Unit 4: Automation

What is automation?

What is automation?
Automation can be defined as the technology concerned with the
application of complex mechanical, electronic, and computer-based
systems in the operation and control of manufacturing systems.

Automation is the use of control systems (such as numerical control,

programmable logic control, and other industrial control systems), in
concert with other applications of information technology (such as
computer-aided technologies [CAD, CAM,]), to control industrial
machinery and processes, reducing the need for human intervention.

Two categories of automation in the production system:

1. Automation of manufacturing systems in the factory
2. Computerization of the manufacturing support systems

Automated Manufacturing Systems

Examples:
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots that perform processing or assembly operations
Automated material handling and storage systems to integrate
manufacturing operations
Automatic inspection systems for quality control

Types of Automation
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation

Fixed Automation
A manufacturing system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration.
Typical features:
Suited to high production quantities
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodating product variety
fixed automationinclude machining transfer lines found in the
automotive industry, automatic assembly machines, and certain
chemical processes

Programmable Automation
A manufacturing system designed with the capability to change the
sequence of operations to accommodate different product configurations
Typical features:
High investment in general purpose equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in product configuration
Most suitable for batch production
Physical setup and part program must be changed between jobs
(batches)

Flexible Automation
An extension of programmable automation in which the system is
capable of changing over from one job to the next with no lost time
between jobs
Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of products
Medium production rates
Flexibility to deal with soft product variety

Product Varity

Programmable
Automation
Flexible Automation

Fixed Automation

100

10000
Production quantity

100000

Reasons for Automating

1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating

CIM
Computer Integrated Manufacturing

The manufacturing engineers are required to achieve the

following objective to be competitive in a global context.

Reduction in Inventory

Lower the cost of the Product

Reduce waste

mprove Quality

ncrease flexibility in manufacturing to achieve immediate and rapid response to

Product change
Production change
Process change
Equipment change
Change of Personnel

All these Objectives are achieved by CIM

What is CIM ?

C- Computer
I- Integrated
M- Manufacturing

CIM encompasses the entire range of product development and Manufacturing ac

h all the functions being carried out with the help of dedicated software.

ll the manufacturing and related activities are carried out under computer contr

M uses a common database whenever feasible and communication technologies

grate design, manufacturing and associated business functions that combine th
omated segments of a factory or manufacturing facility.

CIM

Manufacturing equipment such as CNC machines or computerse

workcentres , robotics works cells, DNS/FMS systems, work hand
CIM Hardware
and tool handling devices, storage devices, sensors, shop floor
Collection devices, inspection machines etc.

CIM Software

CAD/CAM/ CAE software

CIM Elements

FMS ( Flexible Manufacturing system )

MS ( Flexible Manufacturing system )

a manufacturing philosophy based on the concept of effectively controlling mat

hrough a network of versatile production station using an efficient and versatile
al handling and storage.

ible manufacturing system is an arrangement of machine, interconnected

port system. The transport system carries work to the machine on pallets or ot

ace units.

In-line Layout

Loop Layout

Rectangular
Layout

Basic Components of FMS

1. Work station or processing station
2. Automated material handling
3. Computer controlled system

rk station or processing station : They are typically CNC machine tools that perfo
machining operation

utomated material handling : They are used to transport work parts and sub asse
parts between the processing station. AVG

mputer controlled system: It is used to co-ordinate the activities of the processing

stations and the material handling system in the FMS.
MATERIAL STORAGE
MATERIAL HANDELING
Maste
r
PC

Materi
al
Loadin
g

1 or more
integrated M/c
Centre

TYPES OF FLEXIBLITY

Operation flexibility:
It is ability to perform more than one operation on a given part type

Part flexibility:
It is the ability to perform operation on more than one part at a time

Change over flexibility:

It is the flexibility to change from one part to another in negligible change ove
times in parallel when an operation is being performed on another piece.

Routing flexibility:
It means that a particular part an be deliver to any one of the no of alternativ
station

Path flexibility:
It results from the existence of more than one possible path from a specified or
to a specified destination

Types of FMS
1. Flexible Manufacturing cell (FMC)
2. Flexible Manufacturing system (FMS)
3. Flexible Manufacturing Line ( FML )

Group Technology

Types of GT cells
(a) Single machine
(b) Multiple machines with manual
handling
(c) Multiple machines with mechanized
handling
(d) Flexible manufacturing cell
(e) Flexible manufacturing system

Grouping the parts

1. Visual Inspection
2. Production flow analysis ( PFA)
3. Parts Classification and coding system
i. Opitz system
ii. MICLASS system
iii. CODE system

basic code structure used in GT applications

1. Chain-Type Code Structure (Polycode)

MICLASS System
The System consists of 30 digits (maximum)
1 2 3 4 ..... 12
13 14
15 ..... 30
Universal Code
Special Code
(for any part)
(for any company or industry including lot size,
cost data,
time, operation sequence, etc.)

Classification and Coding:

1. Design Attribute Group

Dimensions
Tolerances
Shape
Finnish
Material

2. Manufacturing Attribute Group

Production process
Operational time
Tools required
Fixtures required
Batch size
3. Combined

Opitz coding

The
three groups of digits:
Form
code
12345

system consists of

Supplementary
Secondary
code
code
6789
ABCD

part
geometry and
features
relevant to
part design

information
relevant to
manufacturin
g
(polycode)

Production
processes and
production
sequences

32

33

Form code in Opitz system for rotational parts in classes 3, and 4

34

Supplemental code in Opitz system

35

The OPITZ classification system

Example

36

The OPITZ classification system

Example: Given the part design shown define the "form code" using the Opitz
system
Step 1: The total length of the part is 1.75, overall diameter 1.25, L/D = 1.4
(code 1)
Step 2: External shape - a rotational part that is stepped on both with one
thread (code 5)
Step 3: Internal shape - a through hole (code 1)
Step 4: By examining the drawing of the part (code 0)
Step 5: No auxiliary holes and gear teeth (code 0)
Code: 15100

Computer Aided Process Planning (CAPP)

Computer Integrated Manufacturing

(CIM)
Computer Aided Design (CAD)
2D
3D
Concurrent Engineering

Computer Aided Process Planning (CAPP)

Variant
Generative

Computer Aided Manufacturing (CAM)

CNC
Robotics
Material Handling
Just in Time (JIT)
Group Technology
Flexible Manufacturing Systems

Process planning can be defined as an act of preparing

processing documentation for the manufacturing of a piece, part
or an assembly

When process planning is done using a computer : Computer Aided

Process Planning

1. Process planning is concerned with the preparation of route sheets that

list the sequence of operations and work centers require to produce the
product and its components.

Step-by-step
operations in
a sample part

Components of Process
Planning

Selection of machining operations

Sequencing of machining operations
Selection of cutting tools
Determining the setup requirements
Calculation of cutting parameters
Tool path planning and generation of
NC/CNC programs
Design of Jigs/Fixtures

PROCESS PLANNING STEPS

Study the overall shape of the part. Use this

information to classify the part and determine
the type of workstation needed.
Thoroughly study the drawing. Try to identify
every manufacturing features and notes.
If raw stock is not given, determine the best
raw material shape to use.
Identify datum surfaces.
Select machines for each setup.
For each setup determine the rough sequence
of operations necessary to create all the
features.

PROCESS PLANNING STEPS

(continue)
Sequence the operations determined in the
previous step.
Select tools for each operation. Try to use the
same tool for several operations if it is possible.
Keep in mind the trade off on tool change time
and estimated machining time.
Select or design fixtures for each setup.
Evaluate the plan generated and make
necessary modifications.
Select cutting parameters for each operation.
Prepare the final process plan document.

Variant CAPP