Dr. Osama Al-Habahbah Automation Chapter 1 Introduction
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The economic realities of the modern world that affect
manufacturing enterprises are: Globalization. International
outsourcing. Local outsourcing. Contract manufacturing. Tend toward
the service sector in developed economies. Quality expectations.
Operational efficiency.
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Globalization. More countries are be coming industrialized,
such as China and India, due to their high population and low labor
cost. Local outsourcing. International outsourcing. More parts and
products are outsourced to companies outside the USA. Within the
same country. Due to specialty of the suppliers, cheaper rate in
smaller companies, lack of in hoes manufacturing capability
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Contract manufacturing. The customer designs product while the
supplier makes the product. Quality expectations. Tend toward the
service sector in developed economies. Erosion of direct in
manufacturing. perfect quality is expected Operational efficiency.
used to offset the high labor cost
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Some modern manufacturing technology that help to compete :
AutomationMaterial handling technologiesManufacturing
systemFlexible manufacturingQuality programsComputer Integrated
Manufacturing (CIM)Lean production
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Reduces labor cost, decreases production cycle time, and
improves quality. Include transportation, storage, tracking.
Production line, manufacturing cells. Helps to compete in the
low-volume/hig-mix product categories.
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Such as statistical quality control and six sigma. Includes
(CAD) : Computer Aided Design,(CAM): Computer Aided Manufacturing,
and integrating computer networks. Accomplish more with less
resources increases productivity
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It is a collection of people, equipment, and procedures to
perform the manufacturing operation they are two categories Factory
Equipment Layout Factory Equipment Layout The set of procedures
used by the company to manage production,such as product
design.
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Facilities Manual work system Worker machine Automated Using
unpowered hand too ; Using power equipment Automated facility
branches out-to: Semi-automated machines and fully automated
machines
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Functions of Manufacturing support system Business function
Product design Manufacturing planning Manufacturing planning
control Communicating with customer Either provided by customer or
in house if its proprietary Scheduling, Capacity, planning and
process planning Shop floor control Inventory control Quality
control Product progress Balancing too little and too much
inventory Product quality meets standard
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Examples include :Automated machine tool that process parts,
Automated assembly, industrial robots, Automatic material handling
storage, Automatic quality control (inspection).
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Type of automated manufacturing system Fixed
automationprogrammableflexible High initial investment, high
production rate, inflexibility High investment, low production
rate, flexibility Minimalchange High initial investment, high
production rate, inflexibility
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Computer Integrated Manufacturing (CIM) : Such as CAD /
CAM
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Increase labor productivity. Reduce labor cost. Mitigate the
effect of labor shortages Eliminate routine tasks Improves safety
Improves quality Reduce manufacturing lead time Accomplish
processes that cant be done manual. To avoid the high cost of not
automating (competition)
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It is still needed. It can be preferred to automation in some
cases :
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1- Task is technologically or economically too difficult to
automate.. 2- Short product life cycle. 3- Customized product. 4-
Ups and downs in demand. 5- To reduce risk of products failure. 6-
Lack of capital to invest in automation.
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Equipment maintenance Plant management. Engineering project
work Programming and computer operation
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Stand for
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1- Specialization of operations: Use of special-purpose
equipment for greatest efficiency. 2- Combined operations: Perform
more than one operation at a given machine. 3- Simultaneous
operations: To reduce processing time. 4- Integration of
operations: Linking work-stations together increasing output 5-
Increased flexibility: Maximum utilization of equipment Use the
same equipment for a variety of products.
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6- Improved material handling and storage: reduce work in
process and shorter manufacturing lead times. 7- On-line
inspection: (of quality) reduce scrap and improves quality. 8-
Process control and optimization: process time decrease,quality
increase. 9- Plant operations control (of the factory)
10-Computer-integrated manufacturing CIM: ( Design Operations
Business ) Computer Network
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Moving from manual to automated. Phase 1Phase 2Phase 3 Manual
production. Automated production single-station system. Automated
integrated production multi-station system.
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Shout product introduction time. Gradual automation. Lower risk
at the start.