Automation involves the use of technology and computers to automate production processes. There are different types of automation based on the level of flexibility, including fixed, programmable, and flexible automation. Flexible manufacturing systems (FMS) are highly automated systems that can produce different product varieties with minimal changeover time. An FMS uses a physical subsystem with workstations, material handling systems, and storage to process parts, along with a control subsystem. Common layout configurations for an FMS include line, loop, ladder, carousel, robot cell, and open field layouts. Benefits of FMS include reduced costs, lead times, and inventories, while limitations include high initial costs and need for skilled labor and pre-

1. Automation

2. Automation
It is a technology dealing with the
application of
• mechatronics
• computers
for production of goods and services.
Automation is broadly classified into
• manufacturing automation
• service automation

3. EXAMPLES OF AUTOMATION
• Automatic machine tools to process parts-
CNC m/c
• Industrial robots
• Automatic material handling
• Feedback control systems

4. Types of automation
• Fixed automation
• Programmable automation
• Flexible automation

5. Fixed automation
• Fixed automation refers to the use of
custom-engineered (special purpose)
equipment to automate a fixed sequence
of processing or assembly operations.
• This is also called hard automation.
• The primary drawbacks are the large initial
investment in equipment and the relative
inflexibility.
• GE: 2 million light bulbs
5

6. Programmable automation
• In programmable automation, the equipment
is designed to accommodate a specific class
of product changes and the processing or
assembly operations can be changed by
modifying the control program
• Suited to batch production
6

7. • In programmable automation, reconfiguring
the system for a new product is time
consuming because it involves reprogramming
and set up for the machines, and new fixtures
and tools.
7
Programmable automation contd.

8. Flexible automation
• In flexible automation, the equipment is
designed to manufacture a variety of products or
parts and very little time is spent on changing
from one product to another.
• a flexible manufacturing system can be used to
manufacture various combinations of products
according to any specified schedule.
• Customization
• Honda-for production of cars and bikes
8

9. Source: www.seas.upenn.edu
9

10. 10

11. Reasons for automation
• Shortage of labor
• High cost of labor
• Increased productivity
• Competition
• Safety
• Reducing manufacturing lead time
• Lower costs in the long run
11

12. Reasons against automation
• Labor resistance
• Cost of upgraded labor – new skill set
• Initial investment
12

13. Group technology
• GT is a manufacturing philosophy in which the
parts having similarities (Geometry,
manufacturing process and/or function) are
grouped together to achieve higher level of
integration between the design and
manufacturing functions of a firm.
• The group of similar parts is known as part family
and the group of machineries used to process an
individual part family is known as machine cell.

14. Cont..
• It is not necessary for each part of a part family to
be processed by every machine of corresponding
machine cell
• part family is produced by a machine cell is
known as cellular manufacturing.
• manufacturing efficiencies are generally
increased by employing GT because the required
operations may be confined to only a small cell
and thus avoiding the need for transportation of
in-process parts.

16. Part families
• same set of machines and tools
• Raw material should be reasonably consistent
(e.g. plastic and metallic parts require
different manufacturing operations and
should not be in the same family).
• Fixtures can be designed that are capable of
supporting all parts within the family.
• similar size

17. Process specializing sections

18. GT-Machine cells

19. Methods for Developing Part Families
• There are at least three basic methods that
can be used to form part families:
1. Manual visual search
2. Composite Part families
3. Production flow analysis
4. Classification and coding

20. 1. Manual visual search

21. Composite Part families

22. 3. Production flow analysis

23. Production flow analysis..

25. 4. Coding schemes
code structure
• codes are generally classified as, hierarchical
(also called monocode), chain (also called
polycode), or hybrid.

26. Hierarchical code structure
The meaning of a digit in the code depends on
the values of preceding digits.

27. Chain code
• each value for each digit of the code has a
consistent meaning. The value 3 in the third
place has the same meaning for all parts.
• They are easier to learn but less efficient.
Certain digits may be almost meaningless for
some parts.

29. Hybrid code
• hybrid: combination of both
• Since both hierarchical and chain codes have
advantages, many commercial codes are
hybrid

31. Flexible manufacturing system

32. Types of FMS
• DEPENDING UPON KINDS OF OPERATION
1. Processing operation
2. Assembly operation.
• BASED ON NUMBER OF MACHINES
1. Single machine cell (SMC).
2. Flexible manufacturing cell (FMC).
3. Flexible Manufacturing System (FMS).

33. Cont
• BASED ON LEVEL OF FLEXIBILITY
1. Dedicated FMS.
2. Random order FMS.

34. ELEMENTS OF FLEXIBLE MANUFACTURING
SYSTEM
• “A flexible manufacturing system consists of
two subsystems:”
• Physical subsystem
• Control subsystem

35. Physical subsystem includes the
following elements
1. Workstations. “It consists of NC machines, machine-tools,
inspection equipments, loading and unloading operation,
and machining area.
2. Storage-retrieval systems.(ASRS) “It acts as a buffer during
WIP (work in-processes) and holds devices such as
carousels used to store parts temporarily between work
stations or operations.”
3. Material handling systems. It consists of power vehicles,
various types of automated material handling equipment
such as conveyors , automated guided vehicles and robots
are used to transport the work parts and sub-assemblies to
the processing or workstation.

36. HARDWARE COMPONENTS OF FLEXIBLE
MANUFACTURING SYSTEM
1. Pallets and fixtures
2. Machining centers
3. Robots
4. Inspection equipment
5. Chip removal system
6. In process storage facility
7. Material handling systems

37. LAYOUT CONFIGURATIONS OF FMS
1. Line layout
2. Loop layout
3. Ladder type layout
4. Carousel layout
5. Robot centered cell
6. The open field layout

38. Line layout
• An Automated guided vehicle is most efficient
when the movement is in straight-lines
• In single-row machine layout machines are
arranged only on one side of AGV path, and in
double row machine layout, machines are
arranged on both sides

39. Line layout

40. Loop layout
• “The loop layout uses conveyor systems that
allow unidirectional flow of parts around the
loop.
• A secondary material handling system is
provided at a workstation which permits the
flow of parts without any obstruction.
A possible arrangement of this layout is
shown in fig

42. Ladder type layout
• “Ladder type layout consists of rungs on which
workstations are located. This reduces the
average travel distance thereby reducing the
transfer time between workstations.
• A possible arrangement of this layout is shown
in fig

44. Carousel layout
• “In the Carousel layout configuration, parts
flow in one direction around the loop. The
load, unload stations are placed at one end of
loop.
• A possible arrangement of this layout is shown
in fig

46. Robot centered cell
• “If a handling robot is used in a Flexible
manufacturing system cell , the machines
are laid out in a circle, such a layout is called
circular layout. A possible arrangement of this
layout is shown in fig

48. The open field layout
• “The open field layout is also an adoption of the loop
configuration.
• The open field layout consists of loops and ladders
organized to achieve the desired processing
requirements.
• This is used for the processing of a large family of
parts. The number of different machines may be
limited, 51 and the parts are routed to different
workstations depending on availability of machines.
• A possible arrangement of this layout is shown in fig

50. Benefits of FMS
• Reduction of inventories throughout the complete
chain of manufacturing including work-in-progress
• Reduction of lead time by 40%
• Improved machine utilization by 30%
• Reduction of labour times by 30%
• Reduction of direct and indirect labour costs
• Increased management control over the entire
manufacturing process
• Substantially reduced scrap levels.
• The ability to adapt quickly , new work pieces.

51. Limitations of FMS
• Initial set up cost is high
• Pre-planning required
• Requirement of skilled labor
• Complicated system