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IB-CIM Lecture 4
IB-CIM Lecture 4
Automation
Type of Automation
Automation Strategies
Definition of Automation
The automated elements of the production system can be separated into two categories:
(1) automation of the manufacturing systems in the factory.
(2) Computerization of the manufacturing support systems.
Automated Manufacturing Systems
fixed automation
Fixed automation refers to the use of special purpose equipment to automate a fixed
sequence of processing or assembly operations.
Each of the operation in the sequence is usually simple, involving perhaps a plain linear or
rotational motion or an uncomplicated combination of two.
fixed automation
Advantages:
1. Low unit cost
2. Automated material handling
3. High production rate.
Type of Automation
fixed automation
Disadvantages:
1. High initial Investment
2. Relatively inflexible in accommodating product changes.
Type of Automation
programmable automation
In programmable automation, the production equipment is designed with the capability
to change the sequence of operations to accomodate different product configurations.
The operation sequence is controlled by a program, which is a set of instructions coded.
So that they can be read and interpreted by the system.
New programs can be prepared and entered into the equipment to produce new products.
Type of Automation
programmable automation
Advantages:
1. Flexible to deal with design variations.
2. Suitable for batch production.
Type of Automation
programmable automation
Disadvantages:
1. High investment in general purpose equipment
2. Lower production rate than fixed automation.
Type of Automation
programmable automation
Example:
Numerical controlled machine tools.
Industrial robots.
Programmable logic controller.
Type of Automation
flexible automation
Flexible automation is an extension of programmable automation.
A flexible automation system is capable of producing a variety of parts with
virtually no time lost for changeovers from one part style to the next. There
is no lost production time while reprogramming the system and altering the
physical set up.
Type of Automation
flexible automation
Advantages:
1. Continuous production of variable mixtures of product.
2. Flexible to deal with product design variation.
Type of Automation
flexible automation
Disadvantages:
1. Medium production rate
2. High investment.
3. High ‘unit cost relative to fixed automation.
Type of Automation
Types of facilities and layouts used for different
levels of production quantity and product variety
Type of Automation
information processing
production
product design
planning
Computer Integrated
Manufacturing
Activities in Manufacturing
occur in an occur in
Office the Factory
Computer Integrated
Manufacturing
Activities in Manufacturing
The relationship between the physical activities and the information processing
Computer Integrated
Manufacturing
Activities in
produc Manufacturing
t
design
Manufacturin
g informatio
business
planning n
processing functions
manufacturin
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control
Reasons for Automating
1. Increased productivity.
2. High cost of labor.
3. Labor shortages.
4. Safety.
5. High cost of raw materials.
6. Improved product quality.
7. Reduced manufacturing lead time.
8. High cost of not automating.
Reasons for Automating (1)
Increased productivity
Automation of manufacturing operations help in increasing the
productivity of labor.
This means greater output per hour of labor input.
Higher production rates are achieved with automation than with the
corresponding manual operations.
Reasons for Automating (2)
Labor shortages.
In many advanced nations there has been a general
shortage of labor.
Labor shortages also stimulate the development of
automation as a substitute for labor.
Reasons for Automating (4)
Safety.
Understand
Simplify
Automate the process
Automation Strategies
USA Principle
1. Understand the existing process.
2. Simplify the process.
3. Automate the process.
USA Principle
Automation Strategies
Understand the Existing Process
1.Specialization of operations
1. production machines
2. workstations
5. Increased flexibility
7. On-line inspection
This means that any poor quality product has already been
produced by the time it is inspected.
Automation Migration
Strategy
Phase 1: Manual production
Phase 2: Automated production
Phase 3: Automated integrated production.
Advantages of Automation Migration Strategy
Automation Strategies