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Dr. S.A.Shah
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Dr. S.A.Shah
Industrial Automation - Machines
Storage Systems
Handling Systems
Assembly Lines
Assembly Cells
Machines
Actuators
Sensors
Production Lines
Production Cells
Machines
Actuators
Sensors
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Dr. S.A.Shah
The Production System
Manufacturing
Support System
Production
System
Facilities:
Factory &
Equipment
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Production System Defined
Two categories:
Facilities – the factory and equipment in the facility
and the way the facility is organized (plant layout)
Manufacturing support systems – the procedures
used by a company to manage production and to
solve technical and logistics problems in ordering
materials, moving work through the factory, and
ensuring that products meet quality standards
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Facilities – Factory and Equipment
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Materials ordering
Work movement in the factory
Keeping quality standards of the products
Product design etc.
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Manufacturing Support Systems
Business functions - sales and marketing, order
entry, cost accounting, customer billing
Product design - research and development, design
engineering, prototype shop
Manufacturing planning - process planning,
production planning, MRP, capacity planning
Manufacturing control
shop floor control,
inventory control, quality control
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Manufacturing Systems
Three categories in terms of the human participation in the
processes performed by the manufacturing system:
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Manufacturing Support Systems
The procedures and systems used by a firm to manage its
production operations and solve the technical and logistics
problems associated with:
Designing the products
Planning the processes
Ordering materials
Controlling work-in-process as it moves through the
plant
Delivering quality products to customers
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Dr. S.A.Shah
The Design Process
The general process of design is characterized as an
iterative process consisting of six phases:
1. Recognition of need - someone recognizes the need that
can be satisfied by a new design
2. Problem definition - specification of the item
3. Synthesis - creation and conceptualization
4. Analysis and optimization - the concept is analyzed and
redesigned
5. Evaluation - compare design against original specification
6. Presentation - documenting the design (e.g., drawings)
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Computer-Aided Design (CAD)
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Sequence of Information-Processing
Activities in a Manufacturing Firm
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Fundamentals of Manufacturing
Production:
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3 Modes of Production
Primary Industry:
The basic productive activities present in nature that are the
source of wealth (Agricultural, Mining and Fishing etc.)
Secondary Industry:
If someone manufacture a product for the creation of wealth
Production for the market
Production in this sense mean making things which are tangible
(i.e. Products) [Manufacturing, construction, Public utility (products)
generation]
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3 Modes of Production
Tertiary Industry:
The concept of utility was introduced in this type
Utility, refers to the degree of satisfaction a human want
With this concept the meaning of production was widened i.e.
(Production is a creation of Utility)
Manufacturing:
Is the conversion of a design into a finished product
Production:
Is the physical act of making the product
Factory or Workshop:
A Place which executes manufacturing
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Flows of Manufacturing
1. Flow of Material: (F.O.M)
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Flows of Manufacturing
1. Flow of Material: (F.O.M)
Raw materials are normally supplied by the outside supplier
throughout the process
• From External
Raw Material Supplier
Stored in • As Inventories
Warehouses
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Flows of Manufacturing
2. Flow of Information: (F.O.I)
Instead of just producing products
It is essential to grasp the market needs and Incorporate those
needs in the production process
This is the Management Function (Management Technology)
Manufacturing Technology:
Conducts Planning and Control (This is called F.O.M)
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Flows of Manufacturing
Flow of Cost: (F.O.C)
Through the Production Process: Raw materials are converted into
finished product with value added
This Value Added Process: Is the (Flow of Value) or (Economical
Production) or (F.O.C)
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3 Steps Towards Automation
Main objective of designing a Manufacturing system is to increase the
manufacturing efficiency and labor productivity. Following steps have
increased both:
1. Introduction of Tools
2. Mechanization
3. Automation
Tools
Have increased the manufacturing efficiency
They are then attached to the machine tools due to which the
manufacturing efficiency has further increased
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Steps Towards Automation
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Automation (Groover)
Automation is the technology by which a process or procedure is
accomplished without human assistance
How it is implemented
By using a program of instructions combined with a control system that
executes the instruction
Note:
Power is required to drive the process, program and control system
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Elements of an Automated System
Basic 3 Elements of an Automated System
Power (To accomplish the process and operate the system)
Program of Instructions (To direct the process)
Control System (To actuate the instructions)
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Kinds of Automation
There can be 3 directions in which automation can be brought
Automated flow type production (In Manufacturing Industries)
Automatic control of continuous production (In Process Industries)
Increase in business efficiency (By Computers)
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Kinds of Automation
Factory Automation (FA)
Mechanical and Process Automation are mainly concerned with
direct production processes that convert Raw material into
Products (Flow of Material)
This type of Automation is called Factory Automation
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Kinds of Automation
Low Cost Automation
Automation with a small amount of capital
This emphasize on standardized automatic equipment (Actuators,
Sensors etc.)
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Kinds of Automation
Low Cost Automation
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Kinds of Automation
High Level Automation / Extended Automation
Needs vast amount of Capital
Extended Automation
Design Automation
For speedy automatic design and drawing of parts and
products (CADD)
Laboratory Automation
For automatic measurements, collection and analysis of Test
Data
Store/Sales Automation
For sales management by computers using (POS) point of
sale, techniques
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Kinds of Automation
High Level Automation / Extended Automation
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Computer Integrated Manufacturing
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Automated Manufacturing Systems
Examples:
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots that perform processing or
assembly operations
Automated material handling and storage systems to
integrate manufacturing operations
Automatic inspection systems for quality control
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Transfer Lines
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Transfer Lines
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Automated Assembly Systems
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Industrial Robots
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Automated MHSR Systems
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Automated Inspection Systems
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Automated Manufacturing Systems
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Fixed Automation (Hard Automation)
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Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration
Typical features:
Suited to high production quantities
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodating product variety
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Fixed Automation
Low Production cost and high volumes, but,
With minimal variety and high changes cost (The change
overs)
Hard Automation (Automation for Mass Production)
Produces large number of nearly identical parts
High initial investments (For custom engineered
equipment)
Product Design must be stable (over its life)
Examples
Assembly lines, Transfer Lines
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Fixed Automation
Advantages
Equipment fine-tuned to application (Dedicated to particular
application)
Decreased Cycle Time
Infrequent Setups
Automated Material Handling
Fast and efficient movement of parts
Low W.I.P (Work In Process)
Disadvantage
Inflexible (Setup changes are not easy)
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Programmable Automation (Soft Automation)
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Programmable Automation (Soft Automation)
Typical features:
High investment in general purpose equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in
product configuration
Most suitable for batch production
Physical setup and part program must be changed
between jobs (batches)
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Programmable Automation
Economically producing a wide variety of low volume
products in small Batches
Examples
CAD/CAM Systems
NC/CNC Machines
Industrial Robots (Arms)
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Programmable Automation
Programmable Automation
Sequence controlled by a program
High Investments (In general purpose equipment)
Lower Production Rates
Flexibility to deal with variation
Suitable for Batch Production
Smaller volumes then Fixed Automation (for many different parts)
More flexible then Fixed Automation
Disadvantages
Setups are required to each new part
Large batch size (Due to Setups)
Speed sacrificed for flexibility (Production Rates)
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Flexible Automation
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Flexible Automation
An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs
Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of products
Medium production rates
Flexibility to deal with soft product variety
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Flexible Automation
Require less changeover time and allow continuous
operation of equipment and product variety
Examples
Manufacturing Cell
FMS
Automated Retrieval and Storage
Automated Guided Vehicles
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Flexible Automation
Extension of Programmable Automation
No time lost for change over
High investments (In custom engineered systems)
Production of Product Mix (Product Varieties)
Flexibility to deal with design variations
Low to Medium quantities (Production Quantity)
Programming and Setup performed OFF-LINE
More expensive
Size and Tool change capabilities
Small batch sizes are justified
Reduced WIP and Lead Times
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Product Variety and Production
Quantity for Three Automation Types
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Levels of Automation
1. Device level – actuators, sensors, and other hardware
components to form individual control loops for the next
level
2. Machine level – CNC machine tools and similar
production equipment, industrial robots, material handling
equipment
3. Cell or system level – manufacturing cell or system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system
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Levels of Automation
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Levels of Automation
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Computerized Manufacturing
Support Systems
Objectives of automating the manufacturing support
systems:
To reduce the manual and clerical effort in product
design, manufacturing planning and control, and the
business functions
Integrates computer-aided design (CAD) and computer-
aided manufacturing (CAM) in CAD/CAM
CIM includes CAD/CAM and the business functions of
the firm
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Reasons for Automating
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Manual Labor in
Factory Operations
The long term trend is toward greater use of automated
systems to substitute for manual labor
When is manual labor justified?
Some countries have very low labor rates and
automation cannot be justified
Task is technologically too difficult to automate
Short product life cycle
Customized product requires human flexibility
To cope with ups and downs in demand
To reduce risk of new product failure
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Labor in Manufacturing
Support Systems
Product designers who bring creativity to the design task
Manufacturing engineers who
Design the production equipment and tooling
And plan the production methods and routings
Equipment maintenance
Programming and computer operation
Engineering project work
Plant management
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Manufacturing:
Technological Definition
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Manufacturing:
Technological Definition
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Manufacturing:
Technological Definition
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Manufacturing:
Economic Definition
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Manufacturing:
Economic Definition
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Classification of Industries
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Manufacturing Industries
International Standard Industrial Classification of All Economic Activities
ISIC Code
Food, beverages, tobacco 31
Textiles, apparel, leather and fur products 32
Wood and wood products, cork 33
Paper, printing, publishing, bookbinding 34
Chemicals, coal, petroleum, & their products 35
Ceramics, glass, mineral products 36
Basic metals, e.g., steel, aluminum 37
Fabricated products, e.g., cars, machines, etc. 38
Other products, e.g., jewelry, toys 39
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Process Industries and
Discrete Manufacturing Industries
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Types of Manufacturing
The key factor that determine the type of manufacturing is
the type of products that are made:
Continuous
Involves the continuous production of a product, often using
chemical as well as Physical or Mechanical means
(Production of Fertilizer or Sugar)
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Types of Manufacturing
Discrete
Involves the production of individual items and is further
divided into Mass, Batch and Job-Shop Production
Job-shop (Low Production)
Quantities in the range of (1 – 100) Units per year
Batch (Medium Production)
Quantities ranges between (100 – 10,000) Units per year
Mass (High Production)
Quantities range is 10,000 and above
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Relation between Product Variety and
Production Quantity
Inverse relation exists between the two
When product variety is high, production quantity tends to be low
(Change over time losses)
Production Quantity
Mass
Batch
Job-Shop
Product Variety
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Product Variety
The differences in the designs or shapes of the products may
be small or great
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Product Variety
Hard Product Variety
If the products differ substantially
If the proportion of common parts are very low OR there may be no
common parts
Difference between a CAR and TRUCK (HARD)
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Types of Production
Two types of Production Modes can be adopted
Production to Order (PTO)
Production to Stock (PTS)
PTO
Production of items is based upon customer’s order
PTS
Products are made in advance and then stored as
Inventory, and shipped as orders are received
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Types of Production
PRODUCTION TO STOCK (PTS)
Production processes
Kinds of operations
Kinds and volumes of resources (Raw Materials)
The above key parameters are known in advance, which results in
easy Production Planning
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POLICY
Operate a MTO or ETO Policy
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Job Shop Production??
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Batch Production
Definition
Production of a product in small batches or lots by a series of operations,
each operation being carried out on the whole batch before any
subsequent operation is started on that batch
Characteristics
Main characteristic is medium volume production run of range of Products
Production system (should be reasonably flexible)
General purpose equipment (In order to accommodate fluctuations in
demand)
Large product variety (Hence, has almost the same complexity of the Job-
Shop)
POLICY
Usually uses MTS policy
Can be MTO Dr. S.A.Shah
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Batch Production??
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Mass Production
Major Characteristic is Large Volume Production Runs OF relatively few
Products
Products are highly standardized (level of STANDARDIZATION is High)
Demand is stable for the product
Stable Product Designs (Changes are very rare and little)
Production Facilities consists of:
Highly specialized and dedicated machines, plus associated Tooling
Machines are expensive (However, cost is allocated over very long
Production Runs)
Customer Delivery Time (Low)
Product Life Cycle (Long and Predictable)
Customer Interaction (Low)
POLICY
Uses MTS Policy Dr. S.A.Shah
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Mass Production
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Mass Production
Mass production has two categories:
Quantity Production
Flow Line Production
Quantity Production
Involves mass production of single part on single piece of equipment
Uses standard machines with special tools
Example: (Stamping Machines with Dies)
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Types of Discrete Production
(a) Job shop, Q = 1, (b) batch production, sequential, (c) batch production,
simultaneous, (d) quantity mass production, (e) flow line mass production
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Process Types - Products
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Toyota Mirai production line
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Manufacturing Policies
1. Make to stock (MTS)
2. Assemble to order (ATO)
3. Make to order (MTO)
4. Engineer to order (ETO)
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Manufacturing Policies
Make to stock (MTS)
Manufacture of Products is based on well-known and predictable
demand pattern
Production Volume of each unit is High
Customer Delivery Time (SHORT) [Finished Goods Inventory]
Advantage
Short Delivery Time
Product Life Cycles (Predictable and Long)
Disadvantage
Inventory Costs are High
Customer’s Interaction is Distant i.e. customer’s Input (only to
sales department)
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Manufacturing Policies
Assemble to order (ATO)
Sub-assemblies of the product are made and stocked
After the receipt of order, they are assembled
Delivery Time (Medium)
Delivery Time (is based on the availability of the Major sub-
assemblies)
Assembly only takes place on the receipt of the customer order
Customer’s Input is limited (Sales Department)
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Manufacturing Policies
Make to order (MTO)
Manufacture of the product begins upon the receipt of order
Many of the base components are available along with engineering
designs
The product is not actually completely specified
Configuration of the product may change from the initial
specifications during the processing period
Customer’s Interaction is Extensive (Involves sales and
Engineering)
Delivery Time ranges from Medium to Large (Depends on
capacities of the system)
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Manufacturing Policies
Engineer to order (ETO)
Extension of MTO
Engineering design of the product is based on the
customer’s requirement and specifications
Customer’s Interaction (is even more extensive then
MTO)
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Manufacturing Policies
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Manufacturing Strategy & Lead Time
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Manufacturing Operations
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Processing Operations
Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
4. Material removal processes
5. Additive manufacturing (a.k.a. rapid prototyping)
Property-enhancing operations (heat treatments)
Surface processing operations
Cleaning and surface treatments
Coating and thin-film deposition
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Assembly Operations
Joining processes
Welding
Brazing and soldering
Adhesive bonding
Mechanical assembly
Threaded fasteners (e.g., bolts and nuts, screws)
Rivets
Interference fits (e.g., press fitting, shrink fits)
Other
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Material Handling and Storage
Material transport
Vehicles, e.g., forklift trucks, AGVs, monorails
Conveyors
Hoists and cranes
Storage systems
Automatic identification and data capture (AIDC)
Bar codes
RFID
Other AIDC
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Inspection and Testing
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Production Facilities and Layout
Facilities organised in the most efficient way to serve the
particular mission of the plant and depends on:
Types of products manufactured
Production quantity
Product variety
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Product Variety (P)
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Product Variety vs
Production Quantity
P
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Low Production Quantity
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Fixed-Position Layout
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Fixed-Position Layout
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Process Layout
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Medium Production Quantities
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Cellular Layout
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High Production
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Product Layout
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Process and Product Layout
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Product/Production Relationships
P
Total number of product units = Qf = Q j
Qj = annual quantity of variety ‘j’ j 1
Simplified:
Total number of product units Qf = PQ
Total number of parts produced npf = PQnp
Total number of operations nof = PQnpno
where
P = Product variety
Q = Product quantity
np = Number of parts in product
no = Number of operations in product
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Effect of Number of Parts
and Number of Operations
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Worked Problem
The ABC Company is planning a new product line and will build a
new plant to manufacture the parts for a new product line. The
product line will include 50 different models. Annual production of
each model is expected to be 1000 units. Each product will be
assembled of 400 components. All processing of parts will be
accomplished in one factory. There are an average of 6 processing
steps required to produce each component, and each processing
step takes 1.0 minute (includes an allowance for setup time and part
handling). All processing operations are performed at workstations,
each of which includes a production machine and a human worker. If
each workstation requires a floor space of 250 m2, and the factory
operates one shift (2000 hr/yr), determine (a) how many production
operations, (b) how much floor space, and (c) how many workers will
be required in the plant.
Dr. S.A.Shah
Solution
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Problem 2.4
The XYZ Company is planning to introduce a new product line and will build
a new factory to produce the parts and assembly the final products for the
product line. The new product line will include 100 different models. Annual
production of each model is expected to be 1000 units. Each product will be
assembled of 600 components. All processing of parts and assembly of
products will be accomplished in one factory. There are an average of 10
processing steps required to produce each component, and each processing
step takes 30 sec. (includes an allowance for setup time and part handling).
Each final unit of product takes 3.0 hours to assemble. All processing
operations are performed at work cells that each includes a production
machine and a human worker. Products are assembled on single
workstations consisting of two workers each. If each work cell and each
workstation require 200 ft2, and the factory operates one shift (2000 hr/yr),
determine: (a) how many production operations, (b) how much floorspace,
and (c) how many workers will be required in the plant.
If the company were to operate three shifts (6000 hr/yr) instead of one shift,
determine the answers to (a), (b), and (c).
Dr. S.A.Shah
Solution
Solution:
(a) Qf = PQ = 100(1000) = 100,000 products/yr
Number of final assembly operations = 100,000 assy.opns/yr
Number of processing operations nof = PQnpno = 100(1000)(600)(10) =
600,000,000 proc.opns/yr
(c) Total processing operation time = (600 x 106 ops)(0.5 min./(60 min./hr)) =
5,000,000 hr/yr.
Total assembly operation time = (100 x 103 asby ops)(3 hr/product) = 300,000
hr/yr
Total processing and assembly time = 5,300,000 hr/yr
5,300,000hr / yr
At 2000 hours/yr per worker, w = 2000hr / wor ker = 2650 workers.
(b) With 1 worker per workstation for processing operations, n = w = 2500 =
2500 workstations.
With 2 workers per stations for assembly, n = w/2 = 150/2 = 75 workstations.
Total floor space A = (2575 stations)(200 ft2/station) = 515,000 ft2
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Solution
(a) Same total number of processing and assembly operations but
spread over three shifts.
Number of final assembly operations = 100,000 assy.opns/yr
Number of processing operations nof = PQnpno = 100(1000)(600)(10) =
600,000,000 proc.opns/yr
(c) Same total number of workers required but spread over three
shifts.
Total workers w = 2650 workers. Number of workers/shift = w/3 =
883.33 884 workers/shift.
(b) Number of workers for processing operations = 2500/3 = 833
worker per shift (884 on one shift)
Number of workers for assembly = 150/3 = 50 workers per shift.
Number of workstations n = 833 + 50/2 = 858 (859 on one of the
shifts).
Using the higher number, Total floor space A = (859 stations)(200
ft2/station) = 171,800 ft2
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Cycle time Tc
Production rate Rp
Availability A
Production capacity PC
Utilization U
Manufacturing lead time MLT
Work-in-progress WIP
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Operation Cycle Time
where
Tc = cycle time
To = processing time for the operation
Th = handling time (e.g., loading and unloading the
production machine), and
Tth = tool handling time (e.g., time to change tools)
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(a) Job shop, Q = 1, (b) batch production, sequential, (c) batch production,
simultaneous, (d) quantity mass production, (e) flow line mass production
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Production Rate
Batch production:
batch time Tb = Tsu + QTc
Average production time per work unit Tp = Tb/Q
Production rate Rp = 1/Tp
Job shop production:
For Q = 1, Tp = Tb = Tsu + Tc
For quantity high production:
Rp = Rc = 60/Tp since Tsu/Q 0
For flow line production
Tc = Tr + Max To and Rc = 60/Tc
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Availability
MTBF MTTR
Availability: A
MTBF
Where
MTBF = mean time between failures, and
MTTR = mean time to repair
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Availability
Key: MTBF = mean time between failures, MTTR = mean time to repair.
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Production Capacity
Defined as the maximum rate of output that a production
facility (or production line, or group of machines) is able
to produce under a given set of operating conditions
When referring to a plant or factory, the term plant
capacity is used
Assumed operating conditions refer to:
Number of shifts per day
Number of hours per shift
Employment levels
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Plant Capacity
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Utilization
Defined as the proportion of time that a productive resource
(e.g., a production machine) is used relative to the time
available under the definition of plant capacity
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Work-In-Process
Where
WIP = work-in-process, pc
Rpph = hourly plant production rate, pc/hr
MLT = manufacturing lead time, hr
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Manufacturing Costs
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Fixed and Variable Costs
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Manufacturing Costs
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Typical Manufacturing Costs (J Black)
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Overhead Rates
FOHC
FOHR =
DLC
Corporate overhead rate:
COHC
COHR =
DLC
Where
DLC = direct labor costs
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Cost of Equipment Usage
Where
Co = hourly rate, $/hr
CL = labor rate, $/hr
FOHRL = labor factory overhead rate
Cm = machine rate, $/hr
FOHRm = machine factory overhead rate
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Manufacturing Lead Time
•Operating Times
•Non-operating Times
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e.g.
Set-up Time
5% 95%
On Machine Moving and Waiting
Time
1.5% of total time - adds value
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Manufacturing Lead Time
n1 n2 n3
Time
Operation Time
Non-operation Time
MLT = nm ( To + Tno )
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n1 n2 n3
Q = Number of parts
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Manufacturing Lead Time
n1 n2 n3
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Order #1
Order #2
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Manufacturing Lead Time
In practice
nq
Qi
i 1
Q
nQ
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Operation Times
To = Tm + Th + Tth
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Rate of Production
Tsu + QTo
Tp = Tsu + QTo
Q
• Rate of Production
Rp = 1/Tp
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Lead Times
nq
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Production Capacity
Production Capacity, Pc
Pc = WSwHRp
Pc = WSwHRp / Nm
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Demand Rate
Dw = WSwHRp / Nm
WSwH = DwNm/ Rp
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Work In Progress
Generally:
WIP = PC U (MLT) / Sw H
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WIP Ratio
PC U (MLT)
Sw H
WIP Ratio =
QTo
WU
Tsu + QTo
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Worked Problem
The average part produced in a certain batch manufacturing plant must
be processed sequentially through six machines on average. Twenty
(20) new batches of parts are launched each week. Average
operation time = 6 min., average setup time = 5 hours, average batch
size = 25 parts, and average non-operation time per batch = 10
hr/machine. There are 18 machines in the plant working in parallel.
Each of the machines can be set up for any type of job processed in
the plant. The plant operates an average of 70 production hours per
week. Scrap rate is negligible. Determine (a) manufacturing lead time
for an average part, (b) plant capacity, (c) plant utilization. (d) How
would you expect the nonoperation time to be affected by the plant
utilization?
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Solution
(a) MLT = 6(5 + 25(0.1) + 10) = 105 hr
(b) Tp = (5 + 25 x 0.1)/25 = 0.30 hr/pc, Rp = 3.333 pc/hr.
PC = 70(18)(3.333)/6 = 700 pc/week
(c) Parts launched per week = 20 x 25 = 500 pc/week.
Utilization U = 500/700 = 0.7143 = 71.43%
(d) As utilization increases towards 100%, we would expect
the nonoperation time to increase. When the workload in
the shop grows, the shop becomes busier, but it usually
takes longer to get the jobs out. As utilization decreases,
we would expect the nonoperation time to decrease.
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Utilisation
Utilisation, U = Output/Capacity
Q
Utilization: U =
PC
where
Q = quantity actually produced
PC = plant capacity
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Availability
MTBF MTTR
Availability: A =
MTBF
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Costs of Manufacturing Operations
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Storage Buffers
Storage Buffer can be manually operated or Automated
It may be located between each pair of adjacent Stations or between
Line stages (containing multiple stations)
B.S B.S
m/c m/c m/c m/c
In Put Out Put
Stage 1 Stage 2
B.S
Line Stages Out Put
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Interference (Blocking/Starving)
In a production line with no internal parts storage, the
workstations are interdependent i.e.
When one station breaks down, all other stations on the line are
effected
This phenomenon definitely effects the productivity of the line
The phenomenon is called Interference
Interference may be in the form of Blocking or Starving
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Interference (Blocking/Starving)
Blocking
When station “i” can not release its part to station “i+1”
Starving
When station “i” can not obtain a part from station “i-1”
In either case statin “i” is IDLE during this period even if it is not
malfunctioning and would be able to produce, if it had a part to
operate on
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Storage Buffers
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Storage Buffers
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Storage Buffers
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Storage Buffers
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Blocking, Starving, Buffers
Assume that these are random processing times.
Process Flow
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Manual Assembly Line
Configuration of a manual assembly line with n manually operated workstations
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Typical Products
Made on Assembly Lines
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Manual Assembly Line
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Assembly Workstation
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Line Pacing
A manual assembly line operates at a certain cycle time -
On average, each worker must complete his/her assigned
task within this cycle time
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Coping with Product Variety
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Some Definitions
Work flow
Each work unit should move steadily along the line
Line pacing
Workers must complete their tasks within a certain
cycle time, which will be the pace of the whole line
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Manning Level
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Manning Level
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Manning level
w
Average manning level: M
n
Practically, average manning level: n
wu wi
i 1
M
n
where
M = average manning level of the line,
wu= number of utility workers assigned to the system,
n = number of workstations,
wi = number of workers assigned specifically to station i for
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Work Transport Systems-Manual Methods
Manual methods
Work units are moved between stations by the workers (by hand)
without powered conveyor
Problems:
Starving of stations
The assembly operator has completed the assigned task on
the current work unit, but the next unit has not yet arrived at the
station
Blocking of stations
The operator has completed the assigned task on the current
work unit but cannot pass the unit to the downstream station
because that worker is not yet ready to receive it
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To reduce starving
use buffers
To prevent blocking
provide space between upstream and downstream stations
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Assembly Line Balancing
The purpose of the assembly line balancing technique is:
to
Station Station Station warehouse
or
1 2 3 retailer
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The Assembly Line Balancing Concept
If the cycle time were 10 minutes, each station would hand its work-in-process
unit over to the next station at the end of 10 minutes
to
Station Station Station warehouse
or
1 2 3 retailer
The effective production rate for the assembly line equals one completed
product every 10 minutes, even though each unit requires 30 minutes to build!
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The Assembly Line Balancing Concept
It is impossible to as-
sign tasks to all work
stations so as to get
exact work times at
each station per cycle.
Therefore, a perfectly
balanced assembly line
does not exist !
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Analysis of Single Model Lines
The assembly line must be designed to achieve a production rate
sufficient to satisfy the demand.
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Analysis of Single Model Lines
Rc < Rp [Ideal cycle rate must be less than required production rate]
Work content time (Twc): The total time of all work elements that
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must be performed to produce one unit of the work unit.
Twc WL RpTwc
w* = Minimum Integer w
Tc AT 60 E
where
Twc = work content time, min;
Tc = cycle time, min/station
If we assume one worker per station then this gives the minimum
number of workers
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Theoretical Minimum Not Possible..
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Repositioning Losses
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Repositioning Losses
Ts Tc Tr
Repositioning efficiency Er =
Tc Tc
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Line Balancing Problem
Given:
Total work content consists of many distinct work
elements
The sequence in which the elements can be performed
is restricted
The line must operate at a specified cycle time
Problem:
To assign the individual work elements to workstations
so that all workers have an equal amount of work to
perform
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Work Element Times
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Precedence Constraints
Precedence
diagram
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Work elements are assigned to the stations, such that assembly cost
is minimized:
Labor Cost
Idle Time Cost
Idle Time Minimization (Focus)
Production Constraints (Limits)
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Concepts in Line Balancing
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Terminology used in Line Balancing
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Precedence Constraints:
The restrictions of the sequence in which the job must be
accomplished
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Terminology used in Line Balancing
Precedence Diagram
A network showing order of tasks and restrictions on their
performance
Graphical representation of the sequence of work elements as
defined by the precedence constraints
Shows the sequence in which the work elements must be
performed
Nodes: Represents the work element
Arrows: Indicates the order in which the elements must
be performed
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Example of Line Balancing Problem
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Example: A problem for line balancing
Determine
(a) total work content time,
(b) required hourly production rate to achieve the annual demand,
(c) cycle time,
(d) theoretical minimum number of workers required on the line,
(e) service time to which the line must be balanced.
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Example: Solution
(a) The total work content time is the sum of the work
element times given in the table ne
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Measures of Balance Efficiency
Twc
Eb = Perfect line: Eb = 1
wTs
wTs Twc
d= Perfect line: d = 0
wTs
Overall Efficiency
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Overall Efficiency
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Largest Candidate Rule
1. List all work elements in descending order based on their Tek values;
then,
2. Start at the top of the list and selecting the first element that satisfies
precedence requirements and does not cause the total sum of Tek to
exceed the allowable Ts value
3. When an element is assigned, start back at the top of the list and repeat
selection process
5. Repeat steps 2 and 3 until all elements have been assigned to as many
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stations as needed
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Solution for Largest Candidate Rule
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Solution for Largest Candidate Rule
Solution to line
balancing example:
a) Assignment of work
elements
b) Physical sequence
of stations with
assigned work
elements
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Example:
Balance Efficiency
Twc 4.0
Eb 0.80
wTs 5(1.0)
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Kilbridge and Wester Method
First, the work elements are arranged into columns in the precedence
diagram
Organize the elements into a list according to their columns, with
the elements in the first column listed first
If an element can be located in more then one column, then list all
the columns for that element (In this case element 5 & 8)
Column wise list should be in order of Tek values
When the list is completed, proceed with same steps 1, 2, and 3 as
in the largest candidate rule
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Kilbridge and Wester Method
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Analysis of single model assembly lines
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Work elements are then organized into a list according to their RPW
values, starting with the element that has the highest RPW value
Example:
RPW 11 = 0.5+0.12 = 0.62
RPW 08 = 0.6+0.27+0.38+0.5+0.12 = 1.87
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Ranked Positional Weights (RPW)
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Analysis of single model assembly lines
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Summary
1. Determine Maximum Output
OT (Operating per day)
CT (Cycle time)
D (Desired time)
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Process
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Process Analysis
Why do we need to analyze the process?
To identify inefficient tasks
To spot possible effectiveness improvement tasks
To understand where value can be added
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Holding:
Raw Materials, RM
Work in Process, WIP
Finished Goods Inventory, FGI
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MTO vs MTS
FGI
Task 1 Task 2
Demand
Task 1 Task 2
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How do we measure capacity?
Capacity of a task is the physical limitation in terms of “how much can
be processed at this task”
Cycle Time:
Average time for completion of a unit at a production step or
process. Does not include waiting. Measured as time/unit
Throughput Rate:
Average number of units processed over a time interval.
Measured as units/time
1
Throughput rate =
Cycle Time
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Example:
Producing 100 cars. On average, production takes 5 hours
per car. It takes 50 hours to set up the production line
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Computing Cycle Times
A B
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What is a bottleneck?
Bottleneck is the process stage with the smallest
throughput rate (longest cycle time)
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Capacity of a process
The capacity of the process is:
minimum throughput rate at any of the stages
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Throughput Time
Throughput Time:
Average time that a unit takes to go through the entire process
(including waiting time). Measured as time
Work in Process(WIP):
Average number of units in system over a time interval. Measured
as units
WIP
Throughput time =
Throughput rate
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Example : hammer production process
Description
1. Work begins at the machining center. Here two lines form the
heads of the hammers and place them in a buffer.
2. Handles are attached at the assembly step.
3. Finished hammers are sent to the next stage, where they are
packed and shipped.
machining
pack and
assembly
ship
machining
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Analysis
machining
pack and
assembly
ship
machining
Process Data:
Machining: Set up 80 min. 4 min per unit processing. Batch size
200. Identical lines.
Assembly: Manual by two workers (no set up). Each hammer
requires 40 min processing. 34 workers available.
Pack and ship: 30 min set up, 2 min per unit processing. Lot sizes
of 100.
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Step 1: Machining
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Step 2: Assembly
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Step 3: Pack and ship
Similar to machining:
30 + 100 2 = 230 min/100 units
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Machining 27.26
Assembly 25.50
Assembly is the
bottleneck!
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Process Performance Metrics
=
=
=
=
=
=
=
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= ×
OR
= ×
That is:
= ×
=
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Chapter
Computer Numerical Control
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Development of Machine Tools
NC System (continued…)
The shorter the straight line, the smoother is the curve
Each line segment in the step had to be calculated
This problem led to the development of APT language
APT
A special programming Language for NC that uses statements to:
1. Define the part geometry
2. Describe the cutting tool configuration
3. Specify the necessary motions
Instructional programs had to be written on punch paper, later
replaced by magnetic plastic tapes
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Basic Components of an NC System
1. Program of instructions
Called a part program in machining
2. Machine control unit
Controls the process
3. Processing equipment
Performs the process
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Development of Machine Tools
NC System
Programs had to be stored on punch cards
Paper tapes were easy to damage and difficult to edit or correct
This lead to the development of DNC System (Direct)
DNC System (Direct Numerical Control)
Developed after development of computers
Host computer controls several machines
Programs were to be stored on the Host computer and through
data transmitted cables, these programs had to be sent to the
computers
Problem: If the host computer goes down, all machines had to
stop OR if some damage to the data cable
This problem lead to the development of CNC systems
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Development of Machine Tools
Direct Numerical Control
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Development of Machine Tools
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Computer Numerical Control (CNC)
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NC Coordinate Systems
(a) For flat and block-like parts and (b) for rotational parts
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Rotations:
The thumb represent the X, Y, or Z axis direction
The curl of the fingers represent the clockwise, or positive, rotation
about each axis
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Motion Control Systems
1. Point-to-Point systems
Also called positioning systems
System moves to a location and performs an operation at that
location (e.g., drilling)
Also applicable in robotics
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Point-To-Point Control
NC drilling of
three holes
in flat plate
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Continuous Path Control
NC profile milling
of part outline
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Interpolation Methods
1. Linear interpolation
Straight line between two points in space
2. Circular interpolation
Circular arc defined by starting point, end point, center
or radius, and direction
3. Helical interpolation
Circular plus linear motion
4. Parabolic and cubic interpolation
Free form curves using higher order equations
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Interpolation Methods
1. Linear interpolation
2. Circular interpolation
3. Helical interpolation
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1. Absolute positioning
Locations defined relative to origin of axis system
1. Incremental positioning
Locations defined relative to previous position
Example: drilling
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Absolute vs. Incremental Positioning
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DNC
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General Configuration of a Direct Numerical
Control System
Connection to MCU is behind the tape reader (BTR). In distributed NC, entire
programs are downloaded to each MCU, which is CNC rather than
conventional NC
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Distributed Numerical Control Configurations
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Applications of NC
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a. Turning
b. Drilling
c. Milling
d. Grinding
Turning
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CNC Four-Axis
Horizontal Milling Machine
(a) With safety panels installed and (b) safety panels removed to
show typical axes configuration
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NC Application Characteristics
(Machining)
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Other Applications of NC
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Advantages of NC
Nonproductive time is reduced
Greater accuracy and repeatability
Lower scrap rates
Inspection requirements are reduced
More complex part geometries are possible
Engineering changes are easier to make
Simpler fixtures
Shorter lead times
Reduce parts inventory and less floor space
Operator skill-level requirements are reduced
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Disadvantages of NC
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Motion Control Systems
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Optical Encoder
Device for measuring rotational position and speed: (a) apparatus and
(b) series of pulses to measure rotation
Common feedback sensor for closed-loop NC control
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Part Programming
Program
A program is a set of instructions or commands given to a computer
Part program
A program that is used for machining a part
Program consists of
Dimensional data – the size and shape of the component
Technological data – Sequence of operations, Cutting speed,
feed rate etc.
Miscellaneous data – Coolant ON / OFF, Spindle ON / OFF,
Tool CLAMP /UNCLAMP etc.
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Block Format
Organization of words within a block in NC part program
Word address format - used on all modern CNC
controllers
Uses a letter prefix to identify each type of word
Spaces to separate words within the block
Allows any order of words in a block
Words can be omitted if their values do not
change from the previous block
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Types of Words
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Example: Word Address Format
N001 G00 X70 Y30 M03
N002 Y60
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CNC Codes
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CNC Codes
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CNC Codes
Letter Addresses: are variables used in G and M-codes to make
words. Most G-codes contain a variable, defined by the programmer,
for each specific function
N Block number
G Preparatory function
X X axis coordinate
Y Y axis coordinate
Z Z axis coordinate
I X axis location of arc center
J Y axis location of arc center
K Z axis location of arc center
S Sets the spindle speed
F Assigns a feed rate
T Specifies tool to be used
M Miscellaneous function
U Incremental coordinate for X axis
V Incremental coordinate for Y axis
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Common Word Prefixes Used in Word
Address Format
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Common G-words (Preparatory Word)
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Common M-words Used in Word
Address Format
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G-FUNCTION
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G-FUNCTION
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G-FUNCTION
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G-FUNCTION
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G-FUNCTION
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G-FUNCTION
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Block Format (Part Program)
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Class Practice
%
N10 T104 M06
N20 G97 S2000 G95 F0.1 M03
N30 G00 X18 Z2 M08
N40 G01 Z-22
N50 G01 X26
N60 G00 X200 Z200 M09
N70 M30
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Simple G Code Example CNC Lathe
O0001 Code Explanation
N5 M12 N5 Clamping workpiece
N10 T0101 N10 Changing No.1 tool and executing its offset
N15 G0 X100 Z50 N15 Rapidly positioning to A point
N20 M3 S600 N20 Starting the spindle with 600 r/min
N25 M8 N25 Cooling ON
N30 G1 X50 Z0 F600 N30 Approaching B point with 600mm/min
N40 W-30 F200 N40 Cutting from B point to C point
N50 X80 W-20 F150 N50 Cutting from C point to D point
N60 G0 X100 Z50 N60 Rapidly retracting to A point
N70 T0100 N70 Canceling the tool offset
N80 M5 N80 Stopping the spindle
N90 M9 N90 Cooling OFF
N100 M13 N100 Releasing workpiece
N110 M30 N110 End of program, spindle stopping and Cooling OFF
N120 %
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%
N10 T105 M06 D2500
N20 G96 S150 G95 F.2 M04
N30 G00 X32 Z34 M08
N40 G01 X-1
N50 G00 X29.6 Z36
N60 G01 Z24
N70 G02 X39.6 Z19 R5
N80 G03 X49.6 Z14 R5
N90 G01 X53.6 Z12
N100 G01 Z-1
N110 G00 X200 Z200 M09
N120 M30
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Simple G Code Example CNC Milling
% (Indicates start of program)
N005 G90 G70 (Specifies absolute dimensions, inch units)
N010 G97 G94 T01 (Specifies units for speed and feed rate; loads first tool)
N015 G00 X1000 Y3000 Z250 F0 (Rapid positioning of tool to start point)
N020 G01 Z-375 M03 S500 F10 (Turns on spindle, feeds tool to required depth)
N025 Y750 (Machines the vertical portion of the L)
N030 X2500 (Machines the horizontal portion of the L)
N035 Z250 (Retracts tool to 0.25 in above part surface)
N040 G00 X-1000 Y-1000 (Moves to safe location at rapid rate)
N045 M30 (Turns off all machine functions)
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Circular Interpolation
N20 G50 S2000 T0300
G96 S200 M03
G42 G00 X35.0 Z5.0 T0303 M08
G01 Z-20.0 F0.2
G02 X67.0 Z-36.0 R16.0
G01 X68.0 :
G03 X100.0 Z-52.0 R16.0
G01 Z-82.0
G40 G00 X200.0 Z200.0 M09 T0300
M30
Below is the same CNC program but this version uses I & K with G02 G03 G code.
N20 G50 S2000 T0300
G96 S200 M03
G42 G00 X35.0 Z5.0 T0303 M08
G01 Z-20.0 F0.2
G02 X67.0 Z-36.0 I16.0 K0
G01 X68.0 :
G03 X100.0 Z-52.0 I0 K-16.0
G01 Z-82.0
G40 G00 X200.0 Z200.0 M09 T0300
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M30
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Workpiece Size: X5, Y4, Z1
Tool: Tool #3, 1/4" End Mill
Tool Start Position: X0, Y0, Z1 (Relative to workpiece)
%
:1001
N5 G90 G20
N10 M06 T3
N15 M03 S1200
N20 G00 X1 Y1
N25 Z0.125
N30 G01 Z-0.125 F5
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Workpiece Size: X5, Y4, Z1
Tool: Tool #2, 1/4" End Mill
Tool Start Position: X0, Y0, Z1 (Relative to workpiece)
%
:1001
N5 G90 G20
N10 M06 T3
N15 M03 S1200
N20 G00 X1 Y1
N25 Z0.125
N30 G01 Z-0.125 F5
N35 X4 F20
N40 Y3
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Workpiece Size: X5, Y4, Z1
Tool: Tool #2, 1/4" End Mill
Tool Start Position: X0, Y0, Z1 (Relative to workpiece)
%
:1001
N5 G90 G20
N10 M06 T3
N15 M03 S1200
N20 G00 X1 Y1
N25 Z0.125
N30 G01 Z-0.125 F5
N35 X4 F20
N40 Y3
N45 X1 Y1
N50 Y3
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Workpiece Size: X5, Y4, Z1
Tool: Tool #2, 1/4" End Mill
Tool Start Position: X0, Y0, Z1 (Relative to workpiece)
%
:1001
N5 G90 G20
N10 M06 T3
N15 M03 S1200
N20 G00 X1 Y1
N25 Z0.125
N30 G01 Z-0.125 F5
N35 X4 F20
N40 Y3
N45 X1 Y1
N50 Y3
N55 X4 Y1
N60 G00 Z1
N65 X0 Y0
N70 M05
N75 M30
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Phases of a CNC Program
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VMC
Sample Program :
Workpiece Size: X6,Y4,Z1
Tool: Tool #2, 1/4" Slot Drill
Tool Start Position: X0,Y0,Z1
% (Program start flag)
:1001 (Program number 1001)
N5 G90 G20 (Absolute and inch programming)
N10 M06 T2 (Tool change, Tool #2)
N15 M03 S1200 (Spindle on CW, at 1200 rpm)
N20 G00 X1 Y1 (Rapid over to X1,Y1)
N25 Z0.1 (Rapid down to Z0.1)
N30 G01 Z-0.25 F5 (Feed move down to a depth of 0.25 in.)
N35 Y3 (Feed move to Y3)
N40 X5 (Feed to X5)
N45 X1 Y1 Z-0.125 (Feed to X1,Y1,Z–0.125)
N50 G00 Z1 (Rapid up to Z1)
N55 X0 Y0 (Rapid over to X0,Y0)
N60 M05 (Spindle off)
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N65 M30 (End of program)
VMC
Sample Program (G01):
Workpiece Size: X4, Y3, Z1
Tool: Tool #3, 3/8" Slot Drill
Tool Start Position: X0, Y0, Z1
% (Program start flag)
:1002 (Program #1002)
N5 G90 G20 (Block #5, absolute in inches)
N10 M06 T3 (Tool change to Tool #3)
N15 M03 S1250 (Spindle on CW at 1250 rpm)
N20 G00 X1.0 Y1.0 (Rapid over to X1,Y1)
N25 Z0.1 (Rapid down to Z0.1)
N30 G01 Z-0.125 F5 (Feed down to Z–0.125 at 5 ipm)
N35 X3 Y2 F10 (Feed diagonally to X3,Y2 at 10 ipm)
N40 G00 Z1.0 (Rapid up to Z1)
N45 X0.0 Y0.0 (Rapid over to X0,Y0)
N50 M05 (Spindle off)
N55 M30 (Program end)
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Turning
Turning
Sample Program G01:
Workpiece Size: Length 4", Diameter 2.5"
Tool: Tool #1, Right-hand Facing Tool
Tool Start Position: X2, Z3
%
:1001
N5 G90 G20 G40
N10 T0101
N15 M03
N20 G00 X2.375 M08
N22 Z0.1
N25 G01 Z-2.0 F0.015 (Feed to Z–2.0 at a feedrate of 0.015 ipr)
N30 G00 X2.5
N35 Z0.1
N40 X2.25
N45 G01 Z-1.75 (Feed to Z–1.75 at same feedrate)
N50 G00 X2.375
N55 Z0.1
N60 X2.125
N65 G01 Z-1.5 (Feed to Z–1.5 at same feedrate)
N70 G00 X2.25
N75 Z0.1
N80 X1.875
N85 G01 Z0 (Feed to 0 at same feedrate)
N90 X2.125 Z-0.125 (Feed to (X2.125, Z–1.125) at same feedrate)
N95 G00 X4 M09
N100 Z3
N105 T0100 M05
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N110 M30
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Circular Interpolation (G02/G03)
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Circular Interpolation
G02 X2 Y1 I0 J-1
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Circular Interpolation
G02 X2 Y1 R1
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Circular Interpolation
Sample Program (G02):
Workpiece Size: X4, Y3, Z1
Tool: Tool #2, 1/4" Slot Drill
Tool Start Position: X0, Y0, Z1
%
:1003
N5 G90 G20
N10 M06 T2
N15 M03 S1200
N20 G00 X1 Y1
N25 Z0.1
N30 G01 Z-0.1 F5
N35 G02 X2 Y2 I1 J0 F20 (Arc feed CW, radius I1,J0 at 20 ipm)
N40 G01 X3.5
N45 G02 X3 Y0.5 R2 (Arc feed CW, radius 2)
N50 X1 Y1 R2 (Arc feed CW, radius 2)
N55 G00 Z0.1
N60 X2 Y1.5
N65 G01 Z-0.25
N70 G02 X2 Y1.5 I0.25 J-0.25 (Full circle arc feed move CW)
N75 G00 Z1
N80 X0 Y0
N85 M05
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N90 M30
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Circular Interpolation
G03 CIRCULAR INTERPOLATION (CCW)
Format: N_ G03 X_ Y_ Z_ I_ J_ K_ F_ (I, J, K specify the radius)
G03 X1 Y1 I0 J-1
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G03 X1 Y1 R1
Circular Interpolation
Sample Program (G03).
Workpiece Size: X4, Y4, Z0.25
Tool: Tool #2, 1/4" Slot Drill
Tool Start Position: X0, Y0, Z1
%
:1004
N5 G90 G20
N10 M06 T2
N15 M03 S1200
N20 G00 X2 Y0.5
N25 Z0.125
N30 G01 Z-0.125 F5
N35 X3 F15
N40 G03 X3.5 Y1 R0.5 (G03 arc using R value)
N45 G01 Y3
N50 G03 X3 Y3.5 I-0.5 J0 (G03 arc using I and J)
N55 G01 X2
N60 G03 X2 Y1.5 I0 J-1 (180° arc using I and J)
N65 G01 Y0.5
N70 G00 Z0.1
N75 X1.5 Y2.5
N80 G01 Z-0.25 F5
N85 G03 X1.5 Y2.5 I0.5 J0 (Full circle using I and J)
N90 G00 Z1
N95 X0 Y0
N100 M05
N105 M30 Dr. S.A.Shah
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Circular Interpolation
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Chapter
Flexible Manufacturing Systems
Sections:
1. What is a Flexible Manufacturing System?
2. FMC/FMS Components
3. FMS Applications Considerations
4. Analysis of Flexible Manufacturing Systems
5. Alternative Approaches to Flexible Manufacturing
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Where to Apply FMS Technology
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Flexibility Tests in an Automated
Manufacturing System
To qualify as being flexible, a manufacturing system should
satisfy the following criteria (“yes” answer for each
question):
1. Can it process different part styles in a non-batch
mode?
2. Can it accept changes in production schedule?
3. Can it respond gracefully to equipment malfunctions
and breakdowns?
4. Can it accommodate introduction of new part
designs?
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Is the Robotic Work Cell Flexible?
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Types of FMS
Kinds of operations
Processing vs. assembly
Type of processing
If machining, rotational vs. non-rotational
Number of machines (workstations):
1. Single machine cell (n = 1)
2. Flexible manufacturing cell (n = 2 or 3)
3. Flexible manufacturing system (n = 4 or more)
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Flexible Manufacturing Cell
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Flexible Manufacturing System
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FMS Types
Level of Flexibility
1. Dedicated FMS
Designed to produce a limited variety of part styles
The complete universe of parts to be made on the
system is known in advance
Part family likely based on product commonality
rather than geometric similarity
2. Random-order FMS
Appropriate for large part families
New part designs will be introduced
Production schedule is subject to daily changes
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FMS Components
1. Workstations
2. Material handling and storage system
3. Computer control system
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Workstations
Load/unload station(s)
Factory interface with FMS
Manual or automated
Includes communication interface with worker to
specify parts to load, fixtures needed, etc.
CNC machine tools in a machining type system
CNC machining centers
Milling machine modules
Turning modules
Assembly machines
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Functions:
Random, independent movement of parts
between stations
Capability to handle a variety of part styles
Standard pallet fixture base
Workholding fixture can be adapted
Temporary storage
Convenient access for loading and unloading
Compatibility with computer control
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Material Handling Equipment
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FMS In-Line Layout
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FMS In-Line Layout with
Integrated Storage System
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FMS Rectangular Layout
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FMS Open
Field Layout
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Robot-Centered Cell
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1. Workstation control
Individual stations require controls, usually
computerized
2. Distribution of control instructions to workstations
Central intelligence required to coordinate
processing at individual stations
3. Production control
Product mix, machine scheduling, and other
planning functions
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FMS Computer Functions
4. Traffic control
Management of the primary handling system to
move parts between workstations
5. Shuttle control
Coordination of secondary handling system with
primary handling system
6. Workpiece monitoring
Monitoring the status of each part in the system
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7. Tool control
Tool location
Keeping track of each tool in the system
Tool life monitoring
Monitoring usage of each cutting tool and
determining when to replace worn tools
8. Performance monitoring and reporting
Availability, utilization, production piece counts, etc.
9. Diagnostics
Diagnose malfunction causes and recommend repairs
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FMS Applications
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FMS Design Issues
Production volume
Annual quantities determined number of machines
required
Types of workstations
Variations in process routings
Material handling system
Work-in-process and storage capacity
Tooling
Pallet fixtures
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FMS Operational Issues
Part grouping
Which parts should be on the system at one time
Tool management
When to change tools
Pallet and fixture allocation
Limits on fixture types may limit part types that can be
processed
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FMS Benefits
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FMS Benefits
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