How does ISAT331 fit in the curriculum?
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How does ISAT331 fit in the curriculum?
ISAT 331
Automation in Manufacturing
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211, 330211, 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 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
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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
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Manufacturing System
Manufacturing Support Activities
Automation
Computerization
Production System
CIM
ISAT331
ISAT330
Terminologies
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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
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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
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Fig 1.3
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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
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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
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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 Line’ when multiple stations are
required (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 on production volume and variety of
productsa) Fixed Automationb) Programmable Automationc) Flexible Automation
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Production Quantity
Pro
duct
Var
iety
100 10,000 1 M
Manual vs Automation
Hard
Soft
Low High
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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
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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)
• 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)
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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-engineered equipment)
• 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 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)
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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)Assembly Material handling&StorageInspection (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 plant “operating cost, meeting schedule”, etc)
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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 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)
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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
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