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1. MANUFACTURING SYSTEMS
AND AUTOMATION
CHAPTER 10
DR SHALIZA AZREEN MUSTAFA
25/11/16

2. INTRODUCTIONON AUTOMATIONOF
MANUFACTURINGPROCESSES
AUTOMATION
NUMERICAL CONTROL
ADAPTIVE CONTROL
MATERIAL HANDLING AND MOVEMENT
INDUSTRIAL ROBOTS
SENSOR TECHNOLOGY

3. INTRODUCTION
1950s, manufacturing operations used traditional
machinery:
lacked flexibility,
required high skilled labor,
have to retooled the machinery on each different
product manufactured,
the movement of materials have to be rearranged,
product with complex shapes required trial and error
attempts by the operator in order to set the proper
processing parameters on the machine,
time-consuming
labor cost and production cost increase.

4. INTRODUCTION
• How to improve PRODUCTIVITY? By
MECHANIZATION. Operation runs with the use of
various mechanical, hydraulic, pneumatic, or
electrical devices.
• But still operator have to control the process and
check the machine’s performance, thus to
IMPROVE THE EFFICIENCY of manufacturing
process = AUTOMATION.

6. AUTOMATION
~ The process of having machines follow a
predetermined sequence of operations with little
or no human labor, using specialized equipment
and devices that perform and control
manufacturing process ~
• Area of activities:
Manufacturing processes
Material handling
Inspection
Assembly
Packaging

7. HISTORY OF AUTOMATION

8. THE GOALS OF AUTOMATION
1) To integrate various aspects of manufacturing
operations so as to improve product quality and
uniformity, minimize cycle times and effort and thus,
reduce labor costs.
2) To improve productivity by reducing manufacturing
costs through better control of production.
3) To improve quality
4) To reduce human involvement, boredom, the
possibility of human error.
5) To reduce workpiece damage caused by manual
handling of parts.

9. 6) To increase worker safety.
7) To economize on floor space by arranging
machines efficiently.
8) To accomplish processes that cannot be done
manually.
9) To reduce manufacturing lead time.
Watch video 1
THE GOALS OF AUTOMATION

10. PRODUCTION QUANTITY
• Important to determine type of machinery and level
of automation.
• Total production quantity: total no. of parts to be
made.
• Production rate: the no. of parts produced by unit of
time.
Approximate annual volume of production

11. TYPE OF PRODUCTION

14. NUMERICAL CONTROL

15. COMPUTER NUMERICAL CONTROL

16. TYPES OF CONTROL SYSTEM IN CNC

17. TYPES OF CONTROL SYSTEM IN CNC

18. ADAPTIVE CONTROL

19. PRINCIPLESAND APPLICATIONSOF
ADAPTIVECONTROL

20. PURPOSEOF ADAPTIVECONTROL

21. MATERIAL HANDLING AND MOVEMENT
• Defined as the functions and systems associated
with the transportation, storage, and control of
materials and parts in the total manufacturing
cycle of a product.
• The total time required depends on part size and
shape and on the set of operations required.
• Idle time and the time required for transporting
materials can constitute the majority of the time
consumed.
• It moved either manually or by some mechanical
means.

22. EQUIPMENT
• SELF-GUIDED VEHICLES (Tugger Type)
a) This vehicle can be arranged in
a variety of configurations to
pull caster-mounted cars; it has
a laser sensor to ensure that
the vehicle operates safely
around people and various
obstructions.
b) A self-guided vehicle
configured with forks for use in
a warehouse.

23. EQUIPMENT
AUTOMATED GUIDED VEHICLE (AGV)
Watch video 2

24. INDUSTRIAL ROBOTS

25. TYPES OF INDUSTRIAL ROBOTS

26. APPLICATION OF ROBOTS
• Material handling
• Spot welding
• Spray painting
• Automated assembly is again very repetitive
• Inspection and gaging
• Applying adhesive and sealants grinding and polishing
Watch video 3

27. SENSOR TECHNOLOGY

28. INTRODUCTION ON COMPUTER-
INTEGRATED MANUFACTURING
SYSTEMS
MANUFACTURING SYSTEMS
COMPUTER-INTEGRATED MANUFACTURING
COMPUTER-AIDED DESIGN AND ENGINEERING
COMPUTER-AIDED MANUFACTURING
COMPUTER-AIDED PROCESS PLANNING
GROUP TECHNOLOGY
FLEXIBLE MANUFACTURING SYSTEMS
JUST-IN-TIME PRODUCTION

29. MANUFACTURINGSYSTEMS
• Manufacturing entails a large number of interdependent
activities such as materials, tools, machines, power and
human beings, therefore regarded as a system.
• the word “system” is derived from the Greek word
“systema” meaning “to combine”.
• Focused on integration of manufacturing activities.
• Integration means that manufacturing processes,
operations, and management are treated as a system.

30. • It’s a complex system, some of activities are difficult to
predict and control; supply and cost of raw materials,
market changes, human behavior and performance.
• Thus, should be able to represent a system by
mathematical and physical models.
• Modeling such a complex system can be difficult,
because of a lack of comprehensive or reliable data on
many variables involved.
• Thus, much progress on modeling and simulation in
manufacturing system has been made.
MANUFACTURINGSYSTEMS

31. COMPUTER-INTEGRATEDMANUFACTURING
(CIM)
• CIM are linked all separate functions of research and
development, design, production, assembly, inspection
and QC.
• CIM is not a product that can be purchased and
installed.
• It is a way of thinking and solving problems
• It is the use of integrated systems and data
communications coupled with new managerial
philosophies.
• This integration allows individual processes to exchange
information with each other and initiate actions.

32. POTENTIAL BENEFITS OF CIM

33. KEY CHALLENGES

34. SUBSYSTEMS OF CIM

35. SUBSYSTEMS OF CIM

36. COMPUTER-AIDEDDESIGN(CAD)AND
ENGINEERING(CAE)
• CAD involves the use of computers to create design
drawings and product models.
• It is usually associated with interactive computer
graphics (CAD system)
• CAE simplifies the creation of the database, by allowing
several applications to share the information in the
database.

37. COMPUTER-AIDEDMANUFACTURING(CAM)
• CAM involves the use of computers and computer
technology to assist in all the phases of manufacturing
a product, including process and production planning,
machining, scheduling, management and quality
control.
• Often combined with CAD system known as CAD/CAM
system
• The database during CAD system is stored then it is
processed by CAM into the necessary data and
instructions for operating and controlling production
machinery, material handling equipment and
automated inspection quality.

38. COMPUTER-AIDEDPROCESSPLANNING
(CAPP)

39. CAPP roles in manufacturing

40. Methods of process planning

41. Advantages of CAPP systems over
traditional process planning
1) Improves the productivity of process planners,
reduces lead time, reduces planning costs,
improves consistency of product quality and
reliability.
2) Can be modified to suit specific needs.
3) Routing sheet can be prepared more quickly.
4) Other function such as cost estimating and work
standards can be incorporated into CAPP.

42. GROUPTECHNOLOGY(GT)
• Is a concept that seeks to take advantage of the design
and processing similarities among the parts to be
produced.

43. GT

44. Visual inspection method

45. Parts classification and coding

46. Production flow analysis

47. Traditional functional
layout of machine tools
GT (Cellular)
layout

48. FLEXIBLEMANUFACTURINGSYSTEMS
• Integrates all major elements of manufacturing into
a highly automated system.
• FMS consists a automated machine cells,
interconnected with automated material handling
system and storage system and all interfaced with a
central computer.
• Watch video 4

49. Layout of FMS

53. Benefits of FMS
1) Parts can be produced randomly, in batch sizes as
small as one, and at lower unit cost
2) Direct labor and inventories are reduced, to yield
major savings over conventional systems
3) The lead times required for product changes are
shorter
4) Production is more reliable, because the system is
elf-correcting.
5) WIP inventories are reduced.

54. JUST-IN-TIMEPRODUCTION(JIT)
• Implemented in Japan to eliminate waste.
• 7 type of waste:
• Transportation
• Inventory
• Motion
• Waiting
• Overproduction
• Over processing
• Defects

55. JIT goals
Receive supplies just in time to be used
Produce parts just in time to be made into
subassemblies
Produce subassemblies just in time to be assembled
into finished products
Produce and deliver finished products just in time to
be sold

56. Push v/s Pull system

57. Advantages of JIT
1) Low inventory carrying costs
2) Fast detection of defects in the production or the
delivery of supplies hence low scrap
3) Reduced inspection and rework of parts
4) High-quality parts produced at low cost.