An automated transfer line is consisted of several workstations which are linked together by a material handling system where parts are transferred from one station to the next.

1. MANOJ K
1MS16MCM09
M.TECH (CIM)
TECHNICAL SEMINAR
By
M S RAMAIAH INSTITUTE OF
TECHNOLOGY

2. Content
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 Introduction
 Automated transfer Line
 Buffer storage
 Workstation Breakdown Analysis
 Performance Measurement
 Case study 1
 Case study 2
 References

3. Introduction
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 An automated transfer line is consisted of several
workstations which are linked together by a
material handling system where parts are
transferred from one station to the next
 No internal parts storage
 one station breaks down, all other stations on the
line are affected.
 The other stations will be forced to stop for one
of two reasons:
 Starving of stations
 Blocking of stations.

4. Automated transfer Line
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 Multiple workstations linked together by a
material handling system to transfer parts from
one station to the next.

5. Automated transfer Line
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 Suited for:
• High product
demand
• Stable product
• Long product life
• Multiple operations
 Benefits
• Low direct labour
content
• Low product cost
because cost
• High production rates.
• Production lead time
and WIP are
minimized.
• Factory floor space is
minimized.

6. Buffer storage
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 Buffer storage system is a temporary storage
location for goods being processed
 It is located in between processing stations,
whose processing times are significantly
different.

7. Buffer storage
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Ex. The first operation requires only one shift to
meet production requirements, while the second
step requires two shifts to produce the same
number of units. Buffer is needed between these
operations to temporarily store the output of the
first process.

8. Workstation Breakdown
Analysis
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Common Reasons for Downtime in an
Automated Production Line
 Tool failures at workstations
 Tool adjustments at workstations
 Scheduled tool changes
 Mechanical failure of a workstation
 Mechanical failure of the transfer system
 Insufficient space for completed parts
 Preventive maintenance on the line
 Worker breaks

9. Workstation Breakdown
Analysis
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 Upper-bound approach
 In these cases, the work part is unaffected by the
station malfunction, and there is no reason to
remove the part.
 F=n*P
 Lower-bound approach
 The brake tool must be replaced at the
workstation, and the part must be removed from
the line and cannot proceed to the next stations
for additional processing.
 F=1-(1-P)n

10. Performance Measurement
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 Line efficiency
 Downtime
 Efficiency at stage
 Line efficiency with buffer

11. Performance Measurement
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 Rate of improvement obtained from buffer b
 Case 1
 Case 2

12. A Buffer Analysis in a Transfer
Production Line.
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 Abstract
 Determination of buffer to increase line efficiency
in a transfer line where several workstations are
linked together by a conveyer. One of the
common problems of a transfer line is minor
stoppages. The buffer analysis using constant
downtime distribution is employed in this paper.

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Experiment details
 Separation of the line by a buffer based on the Frequency and
average down time.
 Calculate efficiency for buffer using constant downtime
formulas and compare the efficiencies to select appropriate
buffer size.
 Graph of buffer size against line efficiency is plotted.
 Slope of graph is determined to find appropriate buffer size.

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Graphs & Table

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The result of line efficiency at buffer size of 50
to 250 is summarized in table and plotted in
figure.
It can be seen from the graph that at 150 piece-
buffer size is the most lucrative point
Results & Conclusion

16. A Buffer Design for Mitigation
Downtime Effect in an Automated
Transfer Line
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 Abstract
 Design of buffer capacity between workstations to
alleviate break down effect in an automated
transfer line and increase the production rate

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Experiment details
•Separation of the line by a buffer based on
the Frequency and average down time.
•Calculate efficiency for buffer using
constant downtime formulas and compare
the efficiencies to select appropriate buffer
size.
•Graph of buffer size against line efficiency
is plotted.

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Graphs & Table

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Results & Conclusion
The result of line efficiency at buffer size of 0
to 8 is summarized in table and plotted in
figure.
It can be seen from the graph that at 2 or 3
piece-buffer size is the most lucrative point.
Numerical method to determine the appropriate
number of buffer which is easy to obtain a
solution.

20. References
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 M. P. Groover, Automation, Production Systems and Computer-
Integrated Manufacturing, 2nd ed. Prentice Hall International Inc.
NJ, 1987, ch.18, pp. 565-595..
 A Buffer Analysis in a Transfer Production Line, Yonlanan
Chomnawung, Suksan Prombanpong and Chanakarn Klavohm,
ICIEA 2016 (11th IEEE Conference on industrial Electronics and
application)
 A Buffer Design for Mitigation Downtime Effect in an Automated
Transfer Line, S.Prombanpong, J. Kaewyu, N.Thanadulthaveedech,
and M.Matwangsang, International Journal of Innovation,
Management and Technology, Vol. 4, No. 1, February.
 Modeling of a Two-Stage Merge Production with Buffer Storage,
MEHMET SAVSAR, JKAU: Eng. Sci., vol. 4, pp. 67-81 (1412
A.H./1992 A.D.).
 Buffer Management For Automated Material Handling Systems In
Semiconductor Industries, Christian Fischmann, Fabian Böttinger,
Roland Wertz and Christian Kunz, Proceedings 22nd European
Conference on Modelling and Simulation ©ECMS.

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Thank you