Basics of Mechanical Engineering ( B.M.

E)

Brown Hill College of Engg. & Tech.

UNIT - 7
Manufacturing System (MS) and Numerical Control# (NC)
*

Introduction to Manufacturing System

Manufacturing system to be a collection of integrated equipment and human resources, whose function is to
perform one or more processing and/or assembly operations on a starting raw material, part, or set of parts, the
integrated equipment includes production machines and tools, material handling and work positioning devices,
and computer systems. Human resources are required either full time or periodically to keep the system running.
The manufacturing system is where the value-added work is accomplished on the part or product, the position of
the manufacturing system in the larger production system. Examples of manufacturing systems include:
a)
b)
c)
d)
e)

One worker tending one machine, which operates on semi-automatic cycle

A cluster of semi-automatic machines, attended by one worker
A fully automated assembly machine, periodically attended by a human worker
A group of automated machines working on automatic cycles to produce a family of similar parts
A team of workers performing assembly operations on a production line

Automated manufacturing System

Automated manufacturing systems operate in the factory on the physical product. They perform
operations such as processing, assembly, inspection, or material handling, in some cases accomplishing more
than one of these operations in the same system. They are called automated because they perform their
operations with a reduced level of human participation compared with the corresponding manual process. In
some highly automated systems, there is virtually no human participation. Examples of automated manufacturing
systems include:
a) Automated machine tools that process parts
b) Transfer lines that perform a series of machining operations
c) Automated assembly systems
d) Manufacturing systems that use industrial robots to perform processing or assembly operations
e) Automatic material handling and storage systems to integrate manufacturing operations
f) Automatic inspection systems for quality control
Automated Manufacturing Systems can be classified into three basic types:
1. Fixed automation
2. Programmable automation, and
3. Flexible automation
1. Fixed Automation: Fixed automation is a system in which the sequence of processing (or Assembly)
operation is fixed by the equipment configuration. Each of the operation in the sequence is usually
simple, involving perhaps a plain linear or rotational motion or an uncomplicated combination of the two;
for example, the feeding of a rotating spindle. It is the integration and coordination of many such

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Brown Hill College of Engg. & Tech.

operations into one piece of equipment that makes the system complex. Typical features of fixed
automation are:
1. High initial investment for custom-engineered equipment
2. High production rates
3. Relatively inflexible in accommodating product variety
2. Programmable Automation: In this the production equipment is designed with the capability to change
the sequence of operation to accommodate different product configurations. The operation sequence is
controlled by a program, which is a set of instructions coded so that they can be read and interpreted by
the system. New programs can be prepared and entered into the equipment to produce new products.
Some of the features that characterize programmable automation include:
1.
2.
3.
4.

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

Programmable automated production systems are used in low- and medium-volume production.
Examples of programmable automation include numerically controlled (NC) machine tool, industrial
robots, and programmable logic controllers.
3. Flexible Automation: It is an extension of programmable automation. A flexible automated system is
capable of producing a variety of products with virtually no time lost for changeover from on product
style to the next. The feature of flexible automation as follow:
1.
2.
3.
4.

High investment for a custom-engineered system

Continuous production of variable mixtures of products
Medium production rates
Flexibility to deal with product design variations

Components of a Manufacturing System

A manufacturing system consists of several components. In a given system, these components usually
include:
Production machines plus tools, fixtures, and other related hardware
Material handling system
Computer systems to coordinate and/or control the above components
Human workers
Classification of Manufacturing Systems
We explore the variety of manufacturing system types and develop a classification scheme based on the
factors that define and distinguish the different types. The factors are:
Types of operations performed

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Brown Hill College of Engg. & Tech.

Number of workstations and system layout

Level of automation
Part or product variety
The four factors in our manufacturing systems classified
S. No.
1.

Factor

Alternatives

Types of operations performed

Processing operations versus assembly operations Type of

processing or assembly operation

2.

3.

Number of workstations and One station versus more than one station For more than one station,
system layout

variable routing versus fixed routing

Level of automation

Manual or semi-automated workstations that require full-time

operator attention versus fully automated that require only periodic
worker attention

4.

Part or product variety

All work units identical versus variations in work units that require
differences in processing

EFFECTIVE ENVIRONMENT FOR MANUFACTURING SYSTEM

Flexibility in Manufacturing Systems

Flexibility is the term used for the attribute that allows a mixed model manufacturing system to
cope with a certain level of variation in part or product style without interruptions in production for
changeovers between models.
Flexibility is generally a desirable feature of a manufacturing system. Systems that possess it are
called flexible manufacturing systems, or flexible assembly systems, or similar names. They can produce
different part styles or can readily adapt to new part styles when the previous ones become obsolete. To
be flexible, a manufacturing system must possess the following capabilities:
1. Identification of the different work units: Different operations are required on different part or
product styles. The manufacturing system must identify the work unit to perform the correct
operation. In a manually operated or semi-automatic system, this task is usually an easy one for the
worker(s). In an automated system, some means of automatic work unit identification must be
engineered.
2. Quick changeover of operating instructions: The instructions, or part program in the case of
computer-controlled production machines, must correspond to the correct operation for the given
part. In the case of a manually operated system, this generally means workers who (1) are skilled in
the variety of operations needed to process or assemble the different work unit styles, and (2) know
which operations to perform on each work unit style. In semi-automatic and fully automated
systems, it means that the required part programs are readily available to the control unit.

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Brown Hill College of Engg. & Tech.

3 . Quick changeover of physical setup: Flexibility in manufacturing means that the different work
units are not produced in batches. For different work unit styles to be produced with no time lost
between one unit and the next, the flexible manufacturing system must be capable of making any
necessary changes in fixturing and tooling in a very short time. (The changeover time should
correspond approximately to the time required to exchange the completed work unit for the next unit
to be processed.)
Reconfigurable Manufacturing Systems
In an era when new product styles are being introduced with ever-shortening life cycles, the cost of
designing, building, and installing a new manufacturing system every time a new part or product must be
produced is becoming prohibitive, both in terms of time and money: One alternative is to reuse and
reconfigure components of the original system in a new manufacturing system. In modern manufacturing
engineering practice, even single model manufacturing systems are being built with features that enable
them to be changed over to new product styles when this becomes necessary. These kinds of features
include:
1. Ease of mobility: Machine tools and other production machines designed with a three point base that
allows them be readily lifted and moved by a crane or forklift truck. The three-point base facilitates
leveling of the machine after moving.
2. Modular design of system components: This permits hardware components from different machine
builders to be connected together.
3. Open architecture in computer controls: This permits data interchange between software packages
from different vendors.
4 . CNC workstations: Even though the production machines in the system are dedicated to one
product, they are nevertheless computer numerical controlled to allow for upgrades in software,
engineering changes in the part currently produced, and changeover of the equipment when the
production run finally ends.
#

Introduction to Numerical Control (NC)

Numerical Control is a form of programmable automation in which the mechanical actions of a
machine tool or other equipments are controlled by a programme containing coded alphanumeric data.
The alphanumerical data represent relative positions between a work-head and a work-part as well as
other instructions needed to operate the machine. The work-head is a cutting tool or other processing
apparatus, and the work part is the object being processed. When the current job is completed, theprogram of instructions can be changed to process a new job. The capability to change the program
makes NC suitable for low and medium production. It is much easier to write new programs than to make
major alterations of the processing equipment. Numerical control can be applied to a wide variety of
processes. The applications divide into two categories:
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Machine tool applications, such as drilling, milling, turning, and other metal working
Non-machine tool applications, such as assembly, drafting, and inspection
The common operating feature of NC in all of these applications is control of the work-head movement
relative to the work-part. The first NC machine was developed in 1952.
(The development of NC owes much to the United States Air Force and the early aerospace industry. The
first development work in the area of NC is attributed to John Parsons and his associate Frank Stulen at
Parsons Corporation in Traverse City, Michigan.)
F u n d a m e n t a l s o f Numerical Control (N C ) T e c h n o l o g y
To introduce NC technology, we first define the basic components of an NC system. This is followed by
a description of NC coordinate systems in common use and types of motion controls used in NC.
B a s i c C o m p o n e n t s o f a n N C S y s t e m : An NC system consists of three basic components:
1. A program of instructions
2. A machine control unit, and
3. Processing equipment
The general relationship among the three components is illustrated in below Figure

Program

Machine
Control
Unit

Processing Equipment

A program of instructions: The program of instructions is the detailed step-by-step commands that
direct the actions of the processing equipment. In machine tool applications, the program of
instructions is called a part program, and the person who prepares the program is called a part
programmer. In these applications, the individual commands refer to positions of a cutting tool
relative to the worktable on which the work-part is fixtured. Additional instructions are usually
included, such as spindle speed, feed rate, cutting tool selection, and other functions.
A machine control unit: In modern NC technology, the machine control unit (MCU) consists of a
microcomputer and related control hardware that stores the program of instructions and executes it by
converting each command into mechanical actions of the processing equipment, one command at a
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Brown Hill College of Engg. & Tech.

time. The related hardware of the MCU includes components to interface with the processing
equipment and feedback control elements. The MCU also includes one or more reading devices for
entering part programs into memory. The type of readers depends on the storage media' used for part
programs in the machine shop (e.g., punched tape reader, magnetic tape reader, floppy disk drive). The
MCU also includes control system software, calculation algorithms, and translation software to convert
the NC part program into a usable format for the MCU Because the MCU is a computer, the term
computer numerical control (CNC) is used to distinguish this type of NC from its technological
predecessors that were based entirely on hard-wired electronics. Today, virtually all new MCUs are
based on computer technology.
Processing equipment: It performs useful work; it accomplishes the processing steps to transform
the starting work-piece into a completed part. Its operation is directed by the MCU, which in turn is
driven by instructions contained in the part program. In the most common example of NC, machining,
the processing equipment consists of the worktable and spindle as well as the motors and controls to
drive them
Applications of Numerical Control ( NC)
The operating principle of NC has many applications. There are many industrial operations in which the
position of a work-head must be controlled relative to a part or product being processed. The applications divide
into two categories:
1. Machine tool applications
2. Non-machine tool applications
Machine tool applications are those usually associated with the metalworking industry.
Non-machine tool applications comprise a diverse group of operations in other industries. It should be
noted that the applications are not always identified by the name "numerical control"; this term is used
principally in the machine tool industry.

Numerical Control (NC) Application and Characteristics

NC technology appropriate for low to medium production of medium to high variety
product:
1. Batch Production
2. Repeat Order
3. Complex part Geometry
4. Much Metal need to be removed from the work -part
5. Many Separate Machining operations on the part
6. The part is expensive
7.
8.

Electrical Wire Wrap Machine

Drafting Machines

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9. Coordinate measuring machine

10. Tape laying machines for pol ymer composites
11. Filament winding machines for pol ymer composites
Advantage of Numerical Control (NC)
1. Nonproductive time is reduced
2. Greater accuracy and repeatability
3. Lower scrap rates
4. Inspection requirements are reduced
5. More-complex part geometries are possible
6. Engineering changes can be accommodated more gracefully
7. Simpler fixtures are needed
8. Shorter manufacture lead time
9. Reduced parts inventory
10. Less floor-space required
11. Operator skill-level requirements are reduced
Disadvantage of Numerical Control (NC)
1. Higher investment cost
2. Higher maintenance effort
3. Part programming.
4. Higher utilization of NC equipment
Difference Between NC and CNC
S. No.

NC

CNC

1.

NC Stands for Numerical Control

CNC Stands for Computer Numerical Control

2.

In this NC stores only one part

Storage of more than one part

3.

Here only one form of program input

Various form of program input

4.

In NC no program editing at the time of

machine tool
Complex part geometry

Program editing at the time of machine tool

5.

Tool life monitoring

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6.

Repeat order of programming

Fixed cycle and programming subroutine

7.

In NC there is no Communication
interference

Communication interference

8.

Here no On-line diagnostics for system

breakdown

On-line diagnostics for system breakdown

9.

Much metal needs to be removed from

the work piece
10. In this no Programming diagnostics

Central start-up diagnostics

11. There is no virtual method of

diagnostics
12. It is use for single part or product
production

Preventive maintenance notice

Programming diagnostics

Diagnostics for individual components

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