Types Manufacturing Systems

Dr. P. Kalpana, M.E., PhD.

Faculty of Mechanical Engineering
IIITDM Kancheepuram

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Types of Manufacturing Systems

Factors that define and distinguish manufacturing systems:

Types of operations performed
Number of workstations and System layout
Automation and manning level
Part or product variety/system flexibility

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Types of Operations Performed
Processing operations on work units versus assembly operations to combine individual parts into
assembled entities
Type(s) of materials processed
Size and weight of work units
Part geometry
For machined parts, rotational vs. non-rotational
Part or product complexity
For assembled products, number of components per product
For individual parts, number of distinct operations to complete processing

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Number of Workstations
 Convenient measure of the size of the system
 Let n = number of workstations
 Individual workstations can be identified by subscript i, where i = 1, 2,...,n
 Affects performance factors such as workload capacity, production rate, and reliability
 As n increases, this usually means greater workload capacity and higher production rate
 There must be a synergistic effect that derives from n multiple stations working together vs. n
single stations
 Splitting work content among work stations
 Complex system- Material handling
 System layout
 Applies mainly to multi-station systems
 Fixed routing vs. variable routing
 In systems with fixed routing, workstations are usually arranged linearly
 In systems with variable routing, a variety of layouts are possible
 System layout is an important factor in determining the most appropriate type of material
handling system
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Level of Automation

Level of workstation automation

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

M = average manning level for the system;

wu= number of utility workers assigned to the system
wi = number of workers assigned specifically to station i, for i = 1, 2, ….,n
w = total number of workers assigned to the system

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Part or Product Variety: Flexibility

The degree to which the system is capable of dealing with variations in the parts or products it without
interruptions in production for changeovers between models
Starting material
Size and weight of the work unit
part geometry
part or product complexity
optional features in an assembled product.
flexible manufacturing systems, or flexible assembly systems
adapt to new styles before the previous one obsolete

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Enablers of Flexibility

Identification of the different work units

The system 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

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Classification of Manufacturing Systems

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Classification of Single-Station Manufacturing Cells

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Single-Station Manufacturing Cells
Most common manufacturing system in industry
Operation is independent of other stations
Perform either processing or assembly operations
Can be designed for:
Single model production- all parts or products are identical (sufficient demand/fixed automation)

Batch production- different parts or products are produced by the system, but they are produced in
batches because changeovers are required (hard product variety)

Mixed model production- 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 (soft product variety)

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Single-Station Manned Cell
“One worker tending one production machine (most common model)”
Most widely used production method, especially in job shop and batch production
Reasons for popularity:
Shortest time to implement
Requires least capital investment
Easiest to install and operate
Typically, the lowest unit cost for low production
Most flexible for product or part changeovers
Worker operating a standard machine tool
Worker loads & unloads parts, operates machine
Machine is manually operated
Worker operating semi-automatic machine
Worker loads & unloads parts, starts semi-automatic work cycle
Worker attention not required continuously during entire work cycle
Worker using hand tools or portable power tools at one location
Machine Cluster
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Variations of Single-Station Manned Cell
A worker using hand tools
 screw driver and wrench in mechanical assembly
portable powered tools (e.g., powered handheld drill, soldering iron, or arc welding gun
Manual inspection
Two (or more) workers required to operate machine
Two workers required to manipulate heavy forging at forge press
Welder and fitter in arc welding work cell
Multiple workers combining their efforts to assemble one large piece of machinery
One principal production machine plus support equipment
Drying equipment for a manually operated injection molding machine
Trimming shears at impression-die forge hammer to trim flash from forged part
A grinder used at an injection molding machine

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Single-Station Automated Cell
Fully automated production machine capable of operating unattended for
longer than one work cycle
Worker not required except for periodic attention
Reasons why it is important:
Labor cost is reduced
Easiest and least expensive automated system to implement
Production rates usually higher than manned cell
First step in implementing an integrated multi-station automated system

Supporting equipment
A robot loading and unloading an automated production machine
CNC lathe with chip conveyor
Drying equipment in a fully automated injection-molding machine

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Enablers for Unattended Cell Operation-Identical Parts

For single model and batch model production:

Programmed operation for all steps in work cycle
Parts storage subsystem
Automatic loading, unloading, and transfer between parts storage subsystem and machine
Periodic attention of worker for removal of finished work units, resupply of starting work units, and
other machine tending
Built-in safeguards against self-destructive operation or damage to work units or unsafe to workers

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Enablers for Unattended Cell Operation-different Parts

For mixed model production:

All of the preceding enablers, plus:
Work unit identification:
Automatic identification (e.g., bar codes) or sensors that recognize alternative features of starting
units
If starting units are the same, work unit identification is unnecessary
Capability to download programs for each work unit style (programs prepared in advance)
Capability for quick changeover of physical setup

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Parts Storage Subsystem and Automatic Parts Transfer

Given a capacity = np parts in the storage subsystem, the cell can theoretically operate for a time
 UT = npTc
 where UT = unattended time of operation
In reality, unattended time will be less than UT because the worker needs time to unload finished
parts and load raw workparts into the storage subsystem
Typical objectives in defining the desired parts storage capacity np:
Make npTc= a fixed time interval that allows one worker to tend multiple machines
Make npTc= time between scheduled tool changes
Make npTc = one complete shift
Make npTc = one overnight (“lights-out operation”)

The time of unattended operation increases directly with storage capacity, so there is an advantage to
designing the storage subsystem with sufficient capacity to satisfy the plant’s operational objectives.

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Storage Capacity of One Part

•Example: two-position automatic pallet changer (APC)

•With no pallet changer, work cycle elements of
loading/unloading and processing would have to be
performed sequentially
Tc = Tm + Ts
where Tm = machine time and Ts = worker service time
•With pallet changer, work cycle elements can be
performed simultaneously
Tc = Max{Tm, Ts} + Tr
where Tr = repositioning time of pallet changer

•If Ts > Tm, the machine experiences forced idle time during
each work cycle, and this is undesirable.
CNC Machining Center with Automatic Pallet Changer
•If Ts < Tm machine utilization is high

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Storage Capacities Greater Than One

Figure: in-line shuttle cart system

Automatic pallet changer with with pallet holders along its length,
pallet holders arranged radially, parts-storage capacity = 16
parts-storage capacity = 5

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Storage Capacities Greater Than One

parts-storage carousel, parts-storage

Pallets held on indexing table, parts-storage capacity = 12
capacity = 6

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Parts Storage other Than machining
•Sheet metal stamping

•Plastic injection molding

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CNC Machining Centers and Related Machine Tools
single-station automated cells with CNC tools
machining centers,
turning centers,
mill-turn centers,
multitasking machines.
To reduce the number of separate workstations and corresponding setups
Used in automated and semi automated mode

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CNC Machining Center
Machine tool capable of performing multiple operations that use rotating tools on a workpart in one
setup under NC control”
Typical operations: milling, drilling, reaming, and tapping and related operations
Classification
vertical machining center
horizontal machining center
universal machining center
Typical features to reduce nonproductive time:
Automatic tool changer
Automatic work part positioning
Automatic pallet changer

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 CNC Turning Center

CNC Turning Center

“Machine tool capable of performing multiple operations on a
rotating work part in one setup under NC control”
Typical operations:
Turning and related operations, e.g., contour turning
Drilling and related operations along work part axis of
rotation
Advanced features of turning centers include
work part gaging
tool monitoring
automatic tool changing of worn tools, and
automatic part changing at the completion of the work cycle

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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”
Typical operations:
Turning, milling, drilling and related operations
Enabling feature:
Capability to control position of any-axis in addition to x- and z-axis control (turning center is limited
to x- and z-axis control)

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Part with Mill-Turn Features

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

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Applications of Single Station Manned Cells
CNC machining center with worker to load/unload
CNC turning center with worker to load/unload load/ unload
Cluster of two CNC turning centers with time sharing of one worker to load/unload load / unload
Plastic injection molding on semi-automatic cycle with worker to unload molding molding, sprue, and
runner
One worker at electronics subassembly workstation inserting components into PCB
Stamping press with worker loading blanks and unloading stamping each cycle

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Applications of Single Station Manned Cells
CNC MC with APC and parts storage subsystem
CNC TC with robot and parts storage carousel
Cluster of ten CNC TCs, 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

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Analysis of Single-Station Cells-N umber of Workstations Required

•n = number of cells or workstations;

•WL = workload to be accomplished during the period of interest, hr/period
•AT = available time on one cell in the same period, hr/period/cell
•Workload is defined as the total hours required to produce a given quantity of work units scheduled
during the period of interest

•WL = workload scheduled for the period, hr of work/hr or hr of work/wk, etc

•Q = quantity to be produced during the period, pc/hr or pc/wk, etc
•Tc = cycle time required per piece, hr/pc
•If the workload includes multiple part or product styles

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Analysis of Single-Station Cells-N umber of Workstations Required

•Q j= quantity of part or product style j produced during the period, pc

•Tcj= cycle time of part or product style j, hr/pc

•TTsu= total setup time for all part styles included in the workload to be accomplished.

•Tsuj = setup time for part or product style j produced during the period, hr.

•Defect rate is the fraction of parts produced that are defective

•Qj= quantity of good units made in the process
•Qoj= original or starting quantity; and qj= fraction defect rate

•AT = available time per cell, hr/cell; Hp = actual hours during the period, hr/cell
• A = availability.
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Example 1. Number of Setups is Known

A total of 900 parts must be produced in the lathe section of the machine shop during a particular 40-hr
week. The parts are of 20 different styles, and each style is produced in its own batch. Average batch
quantity is 45 parts. Each batch requires a setup and the average setup time is 2.5 hr. The average
machine cycle time to produce a shaft is 10 min. Availability on the lathes is 100%. How many lathes are
required during the week?

•Solution:
•In this case the number of setups required during the week is known because the number of batches is
known: 20.
•Total workload for the 20 setups and 20 production runs is given by:

•Given that each lathe is available 40 hr/wk,

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Example 2 Number of Setups is Not Known
•A total of 900 parts must be produced in the lathe section of the machine shop during a particular 40-hr
week. The parts are identical. How many lathes will be needed to produce the 900 parts, given that each
machine must be set up at the beginning of the week? Each setup takes 2.5 hr. Availability on the lathes
is 100%.The workload to actually produce the parts remains the same, 150 hr
Solution:
This is similar to Example 1, but the number of setups is equal to the number of machines that will be
required, and that number is not known, at least not yet. In this problem formulation, the number of
hours available on any lathe is reduced by the setup time. Adding the setup workload,

Now dividing by the available time of 40 hr per lathe,

Solving for n,

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Example 3: Including Availability and Defect Rate
Suppose that in the previous Example the anticipated availability of the lathes is 100% during setup and
92% during the production run. The fraction defect rate for lathe work of this type is 5%. Other data
from Example 1 are applicable.
How many lathes are required during the week, given this additional information?
Solution:
For setup, the workload is simply the time spent performing the 20 setups:

The available hours during the week are AT = 40 hr/machine. Thus, the number of lathes required just for
setup is determined as:

Given the fraction defect rate of 5%, the workload for the 20 production runs is computed:
•The available time is affected by the 92% availability:

Total machines required n = 1.25 + 4.29 = 5.54 rounded up to 6 lathes

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Machine Clusters
A collection of two or more machines producing parts or products with identical cycle times and
serviced (usually loaded and unloaded) by one worker
A machine cell consists of one or more machines organized to produce a family of parts or products
Conditions to form Machine cluster
the semiautomatic machine cycle is long relative to the service portion of the cycle that requires the
worker’s attention;
the semiautomatic cycle time is the same for all machines;
the machines that the worker would service are located in close enough proximity to allow time to
walk between them
the work rules of the plant permit a worker to service more than one machine.
For the system to be perfectly balanced in terms of worker time and machine cycle time

The number of machines that should be assigned to one worker is given by

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Machine Clusters
How Many Machines For One Worker?
A machine shop has many CNC lathes that operate on a semiautomatic cycle under part program
control. A significant number of these machines produce the same part, with a machine cycle time =
2.75 min. One worker is required to perform unloading and loading of parts at the end of each cycle.
This takes 25 sec. Determine how many machines one worker can service if it takes an average of 20 sec
to walk between the machines and no machine idle time is allowed.

Solution: Given that Tm= 2.75 min, Ts= 25 sec = 0.4167 min, and Tr= 20 sec = 0.3333 min, the above
Equation can be used to obtain

Each worker can be assigned four machines. With a machine cycle Tc = 3.1667 min, the worker will
spend 4*(0.4167) = 1.667 min servicing the machines, 4*(0.3333) = 1.333 min walking between the
machines, and the worker’s idle time during the cycle will be 0.167 min (10 sec).

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Manual Assembly Lines

Most consumer products are assembled on manual assembly lines

Factors favoring the use of manual assembly lines:
High or medium demand for product
Identical or similar products
Total work content can be divided into work elements
It is technologically impossible or economically infeasible to automate the assembly operations

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Products Usually Made on Manual Assembly Lines

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 Why Assembly Lines are so Productive
Specialization of labor
Learning curve
Interchangeable parts
Components made to close tolerances
Work flow principle
Products are brought to the workers
Line pacing.
Workers must complete their tasks within the cycle time of the line
Speed in moving Assembly line
Space between the parts

Source:https://i1.wp.com/www.allaboutlean.com/wp-content/uploads/2017/04/Continuous-Line-Two-Speed.gif?resize=486%2C281&ssl=1
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Manual Assembly Line Defined

“A production line consisting of a sequence of workstations where assembly tasks are performed by
human workers as the product moves along the line”

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Assembly Workstations
“A designated location along the work flow path at which one or more work elements (tasks) are
performed by one or more workers”

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Assembly Workstations

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Work Transport Systems
Manual Work Transport Systems
Work units are moved between stations by the workers without the aid of a powered conveyor
Problems:
Starving of stations (waiting for a work unit)
Blocking of stations (cannot pass the work unit to the next station)
No pacing
Mitigated by
Work units moved in batches (transfer batch)
Work units moved one at a time
Temporary storage
Troubles in this method
Increase the work in process
Workers are unpaced in lines

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Work Transport Systems

Mechanized Work Transport Systems

Work units are moved by powered conveyor or other mechanized apparatus
Categories:
Work units attached to conveyor (large and heavy product – worker walks along)
Work units are removable from conveyor (not a fixed cycle time)
Problems
Starving of stations
Incomplete units (if the worker runs out of time)
Types
continuous transport,
synchronous transport, and
asynchronous transport

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Continuous Transport

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Synchronous Transport

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Asynchronous Transport

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Material Handling equipment

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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 or else the required production rate will not be achieved.
 Pacing provides a discipline for the assembly line workers that more or less guarantees a certain
production rate for the line
Several levels of pacing:
Rigid pacing
Pacing with margin
No pacing

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Rigid Pacing

Each worker is allowed only a certain fixed time each cycle to complete the assigned task
Allowed time is set equal to the cycle time less repositioning time
Synchronous work transport system provides rigid pacing
Undesirable aspects of rigid pacing:
Incompatible with inherent human variability
Emotionally and physically stressful to worker
Incomplete work units if task not completed

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Pacing with Margin

Worker is allowed to complete the task within a specified time range, the upper limit of which is greater
than the cycle time
On average, the worker’s average task time must balance with the cycle time of the line
How to achieve pacing with margin:
Allow queues of work units between stations (asynchronous transport)
Provide for tolerance time to be longer than cycle time (continuous transport)
Allow worker to move beyond station boundaries

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No Pacing

No time limit within which task must be completed

Each assembly worker works at his/her own pace
No pacing can occur when:
Manual transport of work units is used on the line
Work units can be removed from the conveyor to perform the task
An asynchronous conveyor is used and the worker controls the release of each work unit from the
station
There is no mechanical means of achieving a pacing discipline on the line.

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Coping with Product Variety
Single model assembly line (SMAL)
Every work unit is the same (products with high demand)

Batch model assembly line (BMAL)

Hard product variety
Products must be made in batches

Mixed model assembly line (MMAL)

Soft product variety
Models can be assembled simultaneously without batching on the line

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Analysis of Single model Assembly line

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53
Line Balancing

Components of cycle time at several stations on a manual assembly line

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Line Balancing
Minimum Rational Work Elements
A minimum rational work element is a small amount of work that has a specific limited objective
A minimum rational work element cannot be subdivided any further without loss of practicality
The sum of the work element times is equal to the work content time

•where Tek = time to perform work element k, min; and ne = number of work elements into which the
work content is divided, that is, k = 1, 2, p, ne.
•The task time at station i, or service time as it is called, Tsi, is composed of the work element times that
have been assigned to that station

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Line Balancing
•Precedence Constraints
•Technological requirements on the work sequence are called precedence constraints
•Precedence diagram, which is a network diagram that indicates the sequence in which the
•work elements must be performed
•Work elements are symbolized by nodes, and the precedence requirements are indicated by arrows
connecting the nodes
•The sequence proceeds from left to right

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A Problem for Line Balancing
•A small electrical appliance is to be produced on a single-model assembly line. The work content of
assembling the product has been reduced to the work elements listed in Table. The table also lists the
times for each element and the precedence order in which they must be performed. The line is to be
balanced for an annual demand of 100,000 units/yr. The line will operate 50 wk/yr, 5 shifts/wk, and 7.5
hr/shift. There will be one worker per station. Previous experience suggests that the uptime efficiency
for the line will be 96%, and repositioning time lost per cycle will be 0.08 min.
•Determine (a) total work content time Twc, (b) required hourly production rate Rp to achieve the annual
demand, (c) cycle time Tc, (d) theoretical minimum number of workers required on the line, and (e)
service time Ts to which the line must be balanced.

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A Problem for Line Balancing

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A Problem for Line Balancing
•(a) The total work content time is the sum of the work element times

•(b) Given the annual demand, the hourly production rate is

•(c) The corresponding cycle time Tc with an uptime efficiency of 96% is

•(d) The theoretical minimum number of workers

•(e) The available service time against which the line must be balanced is

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Measures of Line Balance Efficiency
differences in minimum rational work element times and the precedence constraints among the
elements
it is virtually impossible to obtain a perfect line balance
Measures must be defined to indicate how good a given line balancing solution is.
balance efficiency,
which is the work content time divided by the total available service time on the line

The complement of balance efficiency is balance delay,

indicates the amount of time lost due to imperfect balancing as a ratio to the total time available

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Line Balancing Algorithm
•The objective in line balancing is to distribute the total workload on the assembly line as evenly as
possible among the workers

Subject to:

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1.Largest Candidate Rule

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2.Kilbridge and Wester Method

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3.Ranked Positional Weights Method

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 Time-Distance Relationships

L= length of the assembly line, m (ft)

Lsi= length of station i, m (ft)
if Length of all stations are equal

fp = feed rate on the line, units/min

sp = center to center spacing between base parts, m/part (ft/part); and

vc = velocity of the conveyor, m/min (ft/min).

 Tolerance time is the time a work unit spends inside the

boundaries of the workstation. Tt>Tc
ET= Elapsed time a work unit

 The total elapsed time a work unit spends on the Tt = tolerance time, min/part
assembly line 65
Other Considerations in Assembly Line Design

Line efficiency
Methods analysis
Sharing work elements between two adjacent stations
Changing work head speeds at mechanized stations
Preassembly of components
Storage buffers between Stations
Zoning constraints
Parallel workstations

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Parallel Work Stations for Better Line Balance

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Alternative Assembly Systems

single-station assembly cell

Assembly Cells

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Automated production lines

High-volume production of parts that require multiple processing operations

Applications
Robotic spot welding in automobile final assembly plants
Sheet metal press working
Electroplating of metals
Fixed Automation

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Where to use automated production Lines

High demand
Stable product design
Long product life
Multiple operations performed on the product during its manufacture
Advantages
Low amount of direct labor
Low product cost, because the cost of fixed equipment is spread over many units
High production rate
Minimal work-in-progress and manufacturing lead time
Minimal use of factory floor space

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Fundamentals of Automated Production Lines

General configuration of an automated production line.

Key: Proc= processing operation, Aut= automated workstation

Raw material to Finished product

Parallel operation of several parts
Manual quality check
Pacing of work station

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Automated Production Lines
Work transport system
Synchronous
Asynchronous
Palletized transfer line
 Pallet fixtures
Free Transfer Line
Part geometry allows transfer of parts with out fixtures

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System Configurations

in-line
straight line arrangement
segmented in-line
two or more straight-line transfer sections,
available floor space may limit the length of the line,
a work piece can be reoriented
the rectangular layout to return of work-holding fixtures
rotary

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Two machining Transfer lines

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Different Types of Conveyors
Linear Transfer Systems
Walking Beam

Cart on Track

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Rotary Indexing Machine-Geneva mechanism

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Rotary Indexing Machine-Geneva mechanism
Ɵ = angle of rotation of worktable during indexing (degrees of
rotation)
N = rotational speed of driver, rev/min
ns = number of equally spaced slots in the Geneva.
The angle of driver rotation during indexing = 2θ
the angle of driver rotation during which the worktable experiences
dwell time is (360 - 2θ)

Example:
A rotary worktable is driven by a Geneva mechanism with six slots, as in the above. The driver
rotates at 30 rev/min. Determine the cycle time, available processing time, and the lost time each
cycle to index the table

Tc= 1/30 = 0.0333 min = 2.0 sec.

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Example 2

•A Geneva with six slots is used to operate the worktable of a dial-indexing machine. The slowest
workstation on the dial-indexing machine has an operation time of 2.5 sec, so the table must be in a
dwell position for this length of time. (a) At what rotational speed must the driven member of the
Geneva mechanism be turned to provide this dwell time? (b) What is the indexing time each cycle?

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Storage Buffer
A location for temporary storage of Parts
Manual
Automated
To reduce the impact of station breakdowns
To provide a bank of parts to supply the line
To provide a place to put the output of the line
To allow for curing time or other process delay
To smooth cycle time variations
For Rotary Indexing Machine
Before a dial-indexing system
Following the dial-indexing machine
Between pairs of adjacent dial-indexing
machines.

Video
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Control Function in an Automated Production Line

Sequential Control
To coordinate the sequence of action of the transfer systems and work stations
Safety Monitoring
To avoid hazardous operation for workers and equipment
Quality Control
To Detect and Possibly reject defective work units produced on the line

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Control Function in an Automated Production Line
Line Controllers
Programmable Logic Controller
Computer based Control
Benefits of computer control
Recording data on process performance, equipment reliability, and product quality
Diagnostic routines to expedite maintenance and repair when line breakdowns occur and to reduce
the duration of downtime incidents
Generation of preventive maintenance schedules to reduce the frequency of downtime occurrences

81
Cycle Time Analysis

Tc = ideal cycle time on the line, min;

Tsi = the processing time at station i, min;
Tr = repositioning time, called the transfer time here, min

The actual average production time Tp can be formulated as follows

•F = downtime frequency, line stops/cycle

•Td = average downtime per line stop, min.
•The downtime Td includes the time for the repair crew to swing into action, diagnose the cause of the
failure, fix it, and restart the line.
•FTd = downtime averaged on a per cycle basis.

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 Cycle Time Analysis
•The frequency of line stops per cycle is obtained by merely summing the frequencies pi over the n stations,
that is,

where F = expected frequency of line stops per cycle, from Equation

pi = frequency of station breakdown per cycle at station i, causing a line stop
n = number of workstations on the line.
If all pi are assumed equal, which is unlikely but useful for approximation and computation purposes

•where all pi are equal, p1 = p2 = ……….. = pn = p

83
Cycle Time Analysis

•automated transfer line is production rate (actual average production rate, pc/min)

•The ideal production rate

•line efficiency

•the proportion of downtime on the line

•Cpc = cost per piece, $/pc; Cm = cost of starting material, $/pc

•Co = cost per minute to operate the line, $/min
•Tp = average production time per piece, min/pc
•Ct = cost of tooling per piece, $/pc.
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Transfer Line Performance
A machine tool builder submits a proposal for a 20-station transfer line to machine a certain component
currently produced by conventional methods. The proposal states that the line will operate at a
production rate of 50 pc/hr at 100% efficiency. On similar transfer lines, the probability of station
breakdowns per cycle is equal for all stations: p = 0.005 breakdowns/cycle. It is also estimated that the
average downtime per line stop will be 8.0 min. The starting casting that is to be machined on the line
costs $3.00 per part. The line operates at a cost of $75.00/hr. The 20 cutting tools (one tool per station)
last for 50 parts each, and average cost per tool is $2.00 per cutting edge. Determine (a) production rate,
(b) line efficiency, and (c) cost per piece produced on the line.

85
Transfer Line Performance
•(a) At 100% efficiency, the line produces 50 pc/hr. The reciprocal gives the unit time, or ideal cycle time
per piece:

•With a station breakdown frequency p = 0.005, the frequency of line stops is

•Given an average downtime of 8.0 min, the average production time per piece is

•Actual average production rate is the reciprocal of average production time per piece:

86
Transfer Line Performance
•Line efficiency is the ratio of ideal cycle time to actual average production time:

The hourly rate of $75/hr to operate the line is equivalent to $1.25/min

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Automated Assembly System
“The use of mechanized and automated devices to perform the various assembly tasks in an assembly
line or cell”

Most automated assembly systems are designed to perform a fixed sequence of assembly steps on a
specific product that is produced in very large quantities

Where is automated assembly appropriate:

High product demand
Stable product design
A limited number of components in the assembly
The product is designed for automated assembly

Automated assembly Vs Automated Production line

Less Capital Investment
Assemble smaller Unit
Less Space
Consume less power 88
Automated Assembly System
Typical Products:

Automated Assembly Process in Automated Production Line

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System Configuration

Subsystems of Automated assembly system

one or more workstations at which the assembly steps are accomplished
parts feeding devices that deliver the individual components to the workstation(s)
a work handling system for the assembled entity

System Configuration
In-line assembly machine
Dial indexing machine
Carousel assembly system
Single-station assembly cell

90
In-Line Assembly Machine

“A series of automatic workstations located along and inline transfer system”

Either synchronous or asynchronous work transfer used

91
Dial Indexing Machine

•Base parts are loaded onto fixtures or nests attached to a circular dial table, and components are added
at workstations located around the periphery of the dial as it indexes from station to station.

synchronous work transfer

92
Carousel Assembly System

“A hybrid between circular work flow of dial indexing machine and straight work flow of in-line system”

Continuous, synchronous or asynchronous transfer mechanisms

93
Single-Station Assembly Cell

94
Multi-Station vs. Single-Station

Multi-station assembly machine or line

Faster cycle rate
High production quantities
More operations possible
More components per assembly
Single-station assembly cell
Suited to robotic assembly
Intended for lower production quantities

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Parts Delivery at Workstations
Typical parts delivery system at a workstation consists of the following hardware components:
Hopper - container for parts
Parts feeder - removes parts from hopper
Selector and/or orientor - to assure part is in Proper orientation for assembly at work head
Feed track - moves parts to assembly work head
Escapement and placement device – removes Parts from feed track and places them at station

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Vibratory Bowl Feeder

Most versatile of hopper feeders for small parts

Consists of bowl and helical track
Parts are poured into bowl
Helical track moves part from bottom of bowl to outlet
Vibration applied by electromagnetic base
Oscillation of bowl is constrained so that parts climb upward along helical track

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Selector and/or Orientor

Purpose - to establish the proper orientation of the components for the assembly workhead
Selector
Acts as a filter
Only parts in proper orientation are allowed to pass through to feed track
Orientor
Allows properly oriented parts to pass
Reorients parts that are not properly oriented

Selector Orientor
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Feed Track
Moves parts from hopper to assembly workhead
Categories:
Gravity - hopper and feeder are located at higher elevation than
workhead
Powered - uses air or vibration to move parts toward workhead

Escapement and Placement Devices

 Escapement device
Removes parts from feed track at time intervals that are consistent
with the cycle time of the assembly work head
Placement device
Physically places the parts in the correct location at the assembly
workstation
Escapement and placement devices are sometimes the same device,
sometimes different devices

99
Escapement and Placement Devices

100
Quantitative Analysis of Assembly Systems

Parts delivery system at workstations

Multi-station assembly machines
Single-station assembly cells
Partial automation

101
Analysis of Automated Assembly Systems
Parts Delivery System at Workstations
f removal rate of components from the hopper
θ be the proportion of components that pass through the selector-orientor
fθ the effective rate of delivery of components from the hopper into the feed track
(1- θ) recirculated back into the hopper
Assume f θ >Rc which leads queue in the feed track
Lf 2 Location of high level sensor (active length of feed track)
Lf 1 Location of low level sensor (active length of feed track)
Lc length of a component in the feed track
Nf 2 = Lf 2/Lc the number of parts that can be held in the feed track at Lf 2
It is the capacity of the feed tracker
•nf 1 = Lf 1/Lc the number of components in the feed track at this point is
•High level sensor is on – Rate of decrease is Rc
•Low level sensor is on – Rate of increase is f θ - Rc

102
Parts Delivery System in Automatic Assembly
•The cycle time for a given assembly work head = 6 sec. The parts feeder has a feed rate of 50
components per min. The probability that a given component fed by the feeder will pass through the
selector is θ = 0.25. The number of parts in the feed track corresponding to the low-level sensor is nf 1 =
6. The capacity of the feed track is nf 2 = 18 parts. Determine (a) how long it will take for the supply of
parts in the feed track to go from nf 2 to nf1, and (b) how long it will take on average for the supply of
parts to go from nf1 to nf 2.

103
Analysis Multistation Assembly Machines
q is the probability that the component to be added during the current cycle is defective (0≤q≤1)
m = probability that a defect results in a jam at the station and consequential stoppage of the line
Three possible events that might occur
The component is defective and causes a station jam. pi=miqi
The component is defective but does not cause a station jam. (1-mi)qi
The component is not defective. (1-qi)
The probabilities of the three possible events must sum to unity for any workstation
Probability of acceptable products

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105
Analysis Multistation Assembly Machines
•A 10-station in-line assembly machine has an ideal cycle time = 6 sec. The base part is automatically
loaded prior to the first station, and components are added at each of the stations. The fraction defect
rate at each of the 10 stations is q = 0.01, and the probability that a defect will jam is m = 0.5. When a
jam occurs, the average downtime is 2 min. Cost to operate the assembly machine is $42.00/hr. Other
costs are ignored. Determine (a) average production rate of all assemblies, (b) yield of good assemblies,
(c) average production rate of good product, (d) uptime efficiency of the assembly machine, and (e) cost
per unit.

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Single-Station Assembly Machines

•ne the number of distinct assembly elements that are performed on the machine
•Tej Each element has an element time, where j = 1, 2, p , ne.
•Th handling time (Min)

•ideal cycle time Tc

•Average production time Tp

•Line Efficiency

107
Single-Station Automatic Assembly System

A single-station assembly machine performs five work elements to assemble four components to a base
part. The elements are listed in the table below, together with the fraction defect rate (q) and probability
of a station jam (m) for each of the components added (NA means not applicable). Time to load the base
part is 3 sec and time to unload the completed assembly is 4 sec, giving a total load/unload time of Th = 7
sec. When a jam occurs, it takes an average of 1.5 min to clear the jam and restart the machine.
Determine (a) production rate of all product, (b) yield of good product, (c) production rate of good
product, and (d) uptime efficiency of the assembly machine.

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109
Analysis of Partial Automation
Assumptions:
workstations perform either processing or assembly operations
processing and assembly times at automated stations are constant, though not necessarily equal at
all stations
the system uses synchronous transfer of parts
the system has no internal buffer storage
station breakdowns occur only at automated stations

Tc The ideal cycle time

na the number of automated stations and
Td average downtime per occurrence.

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Partial Automation
The company is considering replacing one of the current manual workstations with an automatic work
head on a 10-station production line. The current line has six automatic stations and four manual
stations. Current cycle time is 30 sec. The limiting process time is at the manual station that is proposed
for replacement. Implementing the proposal would allow the cycle time to be reduced to 24 sec. The new
station would cost $0.20/min. Other cost data: Cw = $0.15/min, Cas = $0.10/min, and Cat $0.12/min.
Breakdowns occur at each automated station with a probability p = 0.01. The new automated station is
expected to have the same frequency of breakdowns. Average downtime per occurrence Td = 3.0 min,
which will be unaffected by the new station. Material costs and tooling costs will be neglected in the
analysis. It is desired to compare the current line with the proposed change on the basis of production
rate and cost per piece. Assume a yield of 100% good product.

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