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1. Flexible Manufacturing System

2. Automation, Production System &
Computer Integrated Manufacturing
By Groover

3. FMS

4. FMS

5. 1. Overview of Manufacturing
• Production system
• Automation in production System
• Manual labour in production system
• Manufacturing operation
• Production Facility
• Manufacturing economics
• Manufacturing cost

6. Production System

7. Automation in Production System

8. Manual Labour in production
• Manual labour in factory automation
• Labour in manufacturing support system
a) Equipment Maintenance
b) Programming & computer operation
c) Engineering project work
d) Plant Management

9. Manufacturing Operation

10. Production Facility
• Low production - Quantity In range 1 to 100
• Medium Production- 100 to 1000
• High Production- above 10000

11. Manufacturing Matrices
• Cycle time & Production Rate
• Production capacity & Utilization
• Manufacturing lead time

12. Manufacturing Economics
• Fixed & variable cost
• Direct material, labour & overhead cost
• Cost of equipment usage
• Cost of manufacturing cost

13. 2. Automation & Control
• Elements of Automated system
• Continuous vs discrete control system
• Hardware components for automation:
Sensor & Actuator
• CNC, DNC
• Robot
• PLC

14. Sensor
• A wide variety of sensors are available for collecting data from
the manufacturing process for use in feedback control.
• A sensor is a transducer, which is a device that converts a
physical variable of one form into another form that is more
useful for the given application.

15. Sensor
• In particular, a sensor is a device that converts a physical
stimulus or variable of interest (such as temperature, force,
pressure, or displacement) into a more convenient form
(usually an electrical quantity such as voltage) for the purpose
of measuring the stimulus.

16. Actuator
• In industrial control systems, an actuator is a hardware device
that converts a controller command signal into a change in a
physical parameter.
• The change in the physical parameter is usually mechanical,
such as a position or velocity change.
• An actuator is a transducer, because it changes one type of
physical quantity, such as electric current, into another type of
physical quantity, such as rotational speed of an electric motor.

17. Actuator
• Most actuators can be classified into one of three categories,
according to the type of amplifier:
• (1) electric, (2) hydraulic, and (3) pneumatic.
• Electric actuators are most common; they include electric
motors of various kinds, solenoids, and electromechanical
relays.
• Hydraulic actuators use hydraulic fluid to amplify the
controller command signal.
• Pneumatic actuators use compressed air as the driving power.

18. Elements of Automated system
• An automated system is used to operate some process, and
power is required to drive the process as well as the controls.
• The principal source of power in automated systems is
electricity.
• Electric power can be converted to hydraulic, pnuematic ,
thermal, mechanical

19. Cont..
• An automated system consists of three basic elements:
• (1) power to accomplish the process and operate the system,
• (2) a program of instructions to direct the process.
• (3) a control system to actuate the instructions.

20. Advanced Automation function
• Safety monitoring
• Maintenance & Repair diagnostics
• Error detection & recovery

21. Continuous Variable
• A continuous variable (or parameter) is one that is
uninterrupted as time proceeds, at least during the
manufacturing operation.
• A continuous variable is generally considered to analog, which
means it can take on any value within certain range

22. Discrete Variable
• A discrete variable (or parameter) is one that can take on only
certain values within a given range. The most common type of
discrete variable is binary, meaning it can take on either of two
possible values, ON or OFF, open or closed, and so on.

23. Continuous Vs Discret

24. CNC

25. DNC

26. Robot
• An industrial robot is defined as “an automatically controlled,
reprogrammable, multipurpose manipulator programmable in
three or more axes, which may be either fixed in place or
mobile for use in industrial automation applications.
• It is a general-purpose machine possessing certain
anthropomorphic characteristics, the most obvious of which is
its mechanical arm.

27. Robot
• Other human-like characteristics are the robot’s capabilities to
respond to sensory inputs, communicate with other machines,
and make decisions.
• These capabilities permit robots to perform a variety of
industrial tasks. The development of robotics technology
followed the development of numerical control and the two
technologies are quite similar.

28. Robot
• They both involve coordinated control of multiple axes (the
axes are called joints in robotics), and they both use dedicated
digital computers as controllers.
• Whereas NC (numerical control) machines are designed to
perform specific processes (e.g., machining, sheet metal hole
punching, and thermal cutting),
• Robots are designed for a wider variety of tasks. Typical
production applications of industrial robots include spot
welding, material transfer, machine loading, spray painting,
and assembly.

29. Robot Application
• Material Handling Applications
1) Material Transfer.
2) Machine loading & Unloading
• Processing operation
1) Spot welding
2) Arc welding
4) Spray coating
3) Processing operation

30. Robot Application
• Drilling, routing, and other machining processes.
• Grinding, wire brushing, and similar operations
• Waterjet cutting
• Laser cutting.
• Assembly & inspection

31. PLC
• A programmable logic controller (PLC) can be defined as a
microcomputer-based controller that uses stored instructions in
programmable memory to implement logic, sequencing,
timing, counting, and arithmetic functions through digital or
analog input/ output (I/O) modules, for controlling machines
and processes.

32. PLC
• PLC applications are found in both the process
industries and discrete manufacturing.
• Examples of applications in process industries
include chemical processing, paper mill operations,
and food production.

33. PLC
• PLCs are primarily associated with discrete
manufacturing industries to control individual
machines, machine cells, transfer lines, material
handling equipment, and automated storage systems.
• Before the PLC was introduced around 1970,
hardwired controllers composed of relays, coils,
counters, timers, and similar components were used
to implement this type of industrial control

34. 3. Material Handling
• Material Transport System
• Storage System
• Automatic identification & Storage System

35. Material Transport System
• Transport equipment
• Positioning equipment,
• Unit load formation equipment,
• Storage equipment,
• Identification and control equipment.

36. Transport Equipment
• Industrial Trucks
• Automated Guided Vehicles
• Rail Guided Vehicle
• Conveyor
• Crane & Hoist

37. Industrial Trucks
• Industrial trucks are divided into two categories:
• Nonpowered and powered.
• The non powered types are often referred to as hand trucks
because they are pushed or pulled by human workers.
• Powered truck are self propelled & guided by worker

38. Automated Guided Vehicle
• An automated guided vehicle system (AGVS) is a material
handling system that uses independently operated, self-
propelled vehicles guided along defined pathways.
• The AGVs are powered by on-board batteries that allow many
hours of operation (8–16 hr is typical) before needing to be
recharged.
• Types of AGV
• (1) towing vehicles for driverless trains
• (2) pallet trucks
• (3) unit load carriers

39. Driverless train
• A driverless train consists of a towing vehicle (the AGV)
pulling one or more trailers to form a train,
• It was the first type of AGVS to be introduced and is still
widely used today. A common application is moving heavy
payloads over long distances

40. Pallet Truck
• Pallet truck used to move palletized load along predetermined
routes.
• In typical application the vehicle backed into the loaded pallet
by a human worker who steers the truck and uses its forks to
elevate the load slightly.
• Then the worker drives the pallet truck to the guide path and
programs its destination, and the vehicle proceeds
automatically to the destination for unloading.
• The load capacity of an AGVS pallet truck ranges up to several
thousand kilograms

41. Unit Load Carrier
• AGV unit load carriers are used to move unit loads from one
station to another.
• They are often equipped for automatic loading and unloading
of pallets by means of powered rollers, moving belts,
mechanized lift platforms

42. AGV Application
• Driverless train operation
• Storage and distribution
• Assembly line operations
• Flexible manufacturing system

43. Vehicle Guidance Technologies
• The guidance system is the method by which AGVS pathways
are defined and vehicles are controlled to follow the pathways.
• The technologies used in commercial AGV systems for vehicle
guidance include
(1) imbedded guide wires
(2) paint strips,
(3) magnetic tape,
(4) laser-guided vehicles (LGVs)
(5) inertial navigation.

44. Vehicle Management System
• For AGV to oprate efficiently the vehicle must be well
managed.
• Delivery tasks must be allocated to vehicles to minimize
waiting times at load/unload stations.
• Traffic congestion in the guide-path network must be
minimized.
• Two aspects of vehicle management are considered here:
• (1) traffic control
• (2) vehicle dispatching.

45. Traffic Control
• The purpose of traffic control in an automated guided vehicle
system is to minimize interference between vehicles and to
prevent collisions.
• Two methods of traffic control used in commercial AGV
systems are
• (1) on-board vehicle sensing
• (2) zone control.

46. Cont…
• On-board vehicle sensing, also called forward sensing
• uses one or more sensors on each vehicle to detect the
presence of other vehicles and obstacles ahead on the guide
path.
• In zone control,
• the AGVS layout is divided into separate zones, and the
operating rule is that no vehicle is permitted to enter a zone
that is already occupied by another vehicle.
• The length of a zone is at least sufficient to hold one vehicle
plus allowances for safety and other considerations.

47. Dispatch Control
• For an AGVS to serve its function, vehicles must be
dispatched in a timely and efficient manner to the points in the
system where they are needed.
• Several methods are used in AGV systems to dispatch
vehicles:
(1) on-board control panels
(2) remote call stations,
(3) central computer control.
• These dispatching methods are generally used in combination
to maximize responsiveness and efficiency

48. Cont…
• In addition, AGVs are usually provided with several other
features specifically for safety reasons.
• A safety feature included in most guidance systems is
automatic stopping of the vehicle .
• Another safety device is an obstacle detection sensor located
on each vehicle. This is the same on-board sensor used for
traffic control.
• The sensor can detect obstacles along the path ahead,
including humans.
• The vehicles are programmed either to stop when an obstacle
is sensed ahead or to slow down.

49. Rail-Guided Vehicle
• The third category of material transport equipment consists of
motorized vehicles that are guided by a fixed rail system.
• The rail system consists of either one rail, called a monorail, or
two parallel rails.
• Routing variations are possible in rail-guided vehicle systems
through the use of switches, turntables, and other specialized
track sections. This permits different loads to travel different
routes, similar to an AGVS. Rail-guided systems are generally
considered to be more versatile than conveyor systems but less
versatile than automated guided vehicle systems.

50. Conveyors
• A conveyor is a mechanical apparatus for moving items or bulk
materials, usually inside a facility. Conveyors are generally
used when material must be moved in relatively large quantities
between specific locations over a fixed path, which may be in
the floor, above the floor, or overhead.
• Conveyors are either powered or nonpowered.
• In powered conveyors, the power mechanism is contained in the
fixed path, using chains, belts, rotating rolls, or other devices to
propel loads along the path

51. Types of Conveyors
• In nonpowered conveyors, materials are moved either
manually by human workers who push the loads along the
fixed path or by gravity from one elevation to a lower
elevation
• Roller conveyors
• Belt conveyors.
• Chain conveyor

52. Crane & Hoist
• Cranes are used for horizontal movement of materials .
• hoists are used for vertical lifting
• hoist component of the crane lifts the load, and the crane
transports the load horizontally to the desired destination
• a hoist consists of one or more fixed pulleys, one or more
moving pulleys, and a rope, cable, or chain strung between the
pulleys.
• The number of pulleys in the hoist determines its mechanical
advantage,
• The driving force to operate the hoist is usually applied by
electric or pneumatic motor.

53. Storage System Performance
• The function of a material storage system is to store materials for
a period of time and to permit access to those materials when
required.
• The performance of a storage system in accomplishing its
function must be sufficient to justify its investment and
operating expense.
• Various measures used to assess the performance of a storage
system includes
• (1) storage capacity (2) storage density
• (3) accessibility (4) throughput.
• (5) utilization and (6) reliability

54. AS/RS Applications.
• They can also be used to store raw materials and work-in-
process in manufacturing.
• Three application areas can be distinguished:
• (1) unit load storage and handling,
• (2) order picking, and
• (3) work-in-process storage.

55. AS/RS
• Components and Operating Features of an AS/RS. consist of
the following components,
(1) storage structure
(2) S/R machine
(3) storage modules
(4) one or more pickup-and-deposit stations.
(5) a control system is required to operate the AS/RS

56. Automatic Identification & Data Capture
• Automatic identification and data capture (AIDC) refers to
technologies that provide direct entry of data into a computer
or other microprocessor-controlled system without using a
keyboard.
• Many of these technologies require no human involvement in
the data capture and entry process.
• Automatic identification systems are being used increasingly
to collect data in material handling and manufacturing
applications

57. Bar code system

58. Other AIDC Technology
• Magnetic stripes attached to a product or container are
sometimes used for item identification in factory and
warehouse applications.
• Optical Character Recognition Optical character recognition
(OCR) is the use of specially designed alphanumeric
characters that are machine readable by an optical reading
device.

59. AIDC
• The principal application of machine vision is for automated
inspection tasks For AIDC applications, machine vision
systems are used to read 2-D matrix symbols, such as Data
Matrix and they can also be used for stacked bar codes, such
as PDF
• For example, machine vision systems are capable of
distinguishing among a variety of products moving down a
conveyor so that the products can be sorted.

60. 4. Manufacturing System
• Single station manufacturing cells
• Manual assembly line
• Automated Production lines
• Automated Assembly System
• Group Technology & Cell manufacturing
• FMS

61. 5. Quality Control System
• Traditional & Modern Quality Control
• SQC
• Six Sigma
• ISO 9000
• Taguchi Method in Quality
• Sample inspection & 100% inspection
• Automated inspection

62. Cont…
• CMM
• Surface Measurement
• Machine Vision System
• Non contact & Non optical inspection

63. 6. Manufacturing Support System
• CAD/CAM, CIM
• CAPP
• Material requirement Planning
• Inventory control
• Capacity planning
• JIT & Lean production

64. Unit-1
• Introduction to Manufacturing Systems : Components,
Classification Scheme
• Single Station Automated Cells, Applications of Single
Station Automated Cells
• Fundamentals of Manual Assembly Lines, Analysis of Manual
Assembly Lines,
• Line Balancing Algorithms,
• Considerations in Assembly Line Design

65. Unit-2
• Automated Production Lines : Fundamentals, Applications
• Analysis of Transfer Lines. Fundamentals of Automated
Assembly Lines
• Cellular Manufacturing
• Part Classifications and Coding,
• Applications of Group Technology,
• Quantitive analysis of Cellular Manufacturing.

66. Unit-3
• Flexible Manufacturing Systems : Introduction, Components
of FMS, Applications, Benefits, FMS planning and
Implementation issues, Quantitive Analysis of FMS.
• Fundamentals of NC Technology, Computer Numerical
Control, Distributed Numerical Control,
• Applications of NC, NC part programming. Sample NC
programs including step, groove, taper, and profile turning.

67. Unit-4
• Quality Programs in Manufacturing : Process Variability and
Process capability,
• Statistical Process Control, Six Sigma, Taguchi Methods in
Quality Engineering, ISO 9000.
• Coordinate Measuring Machine, Machine Vision, Non contact,
Non Optical Inspection Techniques

68. Unit-5
• Process Planning, Computer Aided Process Planning,
Concurrent Engineering and Design for Manufacturing,
• Advanced Manufacturing Planning, Material Requirement
Planning, Capacity Planning.
• Shop Floor Planning, Inventory Control, Lean Production,
Just in Time Production Systems, Automation