Manufacturing

Slide 1: Manufacturing Automation MAE 464-564

Slide 2: Course requirements • Lecture classes – Mid term and final exam • Laboratory exercise – Robotics – PLC Two projects – CNC Programing • One research oriented paper for Grad. students

Slide 3: Announcements • Interactive class - Unique opportunities • Discussions - One topic every two weeks – Respond to it actively • Resources and sites – Research projects and Other organizations • http://wings.buffalo.edu/academic/departme nt/eng/mae/460-564/

Slide 4: Manufacturing Changing raw material finish product Flow of material, energy, information Proceses that added value Conceptual design into a real product

Slide 5: What is manufacturing? • Conversion of raw material to end product • Adding value • Improvisation, innovation, solving problem, • Process of Man, material and machine o get a product • Time to market • Processes • Supply chain • Need or want • Customer sastisfaction

Slide 6: What is Manufacturing

Slide 7: What is manufacturing • Process • Safety – • Conversion of raw • Cost – revenue – materials • Concept – product • Design realization • Sequential process • Control processes- feedback systems • Manufacturing Mass – custom- mid size – • Quality control – • Efficiency prductivity-

Slide 8: What is Manufacturing • Workflow • Assembly • Processes raw material • Product design • Quality control • Stacking/packaging • Inventory control – JIT • Production planning • R& D • Volume manufacturing Market survey

Slide 9: What is Manufacturing? • Mass production • Ergonomics of • Prodction of a product manufacturing • Design/improve product • Low cost, lead time • Converting a concept in to and quality product • Raw material into prodcut • Complex assemblies and methods • Creatino BOM • Quallity • Best process for ….. • Best practises for ..

Slide 10: Manufacturing A series of interrelated activities and operations involving design, material selection, planning, production, quality assurance, management, and marketing of discrete consumer and durable goods. Manufacturing is a Systematic process of converting raw materials to its value added form

Slide 11: • Robots • Production line • Least human intervention • Conveyors • AGVs, MH • Timely process • Control of processes – • Repetitive processes • Computers – Quality, motions, engineering, • Feedback and adaptive systems imrove • Cell, FMS, DNC, lines, • Efficiency, optimization, cost, effectiveness • Customization vs mass production.

Slide 12: What processes are manufacturing • • Punching, stamping Metal cutting • • Brazing Shapping • • Hydroforming, waterjet Turning/milling/drilling cutting, explosive forming • Molding • ECM – PCB, • Forging, extrusion, casting, • Induction, HT • • Painting, polishing Rapid Prototyping • • Rubber forming, plastic Welding • • Casting Grinding • • Ceramics, polymers EDMs • Rolling • Broaching

Slide 13: What process contribute to Manufacturing? • • Machining Processing – – HT, - Anneal,, CNC – – Coating – Turn, grijdin,millin – Welding, brazing, – Stamping, forging, sheet metal Joining, Assembling – Extrusion, riveting, welding, adhesives, fastners, – Molding – plastic, glass Etching, – Casting Rapid protityping, – Drawing – Braoching etc Quality – CMM, prfileing, SQC, – Surface finishing Inspecion—NDT, – EDM, ECM, Ultrasonic m/c Rubber, polymer, ceramics, – LBM, Waterjet, EBM

Slide 14: What process contribute to Manufacturing? • • Casting , plastic Sheet metal forming • • Forging/forming/etxrusion Tool and die making • • Milling Powder metal. • • Drilling Sintering • • Boring/metalcutting Finishing – deburring, grinding, polishing, • Welding – joining process painting, coating • Assembly • Composite manufacturing • HT treatment – carbon , metal matrix • Chemical – plating and • Rapid prototypeing coating • Drawing, rendering, • ECM – special puropse planning • EDM – Electro discharge • Water jet – Laser, EBM, maching – wire cutting,

Slide 15: What processes are considered manufacturing ? • CNC machining • Molding, casting, • Forging, Rolling, • Turning/milling,shaping, grinding, Boring, • EDM, LBM, Air jest, waterjet • Assembling putting prodcut • Fabrication welding, riveting, plumbing • Plastics plymers, glass, production • Rapid Prototypes • HT, Electroplating • Inspection and quality

Slide 16: Types of manufacturing • Process (continuous) type – steel, glass, chemical, semi-conductors – High degree of automation • Part discrete type – individual parts are made – Quite often complex assembly is required – Mechanical, electromechanical and electronic

Slide 17: What are the elements of Mfg. Automation?

Slide 18: Software or systems?

Slide 19: Manufacturing Automation • Manufacturing with little • Computer vision – or no intervention • Assembly process – • Robotics • Software • Reducing human error – Plc • Agv – Automated material – CAM – handling Inventory control – PPC • Improve prcision in higher – Machine control soft = Post volume processors • CNC machines – Quality control and • Transfer lines measurment – CMM – Communcation – between • FMS – Flexible PLC, between machines, manufacturing – Cellular plants, control centers sys

Slide 20: Manufacturing Automation? • • CNC Controllers, • • Robots CELLS • • Conveyor – MH Auto gauging – CMMs • • AGV – Auto tool changers • • SQC, Packaging, • • USM, Flexibility of automation, • • FMS, JIT, Kanban, Agile, Lean mnaufacturing, Six Sigma, • Storage and retraival • Kaizan, • Production – line – assembly line

Slide 21: • Software – CADm-CAM • PDM, • PPC, MRP I, II • ERP

Slide 22: Manufacturing Automation? • Transfer of parts • PPC, MRP II, • Automation in hazardous env. inventory control, • Robot • CNC machines milling, edm, lathes, • Packging etc dril, etc etc • Pipe bending machines, • Web retailing, Supply • Presses, forging , stamong presses, chain etc I2 forming, • CAD-CAM • Automted machines CAM • PLC s • Conveyors • CMM, automated measurements sensors, inspection • Finishing processes, • Deburring, polishing

Slide 23: What types of Mfg. Automation? • Conveyors • Moving assembly line • CNC machines • Robotics • Routing • Tools which aid some • PLCs process • Scheduling, production • AGVs • Lay-out of plants • Production planning • Storage and retreival • Sequencing, lead-time of • CAD-CAM process • Maintenance • Inventory • Tool magement • MRP

Slide 24: Manufacturing Automation • Organized and Systematic method of increasing the productivity and reducing the product development cycle.

Slide 25: Well Defined Enterprise Finance BUSINESS Marketing ENVIRONMENT Human Resources Design PEOPLE Manufacturing PROCESSES Information Systems Logistics / Support TOOLS Un der Etc. sta  nd Co TECHNOLOGIES ing mp  on Int ent erf s Int ace egr atio s ORGANIZATIONAL Go n od Bu STRATEGY si De sig ness n SUCCESSFUL BUSINESS

Slide 26: History of Automation • When did automation start ? – CAM based machines were used in 1930 and 40s – Multiple head turning and milling – Flow line assembly with several repetitive machines – Electronic controller – PLCs and computer – CNC machines, CAD, FMA cellular systems.

Slide 27: Manufacturing Perspective 1970’s - Cost focused 1980’s - Quality first 1990’s - Delivery performance, customization, and environmental issues 2000’s - Information and Knowledge integration Proper Strategy Formulation Competitive Advantage  Understand customer desires  Internal rapid response mechanisms  Faster and cost effective products

Slide 28: Design for Manufacturing (Verb) The process of creating a specification for construction of a part which involves synthesis, analysis, and optimization. (Noun) The resulting specification and includes geometry, topology, tolerances, material, and other parameters necessary for manufacturing the part.

Slide 29: Highly Agile Product Automation Manufacturing Processes: Design Automation to allow easy design CAD Missing Link Manufacturing Automation Design for: CAM Manufacturing Assembly Automation Inspection

Slide 30: Made to order? Software Information Manufacturing Automation Customer Planning Specs. Design Hardware Automation

Slide 31: Enterprise Level Automation Information Hardware Soft based Automation Automation Automation •PLCs •GT-based •Web •Robots •CAPP •Message •CNC •Features •PMI •AGVs •FMS •ERP

Slide 32: Types of Automation • Fixed and Hard Automation – CAM, levers – Where is it used ? – High volume, High reliability, High production rates, High initial investment • Flexible Automation – Programmable automation, Low production rates, medium quantity and varied production batches.

Slide 33: Key elements • In the year 2001, this may include: – Automated hardware – Efficient algorithms and methods – CA “X” - CAM CAD CAPP CAI – Open and closed architecture – Information technology – Virtual enterprises – Internet and WEB – 3D printing

Slide 34: Philosophies of automation • Concept A – Machines which are completely automated should be used in production • Concept B – Machines with limited automation, intelligence and capabilities aided by human intelligence • Use machines for what it does the best • Use human to ease the complexities

Slide 35: Robotics • How can robot help ? • What level of intelligence ? • Theory behind programming – Lead through, CAD based, Interactive VR – Telerobotics • Where ? – Routine tasks – Environment not safe for humans to work

Slide 36: Features and Geometry • Cognitive foundation • Features in engineering – Forms – Tolerance – Assembly • Feature based automation – Automatic development of CNC programming – Automatic Assembly design

Slide 37: Product development • CAD-CAM • Geometric modeling • Solid modeling – CSG, B-Rep, Parametric modeling, NURB • Design - FEM • Integration - Manufacturing

Slide 38: Information • Product Management Information • Enterprise Resource Planning • MRP II • Web based Databases etc.

Slide 39: Topics to be covered • Theory of Automation: PLC, Concept of Assembly languages • Robotics - Definitions, design, applications in manufacturing, programming, planning, sensors, vision etc • CAD-M interface and automation issues • Reverse Engineering - Modeling from data

Slide 40: Key challenges • Globalization and virtual enterprises • One of a Kind production (OKP) as opposed to mass production • Co-existence of various hardware and software systems – Protocol, networks, standards • Integration of vast knowledge base - information overload ? • Making the manufacturing ready for internet

Slide 41: Contd. • Rapid prototyping - different applications. • AI techniques in manufacturing • Virtual environments - hardware, software, concepts in manufacturing • Web centric engineering and its application in manufacturing

Slide 42: Next class • Next class we will start PLCs • Read section 6.8 of the text book