MM 323 MANUFACTURING SYSTEMS

PRODUCTION MACHINES

Production Machines

In virtually all modern manufacturing systems, most of the

actual processing or assembly work is accomplished by
production machines.
Classification of production machines:
1. Manually operated machines are controlled or
supervised by a human worker
2. Semi-automated machines perform a portion of the work
cycle under some form of program control, and a worker
tends the machine the rest of the cycle
3. Fully automated machines operate for extended periods
of time with no human attention

Classification of Production Machines

Automation and Manning Levels at

Production Machines
Level of machine automation
Manually operated
Semi-automated
Fully automated
Manning level Mi = proportion of time worker is in
attendance at machine i
Mi = 1 means that one worker must be at the machine
continuously
Mi 1 indicates manual operations
Mi < 1 usually denotes some form of automation

Manually Operated Machine

Manually operated machines are controlled or supervised

by a human worker. The machine provides the power for
the operation and the worker provides the control. The
entire work cycle is operator controlled. Worker loads and
unloads parts and operates machine.

Semi-Automated Machine

A semi-automated machine performs a portion of the work cycle

under some form of program control, and a worker tends to
the machine for the remainder of the cycle. Typical worker
tasks include loading parts (resupply of starting work units),
unloading parts (removal of finished work units), starting semiautomatic work cycle and periodic attention.

Applications of Semi-Automated Production

Machines (with LOAD/UNLOAD WORKERS)
CNC machining center with worker to load/unload
CNC turning center with worker to load/unload
Cluster of two CNC turning centers with time sharing of one
worker to load/unload
Plastic injection molding on semi-automatic cycle with
worker to unload molding, sprue, and runner
One worker at electronics subassembly workstation
inserting components into PCB
Stamping press with worker loading blanks and unloading
stampings each cycle

Fully-Automated Machine

Machine operates for extended periods (longer than one

work cycle) without worker attention.

Applications of Fully-Automated
Production Machines
CNC Machining Center with APC and parts storage
subsystem
CNC Turning Center with robot and parts storage carousel
Cluster of ten CNC Turning Centers, each with robot and
parts storage carousel, and time sharing of one worker to
load/unload the carousels
Plastic injection molding on automatic cycle with robot arm to
unload molding, sprue, and runner
Electronics assembly station with automated insertion
machine inserting components into PCBs
Stamping press stamps parts from long coil

PRODUCTION MACHINE
WHAT DO WE WANT FROM A PRODUCTION MACHINE?

----FLEXIBILITY HIGH
----MANUFACTURING LEAD TIME (LOADING; SET-UP
(CHANGEOVER); ADJUSTMENT; ACTUAL OPERATION;

UNLOADING TIMES) LOW

----CONSSTENCY (REPEATABILITY) HIGH
----ACCURACY (TOLERANCES) HIGH
----CAPABILITY (MULTIPLE OPERATIONS WITH THE SAME
SET-UP IN THE SAME MACHINE) HIGH

WHAT IS FLEXIBILITY FOR A

PRODUCTION MACHINE?
Flexibility of a production machine is directly proportion to the
degree to which the system is capable of dealing with
variations in the parts or products it produces.
Three flexibility levels (from lowest to highest):
1. Single-model case - all parts or products are identical.
2. Batch-model case - different parts or products are
produced by the system, but they are produced in batches
because changeovers are required.
3. Mixed-model case - different parts or products are
produced by the system, but the system can handle the
differences without the need for time-consuming
changes in setup.
The difference between 2. and 3. is SET-UP TIME.

SET-UP TIME
WHEN THE SET-UP (CHANGEOVER) TIME TO PRODUCE
A DIFFERENT PART/PRODUCT TYPE AFTER THE
CURRENT ONE IS HIGH, WE ARE FORCED TO
PRODUCE IN BATCHES TO INCREASE UTILIZATION
OF THE MACHINE. BATCH PRODUCTION INCREASES
MANUFACTURING LEAD TIME AND WORK-IN
PROCESS (WIP) INVENTORY. TO PRODUCE IN MIXED
MODEL CASE WE HAVE TO REDUCE SET-UP TIMES.
SO, THE KEY TO HIGH FLEXIBILITY THROUGH MIXEDMODEL CASE IS TO REDUCE SET-UP TIMES AT
PRODUCTION MACHINES.

Three Cases of Flexibility

1.Single-model case

2. Batch model case,

3. Mixed-model case
When we can produce in mixed-model case (lot size =1) what
happens to manufacturing lead time for a single part/
product?much lower. When manufacturing lead time is
lower, then we can react to customers actual orders
(PRODUCE TO ORDER) instead of trying to anticipate and
produce to stock (PRODUCE TO STOCK).

How do we achieve high flexibility

(Mixed model case) at a production
machine?---reduce set-up time
TO REDUCE SET-UP TIME
Automatic identification of the different work units
The machine must be able to identify the differences
between work units in order to perform the correct
processing sequence
Quick changeover of operating instructions
The required work cycle programs must be readily
available to the control unit
Quick changeover of the physical setup
System must be able to change over the fixtures and
tools required for the next work unit in minimum time

REMOVE WORKERS to achieve high repeatability,

high accuracy, low production time and high
production rates.
FULLY AUTOMATED production machines capable of
operating unattended for longer than one work cycle. The
ROUTINE functions (loading parts, adjusting, operating,
control, changing the tools, removing chips, measurement,
quality control and unloading parts, etc.) are performed by
the machine itself. The maintenance and recovery from
unexpected failures are also perfomed by the machine.
----GOAL OF THE MACHINE PRODUCERS: Produce A
MACHINE that needs no (or minimum essential) human
involvement while producing in mixed model case.
----A fully automated machine is a first step in implementing an
integrated multi-station fully automated flexible system.

Enablers for FULLY AUTOMATED MACHINE

(Unattended Machine Operation)
NOW AUTOMATED MACHINES HAVE
Programmed and automated (without interruption for removal of chips
or changing tools) operation for all steps in work cycle
Parts storage subsystem
Automatic loading, unloading, and transfer between parts storage
subsystem and machine
Automatic measurement and quality control and ability to adjust
automatically based on measurements.
Built-in safeguards to avoid self-destructive operation or damage to
work units and RECOVERY FROM FAILURES when failures occur.
Automatic identification (e.g., bar codes) that recognize alternative
features of starting units with the usage of sensors/bar-code readers
and communication devices.
Capability to download programs for each work unit style (programs
prepared in advance)
Capability for quick changeover of physical setup

AUTOMATED MACHINES
How do they function without workers?
Machining centers:
Various designs of parts storage unit interfaced to
automatic pallet changer (or other automated transfer
mechanism) for automatic part loading and unloading

Turning centers:
Industrial robot interface with parts carousel for part
loading and unloading.

Plastic molding or extrusion:

Hopper contains sufficient molding compound for
unattended operation

Sheet metal stamping:

Starting material is sheet metal coil

Automated Machines:
CNC MACHINING CENTERS
Machine tool capable of performing multiple operations (more
operations mean more capability) that use rotating tools on
a workpart in one setup under NC control.
Typical operations: milling, drilling, and related operations
Typical features to remove worker from machines:
Automatic tool changer (to change cutting tools)
Automatic workpart positioning (automatic adjustment)
Automatic pallet changer (automatic loading and unloading
parts) with part storage unit.

CNC
Machining
Center
Example

CNC Machining Center Example

EXAMPLE FOR AUTOMATED MACHINES:

CNC Machining Center with Automatic Pallet
Changer - Stores One Part
PERFORM ALL NECESSARY SET-UP FOR THE NEW PART ON A PALLET WHILE THE MACHINE IS
MACHINING THE EXISTING WORK PART. IN SUCH A CASE THE MACHINE DOES NOT STOP FOR ANY
SET-UP. WHATEVER PRODUCT/PART TYPE ARRIVES AFTER THE EXISTING WORK PART, THERE IS NO
STOPPAGE FOR A SET UP. The CYCLE loading time+machining time+tool changing time+ unloading time repeats
for the machine without set-up time for a new product type.

With the usage of automatic pallet

changer and part storage unit, the setup of the new work part can be
performed while the machine is
operating on the existing work part.
There is still a set-up for the new part
but we do NOT LOSE ON-LINE
SET-UP TIME with the usage of
automatic pallet changer and part
storage unit.

PALLETS --An automatic moveable table that supports a workpiece and slides or
pivots into and out of the machining center. Multiple pallets allow an operator to set up a part while
another is being machined.
--The fixture clamps the part to the pallet for loading and unloading in the machine.

Precision blank tooling plates

that are ready to mount on
standard machining-center
pallets, reducing tooling cost
and lead time considerably.

PALLET EXAMPLES (QUICK PALLETS)

ANOTHER QUICK PALLET EXAMPLE

http://www.thame-eng.com/downloads/Quick%20Point.pdf

MOUNTING QUICK PALLETS ON MACHINE TABLES

http://www.thame-eng.com/downloads/Quick%20Point.pdf

PALLET EXAMPLES

PALLET EXAMPLE

http://www.schunk.com/

AUTOMATIC PALLET LOADING

Automatic loading of a milling machining center with
the clamping pallet prepared on the assembly system.
After the introduction of the clamping pin, the quickchange pallet module positions and clamps the pallet.

Cam-Driven Pallet Changer

Auto pallet changer allows operator to setup a part while another part is being machined. Spindle idle time is
greatly reduced. The pallet changer utilizes heavy duty cam-driven design that features high speed and high
load capacity: a pallet change takes only 5 seconds and each side of the pallet table can hold up to 770 lbs. A
3-piece clutch gear clamping mechanism allows table unclamp, rotate and clamp all without raising table
elevation. Table positioning accuracy and stability are both greatly improved.

AUTOMATIC TOOL CHANGER

When the machining center is operating

on the existing work part, a worker can
put new cutting tools which will be
needed to machine the arriving work part.
NO LOST ON-LINE SET-UP TIME with
the usage of TOOL STORAGE UNIT.

TOOL STORAGE UNIT (TOOL MAGAZINE)

TOOL STORAGE UNIT (TOOL MAGAZINE)

Chain Type Automatic Tool Changer (ATC)

Drum Type Automatic Tool Changer (ATC)

EXAMPLE FOR AUTOMATED MACHINES:

CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and automatic pallet changer with pallet

holders arranged radially; PART STORAGE CAPACITY = 5.

EXAMPLE FOR AUTOMATED MACHINES:

CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and in-line shuttle cart system with pallet

holders along its length; PART STORAGE CAPACITY = 16

EXAMPLE FOR AUTOMATED MACHINES:

CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center with pallets held on indexing table;

PART STORAGE CAPACITY = 6.

EXAMPLE FOR AUTOMATED MACHINES:

CNC Machining Center with Automatic Pallet
Changer - Storage Capacities Greater Than One

Machining center and parts storage carousel with parts

loaded onto pallets; PART STORAGE CAPACITY = 12.

CNC Machining Center Example

CNC Machining
Center Structure:

The main parts of CNC machining centers are the bed, saddle, column, table, servomotors, ball screws, spindle, tool changer, and the
machine control unit (MCU)
Bed: The bed is usually made of a high quality cast iron which porvides for a rigid machine capable of performing heavy-duty machining and
maintaining high precision. Hardened and ground ways are mounted to the bed to provide rigid support for all linear axes.
Saddle: The saddle, which is mounted on the hardened and ground bedways, provides the machining center with the X-axis liear movement.
Column: The column, which is mounted to the saddle, is designed with high torsional strength to prevent distorsion and deflection during
machining. The column provides the machining center with the Y-axis movement.
Table: The table, which is mounted on the bed provides the machining center with the Z-axis linear movement.
Servo System: The servo system, which consists of servo drive motors, ball secrews, and position feedback encoders, provides fast, accurate
movement and positioning the XYZ axes slides. The feedback encoders mounted on the ends of the ball scrwes form a closed-loop system which
maintains consistent high positioning unidirection repeatability of 0.0001 in.
Spindle: The spindle, which is programmable in 1-r/min increments. Has a speed range of from 20 to 6000 r/min. The spindle can be of a fixed
position (horizontal) type, or can be a tilting/contouring spindle which provides for an additional (A) axis.
Tool Changers: There are basically two types of tool changers, the vertical tool changer and the horizontal tool changer. The tool changer is
capable of storing a numberof preset gram. Tool changers are usually bidirectional, which allows for the shortest travel distance to randomly
access a tool. The actual tool change time is usually only 3 to 5 sec.
MCU: The MCU allows the operator to perform a variety of operations such as programming, machining, diagnostics, tool and machine
monitoring, atc. MCUs vary according to manufacturers specifications; new MCUs are becoming more sophisticated, making machine tools
more reliable and the entire machining operations less dependent on human skills.

MACHINE AXES:Five-axis machining Center

1) X axis Linear Movement; 2) Y axis Linear Movement; 3) Z axis Linear Movement;
4) A axis Tilt/contour spindle; 5) B axis Rotary Table

Automated Machines:
CNC TURNING CENTERS
Machine tool capable of performing multiple operations on a rotating workpart in one setup under NC control.
Typical operations:
Turning and related operations, e.g., contour turning
Drilling and related operations along workpart axis of rotation

In turning centers, off-line set-up is not

possible. We should reduce set-up time
or eliminate the need for set-up.

EXAMPLE FOR AUTOMATED MACHINES:

CNC Mill-Turn Center
Machine tool capable of performing multiple operations either with
single point turning tools or rotating cutters in one setup
under NC control. We reduced the number of set-ups.
Typical operations:
Turning, milling, drilling and related operations
Enabling feature:
Capability to control position of c-axis in addition to x- and zaxis control (turning center is limited to x- and z-axis control)
Example Part which can be processed in
one set-up at CNC Mill-Turn Center:
---turning, milling, and drilling operations
are required to produce this part.

Sequence of Operations for the

example part at the Mill-Turn Center

(1) Turn smaller diameter, (2) mill flat with part in

programmed angular positions, four positions for square
cross section; (3) drill hole with part in programmed
angular position, and (4) cutoff of the machined piece

EXAMPLE FOR MILL TURN CENTER

WATCH THE VIDEOS at the web site:
http://www.compumachine.com/regional/mill-turn.htm

EXAMPLE FOR MILL TURN CENTER

WATCH THE VIDEOS at the web site:
http://www.compumachine.com/regional/mill-turn.htm

EXAMPLE FOR AUTOMATED MACHINES:

Automated Stamping Press

Stamping press on automatic cycle producing stampings

from sheet metal coil