1. Automated Manufacturing
Unit 5
Automated Manufacturing

2. Automated Manufacturing
Automation is the use of control systems such as numerical control, programmable logic control, and other industrial control systems and information technology including computer-aided technologies, to control industrial machinery and processes, reducing the need for human intervention

3. Reasons for Automation in the Factory Include
Reduced labor costs
Sales growth
Better quality
Reduced inventory
Increased worker productivity

4. Two Types of Automation
Fixed systems and
Flexible systems

5. Current Factory Technology Includes:
Computer networks including ERP
Data collection and reporting
Automated material handling
Cells and work centers
Automated inspection and testing
The paperless factory
Robots

6. Production Support Machines and Systems
Chapter 11
Production Support Machines and Systems

7. Industrial Robots
A robot is an automatically controlled, programmable, multipurpose, manipulating machine with several programmable axes, which may be either fixed in place or mobile for use in industrial automation applications.
Key words are reprogrammable and multipurpose

8. Industrial Robot at Work

9. Industrial Robots
The basic robot system consists of manipulator, power supply, controller, end effectors, interfacing or required equipment such as devices and sensors and any communications interface that is operating and monitoring the robot, equipment and sensors
The mechanical arm is driven by electric motors, pneumatic devices, or hydraulic actuators
Six motions are identified: Arm sweep, shoulder swivel, elbow extension, pitch, yaw, and roll.

10. Industrial Robots
Robotic arm geometry classification includes the following: Cartesian geometry, cylindrical geometry, spherical geometry, and articulated geometry.
End effector or end-of-arm tooling must be provided for robots to have production capability
The controller is a special-purpose computer with a central processing unit which controls the robot’s arm and the work cell in which it is operating.
Robots are programmed by keying in or selecting menu commands in the controller language, moving the robot arm to the desired position in the work cell, and recording the position in the program often with a teach pendant.

11. Industrial Robots Programming methods include:
Active robot teaching (teach pendant)
Passive robot teaching (lead-through)
Off-line robot programming
Robot applications include: Material processing, material handling, and assembly and fabrication.
Selecting and justifying robot application requires a detailed design process and cost analysis.
Justifying a robotic system is performed using this model: [P = I/(S-E)], where:
P = # of years for pay back
I = Investment in robot
S = Savings in robot
E = Cost of servicing the robot

13. Automated Material Handling
Material-handling process for parts and raw materials should be automated only after every unnecessary inch of material transport distance has been removed from the production process.
The work simplification and analysis process that precedes the design and selection of material-handling automation starts with a diagram of the production flow, using process flow analysis symbol shown on page 461.

14. Automated Material Handling
The transfer mechanism used to move parts between work cells and stations serves two main functions:
Move the part in the most appropriate manner between production machines, and
Orient and position the part with sufficient accuracy at the machine to maximize productivity and quality.
Automated transfer systems include:
Continuous transfer such as overhead monorail
Intermittent or synchronized transfer such as the walking beam transfer system
Asynchronous transfer or power-and-free systems as in conveyor and pallet system.

15. Integrated Material Handling Systems

16. Automatic guided vehicles (AGV)
An AGV is a vehicle equipped with automatic guidance equipment capable of following prescribed guide paths and may be equipped for vehicle programming and stop selection, blocking, and any other special function required by the system.

17. Automatic guided vehicles (AGV)
AGV types include: Towing vehicles, unit load vehicles, pallet truck vehicles, fork lift vehicles, light load vehicles, and assembly line vehicles.
AGV systems must perform five functions, namely: Guidance, routing, traffic management, load transfer, and system management.
AGV systems must be justified based on the current and future material-handling requirements.

18. AGV

20. Typical AGV Route

21. AGVs

22. Automated Storage and Retrieval Systems (AS/RS)
Materials to be stored and retrieved include: 1) raw materials, 2) unsold finished products, 3) production parts, 4) purchased parts and subassemblies used in the assembly of products, 5) rework and scrap that result from production operations, 6) spare parts for repair of production machines and facilities, and 7) general office supplies including tools and instruments.
AS/RS is a combination of equipment and controls that handles, stores, and retrieves materials with precision, accuracy, and speed under a defined degree of automation.

28. Automated Machine Tools and Tooling
Includes different machines and tooling systems…:
Machine tools
Auxiliary equipment (MHS, robots etc)
Tools
Tooling

29. Conventional and CNC Lathes

30. CNC Milling Machines

31. Drilling Machines

32. Sawing Machines

33. Surface Grinder

34. Fold and Shear Coiline

35. Automated Punching Machine

36. Hydraulic CNC Folder

37. Plastic injection molding machine

38. Extrusion Machine

39. Gas Furnace

40. Column Press and Straight Side Press

41. Forging Machine

48. PalletShuttle

52. Quality and Human Resource Issues in Manufacturing
Chapter 13
Quality and Human Resource Issues in Manufacturing

56. SPC and the Normal Curve

57. Review Deming’s 14 points for management
Total quality management (TQM)
Quality tools and processes (for quiz 3)

58. Bringing it all Together
Programmable Logic Controllers (PLC)

60. Components of Flexible Manufacturing System
FMS workstations:
FMS for prismatic parts
FMS for rotational parts
Robots
Fixtures and pallets
Tooling
Operators
Inspection system
Coolant and chip handling systems
Cleaning stations
FMS off-line operations
Control station

61. Components of Flexible Manufacturing System
Material handling system:
Parts delivery:
Material handling outside the FMS
Material handling inside the FMS
Conveyor systems
Cutting tool delivery
Load/unload stations:
Handling equipment
Operator control
Buffer storage

62. FMS Benefits Producing a family of parts Random launching of parts
Reduced manufacturing lead time
Reduced work-in-process
Reduced operator requirements
Expandability
Increased machine utilization
Reduced capital equipment costs
Responsiveness to change
Ability to maintain production
Product quality improvement
Reduced labor costs
Better management control

63. Enterprise Resource Planning (ERP)