1. UNIT-IV Shop Floor Control and Flexible Manufacturing Systems
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2. Shop Floor Control
Shop floor control (or) Production Activity Control Manages the detailed flow of materials inside the production facility
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3. Functions of Shop floor Control
Scheduling
Follow up
Dispatching
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4. Phases of Shop floor Control
Order Release
Order Scheduling
Order Progress
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5. 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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6. Order Scheduling
It executes the dispatching function in production planning and control
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7. Elements of Order Scheduling
1.Machine loading- Allocating orders to work centres
2.Job sequencing- Determining priority in which the jobs should be proceed
Priority 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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8. 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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9. 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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10. 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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11. Types of Data Collection System
Online data collection system
Offline 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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12. 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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13. 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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14. Data Input Techniques
2. Data collection terminals- Workers to input data relative to order progress using simple keyboards (or) conventional alphanumeric keyboards
EX: Push button keyboards, Workstation etc
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15. Automatic Identification methods
Automatic data collection is essential for streaming the flow of information in CIM environments
Types of Automatic identification techniques:
Bar codes
Radio frequency systems
Magnetic stripe
Optical character recognition
Machine vision
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16. Bar code Technology https://www.youtube.com/watch?v=CFubTQ5p4xk
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17. Bar cods Commonly 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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18. Bar cods
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19. Radio Frequency systems
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20. Automated data collection systems
Data acquisition systems
Data logging systems
Multilevel scanning
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21. 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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22. Data Logging Systems (DAS)
Data logger is a device that automatically collects and stores data for off line analysis
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23. Multilevel Scanning More than one level of scanning Low level scan
High level scan
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24. 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 system
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25. Components/Elements of FMS
1.Workstations 2.Material handling and Storage systems 3.Computer control systems 4.Human Resources
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26. 1.FMS Workstations Load/unload Stations Machining Stations
Assembly workstations
Inspection Stations
Other processing stations
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27. Load/Unload stations
Loading and unloading of parts-either manually or automatically
Data entry in system
Soft movement of parts
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28. 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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29. Assembly Workstations
Replace the manual labour for assembling the parts
In this workstations, products made of batches –(Robots are used)
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30. Inspection Workstations
Inspection carried out for the assembly products
Tools used
Coordinate Measuring Machines(CMM)
Special inspection Probes, etc
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31. Other Processing Workstations
Sheet metal processing workstations
Forging process stations,etc
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32. 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 system
2.Types of FMS layout
3.Types of handling equipment used in FMS
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33. 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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34. FMS Layout
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35. FMS Layout
Ladder layout
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36. Types of material handling equipment's
Conveyors
Cranes
Industrial trucks
Rail guided vehicles
Automated guided vehicles
Industrial robots
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37. Conveyors
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38. Cranes
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39. Industrial trucks
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40. Rail guided vehicle https://www.youtube.com/watch?v=UdC_Jm7hDs8
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41. Automated guided vehicle systems(AGVS)
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42. Industrial robots
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