~s1auun in Production Systems AUTO! MATION IN PRODUCTION SYSTEMS cane coneonental of the firm's production system are likely to be automated, whereas Henle Se operated manually or ] automation Equipment applications: Figure 1L4 Opportunities for automation and computerization in & production system.Sec. 12 Product variety a Fixe aces \ To.000 Production quantity ‘ igure 15 Three types of automation relative to production and product variety. quantity { e relative positions of the three types of aut y oma 'd product varieties are depicted in Figure 15. able automation. Ths programm: uction volumes an different prod jomation is a system in which the sequence sing (or assembl ations is fixed uipmer figuration, Each operatis See ually simple, involving pethaps a plain linear or rotational ie Sees the two. such as the feeding-af-a-rotating sind 11 ordination of many such operations into one piece of Stee plex. Typical features of fixed automation are (Jbish initia {ion rates, anc felative ‘Fixed Automation. Fixed aut in ‘an uncomplicated Cot ihe integration and c that makes the system co! i stom-engineered equipment inflexibility of the € e jety. tification for fixed automation is found in products that ax The economic jus produced in very large quantities and at high production rates. The high initial cost of the equipment can be spread over a very large number of units, thus making the unit 1 cost attractive compared with alternative methods of production. Examples of fixed automation include machining tran: es and automated assembly machine: In programmable automation, the productio: Programmable_Automation. equipments designed with the capability to ch; modate different product configurations. The operati program, which is a set of instructions coded so that the ange the sequence of operations to accom ce is-controtled by « jon sequence y can be read and interpreted into the equipment to pro -the system, New programs'can be prepared and enters a prod eee ef the Features that characterize programmable automation iN) ibe igh investment in general purpose equipment.2yfower production rates than fixed ii iat uct configuration 'd changes in prod and (4)ffigh suitability for batch production. } Programmable automated production systems are used jn-low=and.meiit \ as To produce Acme productigg Th e parts or products are typically made in_b each i Fi ess new batch of a different product, the system must be repros ed with \Bi See. 1.2 / Automation in Production Systems u of machine instructions that a uctions that correspond to-the-new-product. The physical setup of The Hachive MUST alae changed. Tools must be loaded. ixtures must B vattached to-the-machine table, and the requied machine setiney must Be entered. This changeover procedure takes time: Consequetily, te TypieaT eyTe Tora given product includes a period during which the setup and reprogramming takes place, followed by a period in which the parts in the batch are produced. Ex automation include_nu and programmable loiie nples of programmable cdi contretied (NC) machine (ols inistial FOBT. “controllers a ~ — pre Texible Automation, Flexible automation is_an_extension_of_programmable c automated systemis-capable-of producing. a variety of parts (or iy no time lost for changeover from one part style to the next The: fe reprogramming the system and altering the physical setup Gooling, fixtures, machine settings). Accordingly, Wic_system can produce various mixes J eB ‘and schedules of parts or products instead of requiring that they be made in batches. What a makes flexible automation possible is that the differences between parts processed by the 1 required between styles is minimal system are not significant, so the amount of chan} r The features of flexible automation inclu high investment for a custom-engineered system;(2Y continuous production of variable mixtures of, rates, and, fexibility to deal with product design variations. Examples of flexible ‘automation are the flexible manufacturing systems for performing machining operations. ‘The first of these systems was installed in. the late 1960s. 125 Computerized Manufacturing Support Systems “Automation of the manufacturing support systems is aimed at reducing the amount of manual and clerical effort in product design, manufacturing planning and control,and the business functions of the firm. Nearly all modern manufacturing support systems are implemented using computers. Indeed, computer technology is used to implement automation of the manufacturing systems in the factory as well. The term computer’ integrated manufacturing (CIM) denotes the pervasive use of computer systems 10 design oattetee plant The production, control the operations, and perform the various information-processing functions needed in a 1; manufacturing firm. True CIM involves integrating all of these functions in one system that operates throughout the enterprise. Other terms are used to identify specific elements of the CIM system. For example computer-aided design (CAD) denotes the use of computer systems to support the prod tict design function, Computer-aided manufacturing (CAM) denotes the use of complet Systems (o perform functions related to manufacturing engineering, such as prove plan- canchrummeri programming. Some comput -r systems perform both CAD and CAM, and so the term CAD/CAM is used to indicate the integration of the 18 into one system. SS ~~ Comiputer-integrated manufacturing involves the information-processing activities that provide the data and knowledge required to successfully produce the product. They are accomplished {p-implement the four basic manufacturipg support functions identi- fied efflier; (1) bfisiness functions, (2) product Close GY auamutaeturing planning, and ‘manufacturing control. These fost functions form a cycle of events that must accom ies but do not directly touch the product. pany the physical production activitier. 2 5 pemvorn to rte bist Hey Companies undertare projects in maruty, teh FF tmatvutecturing tor a variety or BOOd reasons. ga® Mtomay tion are the following rm Be Te increase tabor producn arariapesption rate aa tape mating hour of labor input To reduce labor cost. Ever. in the world’s industrialize. 1y- Automating dl s0eletles Conseen: ie hhas become economically justitiatie replace fbither singly being substituted tor i, fare uMAN labor 14," A To mitigate the fects of labor shortages There is a, advanced nations, and this has stimulated the dey z asa substitute for labor, To reduce or eliminate routine Sac tiat hes: is social value fatiguing. and possibly irksome, working conditions, To improve worker safety, Automating a n active participation in the Process to the operation altogether, makes the wor Safer. The of the worker has become a national obj tional Safety and Health Act (Ostia) or automation, sprove product quality. Automation 1 in manual operation, it also performs id conformity to quality speci manual and cle, in automa Autom: NEN OPeration and tran @ Monitoring rote lective with the in 1970. This has p, ot only resul ts in higher the manuf facturing pr perations, rapic T graphics (CAD) models, and the machir Miaces using computer numerical contro! iis? computer controlled systems. 3h Of Not automating. There is a signitic Hing manufacturing plant. The advania MPainy’s project authorization form. The b pected and intangible ways, such as ‘Telations, and better company image. Cor find themselves at a competitive disadv and the general public.‘Sutmjoeynuew jonpod ayasosip ur Ajuenb npoid pur Ajarea jonposd usemjeq diysuonejsy $7 aan3iy tf Ayquenb uononpoig I “ wnIpeW. AyoueA yonporgences between prody, fuction line. There pwhose variety is soft. | ; ends t0-be hard: the variety betwee; 10. be soft. ; ify three basi portion of: » between different-product- : rnin the same produch e& ee na production qu y jations i the work organization w jety, this is neverthe| models wit ——We can use the three Although there are vart amount of gon the the purpose of 0 production plant s for egory. usually dependin| 0 classify factorie’ able way t 23yV Low Production ction facility usually associated with the quantity range of 1 to 10¢ antities of specialized and customized pr aircraft, and special ma is the job shop, W products are ty pically complex, Suc’ apsules, shop production can also include fabricating t o arts for the prc tomer orders for these kinds of items are often special, and repeat orders may n Equipment in a job shop is general purpose and the labor force is highly skilled ‘A job shop must be designed for maximum. flexibility to d ith the oduct variations encountered (hard pro fact variety). If the product is large fficult to move in the factory, it typically remains in a single Ic quipment are broug and therefore dil final assembly. Workers and processing © This type of layout is The type of, produ wid Jeast during its product, rather than moving the product to the equipment. to asa fixed-positic 7, shown in Figure 2.6(a),in which the product remains ication, Examples of such products include s In actual practice, these items gle location during its eptil craft, railway locomotives, nd heavy machinery. ins le locations, and then the completed modules arc re les al e large products are often made in built i together for final | parts that comprise thes ipment is arranged according to func in another dep: ie individual t, in which the equij a different © that have a, process ope Te lathes are in one department, the milling machines are i and so on, as in Figure 2.6(b).\Different parts, each _requi ghAN Autom Heat pump. Pre, The automo, Bwtomcive ant, alin int plants, the .."'* ingle locator brought 10 layout is re37 Sec. 2.3 / Production Facilitios Worker CK Motite “THT wT]@ Workstations (machines) 8,60 IF ae 886, OF Work, Machines Workerva, ay J ~-O+-O O— Workers in stations Work, d\n => sited a o o o. a Bee leEls ES Work units @ sition layout, Figure 2.6 Various types of plant layout: (a) fixed (b) process layout, (c) cellular layout, and (d) product layout. emermeee 2.3.2. Medium Production In the medium quantity range (100-10,000 units annually), we distinguish between two dif y is hard, ferent types of facility, depending on product variety. Wh pproach is batch production, in which a batch of one product is made, alter which the facility is changed Tver produces batch ofthe nex producti soon Onda 1a the production rate of the equipment is greater than each product are frequently repeate: ach product are peatChap. 2 / Manutacy, 8 ot type, and so the same equipment can rat _any single product type; < - eerie eT he changeover between production runs tak “hos Se raed the time to change tooling and to set uy oor changeover fingg, tis the time to chan ing and os = oe “Tost production time, which is a disadvantagy sat Batch production is commonly 1ake-to-stock situation; is commonly used in m factured to replenish inventory that has been gradually depleted by d. ; factured to reple ecpnich production is usually arranged in a process layout, Figure 2.6(h), "* “uy erative a h to medium range production is possible ALi ao teraan carensive changeovers between one product styi¢ any Sel is soft.n il onfigure the equipment so that groqe! not be required. It is often possible to configure the e ent 30 tha grog parts or products can be made 1 oul signi e ing or assembly of different parts or products is accoy | peer 0 esaral workstations vor machines The term cellular manyj. Sfien associated with this type of production. Eagh cells designed to produc," variety of part configurations that is, the cell specializes in the production of a gy similar parts or products, according to the principles of group technology (Chap The layout is called a cellular layout, depicted in Figure 2.6(c). Ge 3. High Production The high quantity range (10,000 to millions of units per year) is : ‘production facility is dedicated to the manetacture of that product, TWwertatepories of. production can be distinguished: (Ff quantit flow line producti, ‘Quantity praduction invalyes the mass production of single parts on single piecesoteqon ment. The method of production typically involves standard machines (such as stamsin, 24 PR Presses) equipped with special tooling (és, dies arid maletial handling devices), in ci. dedicating the equipment to the production of one part type. The typical layout used = Quantity production is the process layout, Figure 2.6(b).. (9 “Flow line production valves muloTe 3 multiple Workstations arranged in sequence, andi: Sec. 2.4 / Product rin, Parts or assemblies are physically moved through the sequence to complete the produ The workstations consist of production machines and/or worker: 's Equipped with special d tools Fhe collection of stations is designed specifically for the product to maxini: : effcien€ T is workstations are arranged ist0 a ne long line, as depicted in Figure 2.6(d), or into a series of connected line The work is usually moved between stations y powered conveyor. At each station, a snd Smount of the total work is completed on each unit of product. The most familiar example of flow li is cel ‘wih peswtocts sae ple of flow line production is the assembly line, assoc tion s where there years a household appliances. The Pure Ca8€°OF flow Tine prod: te ismade_on the line, Every product is ide asingle- model production line. However, to success!) acta, 3 introduce model variations so that ins! ; le em.F 0 duction viewpoint, the mode] differences pence appeal 7 them From po the’proda iilideapplies to those situations where there is st vatiel) a Si enn eee Modern Automobile assembly is an example. Cars comit! (and, in Many cases, diffey Product, it is ofte3ec. 2.4 / Product/Production Relationships * layout Process i layout y Cellular “4 layout Job shop / Product Baich layout production Cellular | manufacturing] |Ouantity Flow line fatty Mass production Product variety 10,000, 1,000,000 1 100 Production quantity Figure 2.7 Types of facilities and layouts used for different levels of production quantity and product variety. include small and major appliances. The Boeing Commercial Airplane Company uses production line techniques to assemble its 737 model. : Much of our discussion of the types of production facilities is summarized in Figure 2.7, which adds detail to Figure 2.5 by identifying the types of production facilities and plant lay- outs used. As the figure shows, some overlap exists among the different facility types. IRONICT/PRODUCTION RELATIONSHIPS