philosophy based on the similarities exist in design and manufacture of discrete parts.

Introduction Continue…

• In ” family of parts manufacturing” Group Technology achieves advantages on the basis of these similarities. Similar parts are arranged into part families.

• Group Technology examines products, parts and assemblies then groups similar items to simplify design, manufacturing, purchasing and other business processes.

History

• It was formatted by Russian engineer,S.P.Mitrofanov, working with Leningrad OpticalMechanical association by publishing the bookin 1959, entitled as ,” The scientific principle ofGroup technology”.

• He suggested that grouping together ofcomponent parts into families based on theirhaving common features would enable resettingtime to be minimized.

Designing a Group Technology

Technique Component Families

• Grouping of component parts into familiesbased on their common features.

Machine Groups

• Grouping of machines into cells.

Basic Approaches of Group Technology

• Family Formation ‘by eye’

• Coding & Classification

• Tailor made component & classification system

• Production flow analysis

• Designing products for group technology manufacture.

Just In Time

Learning Objectives

• Introduction

• History

• Objectives

• Principles of JIT

• Requirements of JIT

• Advantages & Drawbacks

Introduction

• JIT is a manufacturing philosophy involving an integrated set of procedures/activities designed to achieve a volume of production using minimal inventories.

• A highly coordinated processing system in which goods move through the system, and services are performed, just as they need.

HOW IT WORKS?

HISTORY

• Evolved in Japan after World War II, as a result of their diminishing market share in the auto industry.

• Founded by Taiichi Ohno, a vice president of Toyota.

• Basically implemented in Toyota plant 1950, well established after 1970.

FOLLOWERS

Adopted by General Electrical in the USA in the 1980.Some companies referred JIT with different names:

• TOYOTA – ‘Toyota System’

• IBM – ‘Continuous flow manufacturing’

• GE- ‘Management by sight’

• HEWLETT- PACKARD- ‘stockless production & repetitive manufacturing system’

Objectives of JIT ..

By using JIT technique we can reduce followings

1) Waste of over production

2) Waste of waiting

3) Waste of transportation

4) Waste of Underutilization of Employees

5) Waste of Inventory

6) Waste of motion

7) Waste of making defective products

PRINCIPLES OF JIT

• Total Quality Management

• Production Management

• Supplier Management

• Inventory Management

• Human Resource Management

JIT MANUFACTURING BUILDING BLOCKS

REQUIREMENTS OF JIT• Respond to Customer Requirements• Integrate all Processes• Employee Participation• Company wide Commitment to education• Eliminate redundancy• Reduce all Inventory• Establish Continuous Improvement Goals• Use a Pull Production System• Design products for Manufacturing• Develop Controllable Production Processes• Have Defect Prevention Program• Reduce Setup Times• Build Products to Specification

OBSTACLES IN CONVERSION

• Management not committed

• Workers not cooperative

• Decide which parts need most effort

• Start by trying to reduce setup times

• Gradually convert operations

• Convert suppliers to JIT

• Prepare for obstacles• Suppliers may

resist

ADVANTAGES OF JIT

• High quality

• Flexibility

• Reduced setup times

• Reduced need for indirect labor

• Less waste

• Low warehouse cost

• Synchronization between production scheduling and work hour

Drawbacks of JIT

• Time consuming

• No spare product to meet un expected order

• Supply Shock : If products do not reach on time

• High risk factor

References

• Google

• Wikipedia

• Various books and notes

• Previous Presentations

THANK YOU