In this presentation, we will talk about the importance of technology and factory automation, along with automated manufacturing systems, types of automation, automation principles and strategies.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
By Mrs Sudha A Mujumdar, Founder Member & Hon Secretary, Quality Circle Forum of India, Ankleshwar Chapter presented at Gujarat State Center The Institution of Engineers, Ahmedabad on 12th Feb 2016
By Mrs Sudha A Mujumdar, Founder Member & Hon Secretary, Quality Circle Forum of India, Ankleshwar Chapter presented at Gujarat State Center The Institution of Engineers, Ahmedabad on 12th Feb 2016
Production Planning and Control
Objective of PPC
Classification/Functions of PPC
Levels of PPC
Factors determining Production Planning Procedures
Production Planning System
Factors Determining PC procedures
Lecture 3 (quality of design and quality of conformance)RAJ BAIRWA
in this lecture i will discuss the quality of design and quality of conformance concept. it is very important in term of quality management and quality control purpose in any industrial applications.
Intelligent Manufacturing is a Smart Choice to gain on competitiveness and sustainability. Innovation technologies to boost productivity and visibility of manufacturing opearations.
THIS PPT CONTAINS WHAT IS MEANT BY THE VIRTUAL MANUFACTURING AND APPLICATION AND DRAWBACKS ,
AND IT CONTAINS ABOUT HOW IT IS REALISED USED IN PRESENTSCENARIO.
BASIC POINTS RELATED TO SFC
The area in a manufacturing facility where assembly or production is carried out, either by an automated system or by workers or a combination of both. The shop floor may include equipment, inventory and storage areas.
OBJECTIVES,
Shop floor control is responsible for the detailed management of activities and the flow of materials inside the plant, including employees, materials, machines, and production time. ... Production and process order scheduling. Capacity requirements planning. Material availability assessment.
3 REALS
Go to the real place…
To observe the real thing…
To get the real facts and data.
4P MANAGEMENT
, SETUP, ACTIVITIES, SFCS, BENEFITS, 5S PROGRAM, GENERAL SAFETY RULES.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
In this presentation we will discuss the basics of ERP system and its structure. We will also talk about client server functions.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
Production Planning and Control
Objective of PPC
Classification/Functions of PPC
Levels of PPC
Factors determining Production Planning Procedures
Production Planning System
Factors Determining PC procedures
Lecture 3 (quality of design and quality of conformance)RAJ BAIRWA
in this lecture i will discuss the quality of design and quality of conformance concept. it is very important in term of quality management and quality control purpose in any industrial applications.
Intelligent Manufacturing is a Smart Choice to gain on competitiveness and sustainability. Innovation technologies to boost productivity and visibility of manufacturing opearations.
THIS PPT CONTAINS WHAT IS MEANT BY THE VIRTUAL MANUFACTURING AND APPLICATION AND DRAWBACKS ,
AND IT CONTAINS ABOUT HOW IT IS REALISED USED IN PRESENTSCENARIO.
BASIC POINTS RELATED TO SFC
The area in a manufacturing facility where assembly or production is carried out, either by an automated system or by workers or a combination of both. The shop floor may include equipment, inventory and storage areas.
OBJECTIVES,
Shop floor control is responsible for the detailed management of activities and the flow of materials inside the plant, including employees, materials, machines, and production time. ... Production and process order scheduling. Capacity requirements planning. Material availability assessment.
3 REALS
Go to the real place…
To observe the real thing…
To get the real facts and data.
4P MANAGEMENT
, SETUP, ACTIVITIES, SFCS, BENEFITS, 5S PROGRAM, GENERAL SAFETY RULES.
BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
In this presentation we will discuss the basics of ERP system and its structure. We will also talk about client server functions.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
In this presentation, we will analyze the strength and weakness of ERP systems. Implementation cost, investment required, hidden costs and benefits of implementing ERP will also be covered in this presentation. We will discuss advantages and disadvantages of ERP and analyse the reason behind the failure of ERP in some specific projects.
To know more about Welingkar School’s Distance Learning Program and courses offered, visit: http://www.welingkaronline.org/distance-learning/online-mba.html
A short introduction to Protec, with examples of some of our past projects and for a bit more on what we do and how. Alternatively, please take a look at our website: www.productiontec.com
Reference - Peak Management for Large FactoryGyuhak Choi
LG CNS has implemented a management control system of Peak usage point in the massive production line where it uses a huge amount of power. LG Chemistry's factory in Iksan, Korea, is a case where the world's largest behind-the-meter LiB ESS is applied.
Managing Buyer (Order Booking/ Invoicing), Vender (P.O / Store Receipt), Stock (Finish Goods / Raw Material / Scrap with Cause), Production Planning, Shortage of stock on each stage, Marketing, Support after sale ( Servicing, Sale of Semi finish goods and raw material, Report (Tax wise, Product Wise, Buyer Wise & Bill Wise), Invoicing (With Transport detail, Serial No generation, Tax & Other Charges) and a huge number of report covering the buyer order to delivery and support after sale.
Factory management-1 The Corporate Constitution and Management FrameworkEduardo L. Garcia
Developed over the last 50 years by the Japanese international consultant Koichi Kimura, The Factory Management System is the only empirical and pragmatic model of corporate excellence development as the fundamental basis of the Continuous Improvement and 6σ activities.
WarehouseNet is a warehouse management system for logistics and distribution operation. Extremely suitable for warehouse, distribution center, logistic and storage operation. Stock keeper uses it to keep track of their inventory, movement and leftover. It is able to hold all kinds of general merchandise
inventory, warehouse, receiving, deliveries, leftover, logistic software. WMS, MRP.
Managing shopfloor energy consumption in a smart factoryJulian Krenge
Introduction to the Aachen trial site of the EU-funded FINESCE project focusing on the demand side management in a smart factory, with a bit more detail on the use of FIWARE and Generic Enablers (GEs).
PREDICTIVE MAINTENANCE AND ENGINEERED PROCESSES IN MECHATRONIC INDUSTRY: AN I...ijaia
The paper proposes the results of a research industry project concerning predictive maintenance process
optimization, applied to a machine cutting polyurethane. A company producing cutting machines, has been
provided with an online control system able to detect blade status of a machine supplied to a customer
producing polyurethane components. A software platform has been developed for the real time monitoring
of the blade status and for the prediction of the break up conditions adopting a multi-parametric data
analysis approach, based on the simultaneous use of unsupervised and supervised machine learning
algorithms. Specifically, the proposed method adopts a k-Means algorithm to classify bidimensional risk
maps, and a Long Short Term Memory (LSTM) one to predict the alerting levels based on the analysis of
the last values for some process variables. The analysed algorithms are applied to an experimental dataset.
What are the differences between a CNC & a robotic system? What are their characteristics and how do you determine which one is best suited to the needs of your industry? Go find all the answers in our latest blog post!
Mitsubishi robot system solutions catalogDien Ha The
Mitsubishi ,
Catalog Thiết Bị Điện Mitsubishi , Catalog Thiết Bị Điện
Catalog Phụ Kiện Mitsubishi , Catalog Phụ Kiện,
Catalog Mitsubishi , Catalog,
https://www.dienhathe.com,
Chi tiết các sản phẩm khác của Mitsubishi tại https://dienhathe.com
Xem thêm các Catalog khác của Mitsubishi tại https://dienhathe.info
Để nhận báo giá sản phẩm Mitsubishi vui lòng gọi: 0907.764.966
Mitsubishi robot system solutions catalogDien Ha The
Mitsubishi ,
Catalog Thiết Bị Điện Mitsubishi , Catalog Thiết Bị Điện
Catalog Phụ Kiện Mitsubishi , Catalog Phụ Kiện,
Catalog Mitsubishi , Catalog,
https://www.dienhathe.com,
Chi tiết các sản phẩm khác của Mitsubishi tại https://dienhathe.com
Xem thêm các Catalog khác của Mitsubishi tại https://dienhathe.info
Để nhận báo giá sản phẩm Mitsubishi vui lòng gọi: 0907.764.966
IOSR Journal of Electronics and Communication Engineering(IOSR-JECE) is an open access international journal that provides rapid publication (within a month) of articles in all areas of electronics and communication engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in electronics and communication engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
AUTOMATION IN AUTOMOTIVE MANUFACTURING
The automotive industry is the most highly automated manufacturing industry. A myriad of robotics, programmable controllers and drive systems work in a real-time process environment.
Automotive manufacturing systems need to be highly accurate, efficient and reliable.
Machines rely on complex automation platforms, employing advanced and powerful PLC systems to precisely control multi-axis interpolated motion sequences.
Industry code programming standards such as IEC 61131 have helped improve machine automation programming tremendously.
Automation in machine tools helps meet production targets:
• For machines used by automotive manufacturers such as press lines, welding lines, painting lines, engine assembly and chassis assembly lines
• For machines used by Tier 1 manufacturers to produce ancillaries such as brakes, connecting rods, pistons, clutches, transmission components like steering and axles, differential gear boxes, etc.
Uses of Computers in Manufacturing and production sectorNingela Weasley
This presentation covers the following topics:
-Uses and importance of computers in the manufacturing sector
-Uses of Computer Aided Designing(CAD)
-Uses of Computer Aided Manufacturing(CAM)
-Uses of Computer Integrated Manufacturing(CIM)
-Uses internet in the manufacturing sector
A visit to the ARMC Factory 2050 showed us advanced manufacturing processes with robotics, guided assembly, automated inspection and test.
Source: https://www.metisautomation.co.uk/armc-factory-2050/
In the manufacturing sector, accuracy is vital. To guarantee top performance and quality, each part and every detail must match precisely. Let us introduce CNC drilling machines, which are revolutionizing modern manufacturing. Let us explore how these devices are opening up new possibilities and changing manufacturing processes.
this is the basic slide for the introduction of Industry 4.0. how this works and what are the foundations required for the working of the indusry as it is taking globally a huge transformation.
Welingkar's Online PGDM Program in Supply Chain Mgmt is designed to understand the levels involved in bringing a manufactured product to the right channel.
WeSchool's Online PGDM Program in E-Commerce Mgmt is designed to combine technology, business, marketing, logistics, etc to prepare you for jobs in ecommerce.
We School's Online PGDM Program in International Business Mgmt covers some of the advanced subjects like International Economics & International Business Environment.
We School's Online MBA Program in IT Projects Mgmt prepares IT, project managers, to provide leadership in planning, executing & directing complex IT projects.
WeSchool's Online PGDM Program in E-Business Mgmt will help students interested in getting into the e-business with expertise in e-commerce & online shopping.
WeSchool's Online PGDM Program in Business Administration extensively covers several topics on marketing, investment, functional administration, sales, etc.
Online PGDM Program in Finance Mgmt Descriptionibes the role of Finance Manager, beneficial for professionals interested in a career in finance-related sectors.
WeSchool offers AICTE approved Diploma in Marketing Management. It is a specialized Management program with focus on marketing as a core business function
WeSchool Offers Online MBA Program in Operations Mgmt. Production planning, project management & world-class manufacturing are among the critical concepts.
Gain a better understanding of the various industry functions, business trends and industry regulations in the travel and tourism industry to emerge as a powerful team leader.
Visit our Websites: https://www.welingkaronline.org/
In today's increasingly competitive business environment, organizations are engaged in a rat race to retain customers, build up clientele and simultaneously ensure steady growth. Unfortunately, they often get caught in a web of issues which may not be easily controlled and affect performance. Here comes the play of Financial Accounting. Professional accountants have a vital role in commercial success by using their valuable knowledge to provide their organizations/clients a competitive advantage and an accurate picture of their financial position and performance.
British Aerospace Asset Management Case study will tech you how important is asset management for your business. lern from the experts about the Asset management.
Mc donalds Recruitment Case Study will explain you each and every thing about the Recruitment. hiring a right person at your workplace will be one of the best part of your business management. learn how to hire or recruit perfect person in your company with this case study of Mc donalds Recruitment.
More from We Learn - A Continuous Learning Forum from Welingkar's Distance Learning Program. (20)
The world of search engine optimization (SEO) is buzzing with discussions after Google confirmed that around 2,500 leaked internal documents related to its Search feature are indeed authentic. The revelation has sparked significant concerns within the SEO community. The leaked documents were initially reported by SEO experts Rand Fishkin and Mike King, igniting widespread analysis and discourse. For More Info:- https://news.arihantwebtech.com/search-disrupted-googles-leaked-documents-rock-the-seo-world/
Business Valuation Principles for EntrepreneursBen Wann
This insightful presentation is designed to equip entrepreneurs with the essential knowledge and tools needed to accurately value their businesses. Understanding business valuation is crucial for making informed decisions, whether you're seeking investment, planning to sell, or simply want to gauge your company's worth.
Cracking the Workplace Discipline Code Main.pptxWorkforce Group
Cultivating and maintaining discipline within teams is a critical differentiator for successful organisations.
Forward-thinking leaders and business managers understand the impact that discipline has on organisational success. A disciplined workforce operates with clarity, focus, and a shared understanding of expectations, ultimately driving better results, optimising productivity, and facilitating seamless collaboration.
Although discipline is not a one-size-fits-all approach, it can help create a work environment that encourages personal growth and accountability rather than solely relying on punitive measures.
In this deck, you will learn the significance of workplace discipline for organisational success. You’ll also learn
• Four (4) workplace discipline methods you should consider
• The best and most practical approach to implementing workplace discipline.
• Three (3) key tips to maintain a disciplined workplace.
Improving profitability for small businessBen Wann
In this comprehensive presentation, we will explore strategies and practical tips for enhancing profitability in small businesses. Tailored to meet the unique challenges faced by small enterprises, this session covers various aspects that directly impact the bottom line. Attendees will learn how to optimize operational efficiency, manage expenses, and increase revenue through innovative marketing and customer engagement techniques.
Memorandum Of Association Constitution of Company.pptseri bangash
www.seribangash.com
A Memorandum of Association (MOA) is a legal document that outlines the fundamental principles and objectives upon which a company operates. It serves as the company's charter or constitution and defines the scope of its activities. Here's a detailed note on the MOA:
Contents of Memorandum of Association:
Name Clause: This clause states the name of the company, which should end with words like "Limited" or "Ltd." for a public limited company and "Private Limited" or "Pvt. Ltd." for a private limited company.
https://seribangash.com/article-of-association-is-legal-doc-of-company/
Registered Office Clause: It specifies the location where the company's registered office is situated. This office is where all official communications and notices are sent.
Objective Clause: This clause delineates the main objectives for which the company is formed. It's important to define these objectives clearly, as the company cannot undertake activities beyond those mentioned in this clause.
www.seribangash.com
Liability Clause: It outlines the extent of liability of the company's members. In the case of companies limited by shares, the liability of members is limited to the amount unpaid on their shares. For companies limited by guarantee, members' liability is limited to the amount they undertake to contribute if the company is wound up.
https://seribangash.com/promotors-is-person-conceived-formation-company/
Capital Clause: This clause specifies the authorized capital of the company, i.e., the maximum amount of share capital the company is authorized to issue. It also mentions the division of this capital into shares and their respective nominal value.
Association Clause: It simply states that the subscribers wish to form a company and agree to become members of it, in accordance with the terms of the MOA.
Importance of Memorandum of Association:
Legal Requirement: The MOA is a legal requirement for the formation of a company. It must be filed with the Registrar of Companies during the incorporation process.
Constitutional Document: It serves as the company's constitutional document, defining its scope, powers, and limitations.
Protection of Members: It protects the interests of the company's members by clearly defining the objectives and limiting their liability.
External Communication: It provides clarity to external parties, such as investors, creditors, and regulatory authorities, regarding the company's objectives and powers.
https://seribangash.com/difference-public-and-private-company-law/
Binding Authority: The company and its members are bound by the provisions of the MOA. Any action taken beyond its scope may be considered ultra vires (beyond the powers) of the company and therefore void.
Amendment of MOA:
While the MOA lays down the company's fundamental principles, it is not entirely immutable. It can be amended, but only under specific circumstances and in compliance with legal procedures. Amendments typically require shareholder
Discover the innovative and creative projects that highlight my journey throu...dylandmeas
Discover the innovative and creative projects that highlight my journey through Full Sail University. Below, you’ll find a collection of my work showcasing my skills and expertise in digital marketing, event planning, and media production.
Unveiling the Secrets How Does Generative AI Work.pdfSam H
At its core, generative artificial intelligence relies on the concept of generative models, which serve as engines that churn out entirely new data resembling their training data. It is like a sculptor who has studied so many forms found in nature and then uses this knowledge to create sculptures from his imagination that have never been seen before anywhere else. If taken to cyberspace, gans work almost the same way.
2. Production Technology
FACTORY AUTOMATION
Production automation is fundamental to Japan's
competitiveness in terms of the cost and quality of its
consumer electronic products.
In addition, a growing labor shortage, demands for
improved working environments, and company-wide
computer-integrated manufacturing have made automation a
necessity for many companies.
Since most fabrication activities have already been
automated, the current focus of attention is on the
automation of assembly lines, where labor content has been
highest.
There are several stages of assembly line automation, with
varying impacts on flexibility and product design.
3. Production Technology
FACTORY AUTOMATION
The move from hand assembly to robot assembly of
existing products can be termed "first-generation"
automation. "Second-generation" lines require some product
design changes for assembly line automation. Automation
that requires broad product design changes is termed "third-
generation" automation.
The JTEC panel observed widespread automation during
its plant tours. The leading Japanese electronic companies
have implemented the following FA concepts (Kahaner
1993, 33-56):
in-line systems with a series of progressive operations
4. Production Technology
FACTORY AUTOMATION
computer control of raw material storage and retrieval
automated guided vehicles used in the delivery of material
to the assembly line, and in some cases, automated loading
of the assembly equipment
bar code identification of raw material and product mix
machine instructions downloaded from a host computer
in-line automated assembly and process equipment
in-line automated inspection and testing equipment
following each preceding assembly or fabrication operation
automated real-time process control to achieve automated
calibration of assembly equipment and products
5. Production Technology
FACTORY AUTOMATION
Key benefits cited for the use of automation include
reducing factory set-up time, manufacturing defects, product
lead time, and direct labor, and increasing the ability to
rapidly deploy manufacturing operations around the world.
Sony management described the following as an example
of the benefits gained from the company's factory
automation activities: It took three to four months to start up
Sony's original production lines in Japan, but it required
only two to three weeks to bring replicated lines up to speed
in Singapore and France. Changing models required only
9.1% of additional capital investment in Sony's first
changeover, 3.5% in the second changeover, and only 1.5%
in the third changeover.
6. Production Technology
FACTORY AUTOMATION
In addition, the move to automation resulted in improved
quality. The best defect rate using manual labor was 2000
parts per million (PPM), compared to 20 PPM after the first
week of automation.
Sony's personnel policy was to remove employees from
manual labor jobs through automation so that "they could
become more creative in solving problems and improving
operations."
Due to Sony's strong knowledge base in automation and
its focus on design for manufacturability, between 1987 and
1990 it increased sales by 121% with an increase of only 35
employees.
7. Production Technology
FACTORY AUTOMATION
Automation for Miniaturization
Japanese electronics companies have made and continue
to make large investments in production technologies and
factory automation because of their commitment to
miniaturization as well as to high product reliability and low
product cost. As electronic components shrink to as small as
1.0 mm by 0.5 mm (called "1005" parts), and as component
lead pitch approaches 0.2 mm, human assembly is no longer
feasible.
The Japanese strategy to develop key components for use
in electronic products has also required investments in
equipment development.
8. Production Technology
FACTORY AUTOMATION
"Off-the-shelf" equipment is generally inadequate to meet
the manufacturing needs of new component technologies.
Without exception, each Japanese company the JTEC panel
visited was designing and building critical equipment in-
house. According to these companies, equipment provides a
major competitive advantage because it is designed to
respond to the specific manufacturing requirements of the
companies' components or products.
The JTEC panel was impressed by the fact that some
Japanese component suppliers also supplied buyers with the
equipment required to assemble their advanced components.
TDK, Murata, and Matsushita,
9. Production Technology
FACTORY AUTOMATION
for example, developed internally the production
technology to make 1005 parts, and they also supplied the
assembly equipment required for customers to utilize these
ultra small parts in SMD assembly. The equipment makers
introduced the equipment at the same time as the new
miniature parts were made available to the market. The
production technology is being developed to ensure that new
components are rapidly included in next-generation product
designs.
Miniaturization is forcing assembly technologies to
become faster and more precise. Precision robots have
improved repeatability from .05 to .01 mm over the past
decade.
10. Production Technology
FACTORY AUTOMATION ISSUES
Final Assembly Design Techniques
In assembly operations, parts handling and feeding and
line control are very complex; however, with the advances
made in equipment, production control, and computers over
the past decade, automated assembly lines are no longer
unusual.. There are three critical advances (Kahaner 1993,
34):
positioning technology for robot control
flexible line construction technology for mixed flow
production of multiple product models
modular product design technology for assembly line
automation
11. Production Technology
FACTORY AUTOMATION ISSUES
Positioning is the most common problem for assembly
automation. Different sizes and shapes of components make
assembly difficult. Precision positioning of parts for printed
circuit boards in consumer electronic products is especially
challenging.
If the board is out of position, the problem is compounded.
This is a problem with board warp age where accurate sensor
detection is especially difficult. NEC in Gunma Prefecture
developed a triangular measuring optical sensor that is used
in a procedure to detect the height of three points on a print
board.
12. Production Technology
FACTORY AUTOMATION ISSUES
A two-dimensional curving warp can be represented by
three points, so the company had to come up with
innovations in measurement point selection and interpolation
techniques.
Jigs are fundamental to positioning parts properly before
assembly. Complex part shapes can make such positioning
difficult.
Visual sensors can detect the positions of parts and also
allow for mixed-flow production operations. These sensors
can also detect parts' shapes and therefore are useful in
product quality control applications.
Toshiba's most recent application of CCD technology to
visual sensors has allowed for 0.02 mm positioning accuracy.
13. Production Technology
FACTORY AUTOMATION ISSUES
More typical sensors, combined with the mechanical error
of a robot, result in errors of several hundred microns.
Flexible lines are required to cope with the demands of
multiple-model, mixed-flow production. Movable jigs and
visual sensors are used to adjust to changing parts shapes. In
mixed-flow assembly lines, product model information must
be controlled to match parts with the models on the line.
Some companies have used memory cards on parts pallets to
achieve this control. Integration of such parts flows with
mixed-line assembly is based on sophisticated parts-feeding
equipment, which may account for 80% of the automation
success.
14. Production Technology
FACTORY AUTOMATION ISSUES
Modular product designs are used to reduce equipment
costs and to improve product reliability. It is essential to
implement design features that are compatible with
automated assembly operations. It is then possible to
simplify assembly and enhance operational reliability by
orienting all the assembly steps in one direction or
employing connection techniques amenable to automation.
For complex assembly operations that could be handled by
robots, Fujitsu developed special supplemental mechanisms
that required changes in such details as screw shape.
Product structures are divided into a number of modules
for design purposes.
15. Production Technology
FACTORY AUTOMATION ISSUES
Each module is assembled on a sublime, and the assembly
operations not amenable to automation are concentrated in
the final assembly line. It is easy to achieve higher
automation rates in the total assembly process because each
module is designed to be compatible with automated
assembly. In the personal computer, for example, every
component used in final assembly simply slides into a slot or
connector without difficulty. At NEC's PC assembly factory,
each module is designed to be compatible with automation of
the total assembly process.
16. Production Technology
FACTORY AUTOMATION ISSUES
Now that robots have become highly functional, Seiko
Epson has designed its printers for the lowest total
manufacturing cost and then constructed its assembly line
accordingly. It has set about improving the automation rate
while developing ways to handle multiple-module, mixed-
flow production. The mixed-flow production approach helps
hold down equipment costs and allows for flexibility in
adjusting to demand fluctuations. Development of designs
compatible with assembly automation is a new key concept
that has great potential.
17. Production Technology
Automated Manufacturing Systems
CAD ,CAE ,CAPP
CAM ,CIM
Computer Aided
Fixed Automation (transfer lines)
Hard automation, automation for mass production
Produces large numbers of nearly identical parts
High initial investment for custom engineered
equipment
Product design must be stable over its life
Advantages: equipment fine tuned to application -
decreased cycle time, infrequent setups, automated
material handling - fast and efficient movement of parts,
very little WIP
Disadvantage: inflexible
18. Production Technology
Types of Automation
Programmable Automation (NC, CNC, robots)
Sequence controlled by a program
High investment in general purpose equipment
Lower production rates
Flexibility to deal with variation
Suitable for batch production
Smaller volumes (than fixed) of many different parts
More flexible than fixed automation
Major disadvantage: setup prior to each new part
Large batch size (due to setups)
Speed sacrificed for flexibility
19. Production Technology
Types of Automation
Flexible Automation (FMS)
Extension of programmable automation
No time lost for change over
High investment in custom-engineered systems
Production of product mix
Flexibility to deal with design variations
Low to medium quantities
Compromise between fixed and programmable
automation in speed and flexibility
Advantage: programming and setup performed off-
line
20. Production Technology
Types of Automation
More expensive - size and tool change capabilities
Small batch sizes are justified - reduced WIP and lead
time
Typical parts are expensive, large and require some
complex machining
Strengths of Humans
Sense unexpected stimuli
Develop new solutions to problems
Cope with abstract problems
Adapt to change
Generalize from observations
Learn from experience
Make difficult decisions based on incomplete data
21. Production Technology
AUTOMATION PRINCIPLES AND STRATEGIES
Ten Strategies for Automation
1. Specialization of operations.
2. Combined operations.
3. Simultaneous operations.
4. Integration of operations.
5. Increased flexibility.
6. Improved material handling and storage.
7. On line inspection.
8. Process control and optimization.
9. Plant operations control.
10. Computer integrated manufacturing (CIM).
22. Production Technology
AUTOMATION PRINCIPLES AND STRATEGIES
Automation Migration Strategy
Phase 1: Manual production using single station
manned cells operating independently.
Phase 2: Automated production using single station
automated cells operating independently.
Phase 3: Automated integrated production using a multi-
station automated system with serial operations and
automated transfer of work units between stations.
23. Production Technology
AUTOMATION ADVANTAGES
Reduce work-in-process
parts being processed, part waiting to be processed
large WIP: longer time to fill orders, more storage space, value
of unfinished goods that could be invested elsewhere
reduced WIP: better control and scheduling
Reduce manufacturing lead time
processing time, setup time, waiting time
setup time: flexible automation, common fixtures and tooling
processing time: combining or eliminating operations, increase
speed (work measurement principles)
Increase quality
repeatable operations through every cycle - tighter control
limits, easier detection when process is out of control
status of manufacturing operations
24. Production Technology
AUTOMATION ADVANTAGES
Increase productivity
Reduce labor cost
Address labor shortages
Reduce or eliminate routine manual and clerical tasks
Health and Safety
May be the only option
Stay up-to-date (avoid cost of catching up)
25. Production Technology
Factories of Future
Aerospace
Typically, complex, three-dimensional shapes, exotic
materials, medium-volume to low-volume production
quantities
Military and space technology filters down to industrial
applications
Pioneered work in NC machining, CAD/CAM, composites
and flexible manufacturing system applications
Goals: energy efficiency, high strength-to-weight ratio
26. Production Technology
Factories of Future
Automotive
Relatively large production quantities, multiple options:
automated assembly is difficult
Traditionally, primary processes were metalworking:
machining of power train parts, forming and bending sheet
metal; assembly by spot welding and mechanical fasteners;
finishing by spray painting and plating
New materials: plastics, fiberglass
Increasing automation: robots for spot welding and spray
painting
Improved quality with production groups that assemble
large portions of the automobile
27. Production Technology
Factories of Future
Chemical
Chemical processes for man-made fibers and plastics, oil
distillation and pharmaceutical industries
Continuous flow of product and byproducts; some batch
processing
reasonably easy to automate
Food
Large volume industry
Standard products and operations, therefore reasonably
easy to automate
Many products use continuous processes; discrete
processes includes packaging
28. Production Technology
Factories of Future
Semiconductor
Large volume industry
Emphasis on design and production of low-cost integrated
circuits
Smaller size and more stringent requirements for
cleanliness
Process requirements have forced automation
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