6021-B[CIM]

MODULE 4

Discuss the automation related to material handling, storage, inspection

CO4
and manufacturing system.
Describe various automated material
M4.01 4 Understanding
handling and storage systems
Describe various automated inspection
M4.02 5 Understanding
technologies.
Describe the manufacturing systems and
M4.03 5 Understanding
factors for selection.
Series Test - II 1

Contents:
Material handling - Fixed Routing and Variable Routing; List of Material Handling
Equipments for Each Routing.
Storage - Automated Storage/Retrieval System (AS/RS) and Carousel Storage System
(Introduction Level Only).
Inspection Technologies - Comparison of Contact and Non-Contact Inspection Techniques,
CMM and Machine Vision (Introduction with Simple Diagram).
Manufacturing Systems - Factors for Selection, Types - Single Station Cell, Multistation
Fixed Routing, Multistation variable Routing (Introduction Level Only].

1
6021-B[CIM]

Material handling
Material handling refers to the movement, storage, control,
and protection of materials and products throughout the
manufacturing process, distribution, consumption, and
disposal. It plays a crucial role in manufacturing and logistics
operations, contributing to efficiency, safety, and cost-
effectiveness.
➢ Fixed routing
Fixed routing, also known as fixed-path material handling, is a
method used in material handling systems where the
movement of materials or products follows predetermined
and fixed routes within a facility or between specific
locations.

Here are key aspects of fixed routing:

1. Defined Paths: In fixed routing, the paths or routes for

material movement are predetermined and fixed,
usually defined by physical infrastructure such as
conveyor belts, overhead cranes, or automated guided
vehicles (AGVs). These paths are designed based on the
layout of the facility and the flow of materials in the
production process.

2. Limited Flexibility: Unlike flexible routing systems where

paths can be dynamically adjusted, fixed routing systems
2
6021-B[CIM]

have limited flexibility in changing the paths or routes.

Any changes to the routing typically require physical
modifications to the infrastructure.

3. Efficiency: Fixed routing systems are often designed for

specific production processes or material flows, aiming
to optimize efficiency by minimizing travel distances,
reducing congestion, and ensuring a smooth flow of
materials.

4. Predictability: Since the routes are fixed, the movement

of materials in fixed routing systems is predictable and
can be easily monitored and controlled. This
predictability is beneficial for planning production
schedules and managing inventory levels.

5. Automation: Fixed routing systems can be automated

using technologies such as conveyor systems, AGVs, or
automated storage and retrieval systems (AS/RS), which
can operate independently following the predefined
routes.

6. Applications: Fixed routing is commonly used in

manufacturing environments for repetitive production
processes where the material flow is stable and

3
6021-B[CIM]

predictable, such as assembly lines, machining

operations, and material handling in warehouses.

7. Cost-Effectiveness: Fixed routing systems can be cost-

effective in terms of initial investment and maintenance,
especially for high-volume production processes where
the benefits of optimized material flow outweigh the
limitations of flexibility.

While fixed routing offers benefits in terms of efficiency and

predictability, it may not be suitable for environments that
require frequent changes in material flow or flexible
production processes. In such cases, more flexible material
handling systems, such as flexible routing or agile
manufacturing systems, may be more appropriate.
Equipment commonly used for fixed routing in material
handling systems includes:

1. Conveyor Systems: Conveyor belts and roller conveyors

are used to transport materials along fixed paths within
a facility. They are suitable for moving a wide range of
products, from small components to large and heavy
items, and can be configured to accommodate various
layouts and production processes.

4
6021-B[CIM]

2. Overhead Cranes: Overhead cranes are used for lifting

and moving heavy loads along fixed paths in
manufacturing and warehouse environments. They are
typically mounted on tracks attached to the ceiling or
support structures, allowing for efficient movement of
materials within a designated area.

3. Automated Guided Vehicles (AGVs): AGVs are

autonomous vehicles equipped with guidance systems
that allow them to follow predefined paths or routes
within a facility. They are commonly used for
transporting materials between production areas,
storage locations, and loading docks without the need
for human intervention.
4. Palletizers and Depalletizers: These machines are used to
stack and unstack pallets of goods. They can operate
along fixed paths to handle palletized loads efficiently,
especially in warehouse and distribution center
environments.

5. Sortation Systems: Sortation systems use conveyor belts,

diverters, and sensors to sort and route items to
different destinations based on predefined criteria. They
are often used in shipping and distribution centers to
streamline the process of sorting and routing packages.

5
6021-B[CIM]

6. Monorail Systems: Monorail systems consist of a single

rail track on which carriers or trolleys move to transport
materials or products. They are used for continuous or
point-to-point transportation along fixed routes in
manufacturing and assembly operations.

➢ Variable routing:
Variable routing, also known as flexible routing, is a method
used in material handling systems where the paths or routes
for material movement can be dynamically adjusted based on
changing production needs, inventory levels, or other factors.
Here are key aspects of variable routing:

1. Dynamic Path Selection: In variable routing systems, the

paths or routes for material movement are not fixed but
can be dynamically selected or adjusted based on real-
time conditions. This flexibility allows for more agile and
adaptable material flow within a facility.

2. Adaptive Control Systems: Variable routing systems are

often equipped with adaptive control systems that can
analyze current conditions, such as machine availability,
inventory levels, and production schedules, to
determine the most efficient routing for materials.

3. Multiple Path Options: Unlike fixed routing systems,

which have predefined paths, variable routing systems
6
6021-B[CIM]

can offer multiple path options for material movement.

This flexibility allows for optimization of material flow
based on factors such as congestion, equipment
availability, and production priorities.

4. Automation and Robotics: Variable routing systems can

be integrated with automated guided vehicles (AGVs),
robotic arms, or other automated equipment that can
dynamically navigate through the facility and adapt their
routes based on real-time conditions.

5. Real-Time Monitoring and Control: Variable routing

systems rely on real-time monitoring of production data,
inventory levels, and equipment status to make dynamic
routing decisions. This real-time control allows for quick
response to changes in demand or production priorities.

6. Optimization Algorithms: Variable routing systems may

use optimization algorithms to determine the most
efficient routes for material movement, taking into
account factors such as distance, travel time, and
resource availability.

7. Applications: Variable routing is particularly beneficial in

environments with dynamic production processes,
changing production schedules, or high product mix

7
6021-B[CIM]

variability. It is commonly used in industries such as

automotive manufacturing, electronics assembly, and e-
commerce fulfillment centers.

Variable routing systems offer advantages such as improved

flexibility, adaptability to changing production needs, and
optimized material flow. However, they may require more
sophisticated control systems and technologies compared to
fixed routing systems.
➢ Equipment and technologies required for variable
routing:

1. Automated Guided Vehicles (AGVs): AGVs are

autonomous mobile robots that can navigate through a
facility using various guidance systems such as laser,
magnetic tape, or vision-based navigation. They can be
programmed to dynamically adjust their routes based on
real-time conditions.

2. Conveyor Systems with Diverter Gates: Conveyor

systems equipped with diverter gates can redirect
materials to different paths or destinations based on
real-time instructions. This allows for flexible routing of
materials within a conveyor network.

8
6021-B[CIM]

3. Robotic Arms and Manipulators: Robotic arms can be

used to pick, place, and move materials in a flexible
manner. They can adapt their motions and paths based
on the specific requirements of the production process
or the layout of the facility.

4. Real-Time Monitoring and Control Systems: These

systems include sensors, actuators, and control software
that can monitor production data, inventory levels, and
equipment status in real time. They enable the dynamic
adjustment of material handling routes and operations
based on changing conditions.

5. Optimization Software and Algorithms: Advanced

software tools and algorithms can analyze production
data and optimize material handling routes and
operations to maximize efficiency and throughput. These
tools can take into account factors such as machine
availability, inventory levels, and production schedules
to make dynamic routing decisions.

6. Communication and Integration Interfaces: Systems for

communication and integration with other
manufacturing and logistics systems are crucial for
enabling real-time data exchange and coordination of
material handling activities. This includes interfaces with
9
6021-B[CIM]

ERP systems, warehouse management systems (WMS),

and production planning systems.

➢ Automated Storage and Retrieval System (AS/RS):

Automated Storage and Retrieval Systems (AS/RS) are
computer-controlled systems that automatically store and
retrieve materials from storage locations. They are commonly
used in warehouses, distribution centers, and manufacturing
facilities to efficiently manage inventory and improve storage
density. AS/RS systems consist of racks, shelves, and
automated storage and retrieval machines (AS/RS machines)
that move along aisles to access storage locations. The
system is controlled by a central computer that manages
inventory, tracks the location of items, and directs the
movement of AS/RS machines.

➢ Carousel Storage System:

Carousel Storage Systems are automated storage systems
that consist of a rotating shelving unit or carousel. The
carousel rotates horizontally or vertically to bring storage bins
or shelves containing items to a pick station, where operators
can access the items. Carousel systems are used in
warehouses and distribution centers to store and retrieve
small parts or items efficiently. They are often used in
conjunction with picking systems to streamline order
fulfillment processes. Carousels can be controlled manually

10
6021-B[CIM]

or automated using computer control systems for improved

efficiency and accuracy.

Comparison of Contact & Non-contact inspection techniques

Aspect Contact Inspection Non-Contact Inspection

Physically touching the object with a Using optical, laser, or other sensors from a
Method probing device distance

Calipers, micrometers, CMMs with touch Optical scanners, laser scanners, vision
Equipment probes, gauges systems

Accuracy High, especially with precise instruments High, comparable to contact inspection

Depends on complexity and operator skill,

Speed can be slow Can be faster, especially for complex shapes

Surface
Damage May cause surface damage or wear Does not cause surface damage or wear

Suitable for measuring dimensions, depths, Suitable for measuring complex shapes,
Applications and roughness contours, surfaces

Examples:
➢ Contact inspection techniques
• Calipers: Used to measure the distance between two
opposite sides of an object. There are various types of
calipers, including vernier calipers, dial calipers, and
digital calipers.

• Micrometers: Used to measure the diameter or

thickness of small objects with high precision. Types of
micrometers include outside micrometers, inside
micrometers, and depth micrometers.

11
6021-B[CIM]

• Height Gauges: Used to measure the height of objects or

the depth of grooves or holes. They consist of a base, a
vertical column, and a measuring head.

• Coordinate Measuring Machine (CMM) with Touch

Probe: A CMM is a machine used to measure the
geometry of objects. When equipped with a touch
probe, it can measure the dimensions of objects by
physically contacting them at various points.

• Surface Roughness Testers: Used to measure the

roughness of a surface. They typically use a stylus that
moves along the surface to measure the peaks and
valleys.

• Force Gauges: Used to measure the force required to

move an object or compress a material. They can be
handheld or mounted on a testing machine.

• Durometers: Used to measure the hardness of materials,

particularly polymers and elastomers. They typically use
a sharp point or an indenting tool to measure the
material's resistance to penetration.

12
6021-B[CIM]

• Tactile Probes: Used in metrology and quality control to

measure features of a part by physically touching its
surface. Tactile probes are often used in conjunction
with coordinate measuring machines (CMMs).

➢ Non-contact inspection techniques

• Vision Systems: Use cameras and image processing
software to capture and analyze images of the
object. Vision systems are often used for inspecting
surface defects, measuring dimensions, and
verifying assembly processes.
• Laser Scanners: Use laser beams to scan the surface
of the object and create a 3D model. Laser scanners
are used for measuring complex shapes, contours,
and surface profiles with high accuracy.
• Optical Scanners: Use light patterns to capture the
surface of the object and create a digital
representation. Optical scanners are used for
digitizing physical objects for reverse engineering,
quality control, and inspection.
• Profilometers: Use a stylus or laser beam to
measure surface roughness. Profilometers are used
for quantifying the texture and finish of surfaces.
• Infrared Thermography: Use infrared cameras to
measure the temperature distribution of an
object's surface. Infrared thermography is used for

13
6021-B[CIM]

detecting defects, monitoring thermal properties,

and analyzing heat flow.
• Ultrasonic Testing: Use high-frequency sound waves
to inspect the internal structure of objects.
Ultrasonic testing is used for detecting defects,
measuring material thickness, and analyzing
material properties.
• Eddy Current Testing: Use electromagnetic
induction to inspect conductive materials. Eddy
current testing is used for detecting surface cracks,
measuring material thickness, and analyzing
material composition.
• X-ray Imaging: Use X-rays to inspect the internal
structure of objects. X-ray imaging is used for non-
destructive testing of welds, castings, and
assemblies.
CMM and Machine Vision
Coordinate Measuring Machine (CMM) and machine vision
are both technologies used for measurement and inspection
in manufacturing. CMMs are well-suited for high-precision
measurements of complex geometries, while machine vision
systems are more versatile and can be faster for certain
applications. The choice between the two depends on factors
such as the accuracy requirements, speed of measurement,
and the complexity of the objects being measured.

Here's a comparison of the two:

14
6021-B[CIM]

1. Principle of Operation:
• CMM: A CMM is a mechanical system with a
measuring probe that physically touches the
surface of the object being measured. It uses
XYZ coordinates to measure the dimensions
and geometry of the object.
• Machine Vision: Machine vision uses cameras
and image processing algorithms to capture
and analyze images of the object. It measures
dimensions and features based on the image
data.
2. Measurement Accuracy:
• CMM: CMMs can provide high accuracy,
typically in the range of micrometers (0.001
mm). The accuracy depends on factors such as
the type of probe used and the calibration of
the machine.
• Machine Vision: Machine vision systems can
also provide high accuracy, but the accuracy is
influenced by factors such as camera
resolution, lens quality, and lighting
conditions.

3. Speed and Throughput:

• CMM: CMMs are generally slower compared
to machine vision systems, especially for
complex measurements or inspections that
require multiple points to be measured.

15
6021-B[CIM]

• Machine Vision: Machine vision systems can

be faster, especially for measurements that
can be made from a single image or for
inspecting large numbers of parts in a short
time.
4. Complexity of Setup:
• CMM: Setting up a CMM for measurement or
inspection requires careful calibration and
programming of the machine to ensure
accurate results.
• Machine Vision: Setting up a machine vision
system involves configuring cameras, lighting,
and image processing algorithms. While it can
be complex, modern machine vision systems
often have user-friendly interfaces for setup.
5. Applications:
• CMM: CMMs are often used for measuring
complex geometries, inspecting tight
tolerances, and performing 3D measurements
of parts.
• Machine Vision: Machine vision is used for a
wide range of applications, including part
inspection, defect detection, robot guidance,
and barcode reading.
6. Cost:
• CMM: CMMs can be expensive, especially for
high-precision models with advanced features.
• Machine Vision: Machine vision systems can
also be costly, depending on the complexity of
16
6021-B[CIM]

the system and the requirements of the

application.

Co-ordinate measurement machine

17
6021-B[CIM]

Manufacturing systems
Manufacturing systems play a crucial role in production
operations, and selecting the right type of system is essential
for optimizing efficiency, quality, and cost-effectiveness.
Here's an introduction to factors for selection and types of
manufacturing systems:

❖ Factors for Selection of Manufacturing Systems:

• Product Complexity: The complexity of the product

being manufactured can influence the choice of
manufacturing system. Simple products may be
produced more efficiently in a single station cell, while
18
6021-B[CIM]

complex products may require a multistation variable

routing system.
• Production Volume: The volume of production can
impact the selection of a manufacturing system. High-
volume production may benefit from automated
systems, while low-volume production may be more
suited for manual or flexible systems.
• Flexibility: The ability to adapt to changing production
requirements is important. Flexible manufacturing
systems (FMS) or multistation variable routing systems
offer greater flexibility compared to single station cells.
• Automation Level: The level of automation required
depends on factors such as production volume, product
complexity, and cost considerations. Highly automated
systems can improve efficiency but may require
significant investment.
• Quality Requirements: The manufacturing system should
be capable of meeting quality standards. Systems with
built-in quality control measures, such as inspection
stations, may be preferred for ensuring product quality.
• Cost Considerations: The cost of implementing and
operating the manufacturing system is a key factor. It's
important to balance the initial investment with long-
term benefits and ROI.
• Space Availability: The available space in the
manufacturing facility can influence the choice of
system. Systems that require less space, such as single
station cells, may be preferred in limited space
environments.
19
6021-B[CIM]

❖ Types of Manufacturing Systems:

➢ Single Station Cell:
A single station cell is a basic manufacturing system consisting
of a single workstation or cell where all operations are
performed.
It is suitable for simple products with low to medium
production volumes.
Offers low to moderate flexibility, as the production process is
fixed and not easily adaptable to changes.
➢ Multistation Fixed Routing:
In a multistation fixed routing system, the workpiece moves
through a series of workstations or stations, with each station
performing a specific operation.
The routing of the workpiece is fixed, and each station is
dedicated to a specific task.
Suitable for products with moderate complexity and
production volumes, offering higher efficiency compared to
single station cells.
➢ Multistation Variable Routing:
A multistation variable routing system allows for flexibility in
the routing of the workpiece, with the ability to change the
sequence of operations based on production requirements.
Offers high flexibility and adaptability, making it suitable for
complex products with varying production requirements.

20
6021-B[CIM]

May require more sophisticated control systems and

equipment compared to fixed routing systems.
In conclusion, the selection of a manufacturing system
should be based on a careful evaluation of factors such as
product complexity, production volume, flexibility
requirements, automation level, quality standards, cost
considerations, and space availability. Each type of
manufacturing system has its advantages and limitations, and
the choice should be made based on the specific needs and
constraints of the manufacturing operation.

21