AUTOMATED PRODUCTION

LINES
PRODUCTION LINES
high production
require multiple processing operations.
Each processing operation is performed at
a workstation, and
the stations are physically integrated by
means of a mechanized work transport
system to form an automated production
line.
PRODUCTION LINES
Machining (milling, drilling, and similar
rotating cutter operations) is a common
process performed on these production
lines, in which case the term transfer fine
or transfer machine is used.
PRODUCTION LINES
Other applications of automated production
line, include robotic spot welding in
automobile final assembly plants, sheet
metal press working, and electroplating of
metals.
Similar automated lines are used for
assembly operations; however, the
technology of automated assembly is
sufficiently different that we postpone
coverage of this topic until the next
chapter.
PRODUCTION LINES
Automated production lines require a
significant capital investment. They are
examples of fixed automation and it is
generally difficult to alter the sequence and
content of the processing operations once
the line is built. Their application is
therefore appropriate only under the
following conditions:
PRODUCTION LINES
High product demand,
Stable product design
Long product life (at least several years
in most cases)
Multiple operations are performed on the
product during its manufacture.
PRODUCTION LINES

When the application satisfies these

conditions automated production lines
provide the following benefits:
PRODUCTION LINES
Low direct labour content
Low product cost because cost of fixed
equipment is spread over many units.
High production rates.
Production lead time and work-in-process
are minimised,
Factory floor space is minimized.
FUNDAMENTALS OF AUTOMATED
PRODUCTION LINES
An automated production line consists of

multiple workstations that are linked

together by a work handling system that
transfers parts from one station to the next .
A raw work part enters one end of the line,

and the processing steps are performed

sequentially as the part progresses forward.
FUNDAMENTALS OF AUTOMATED
PRODUCTION LINES

The line may include inspection stations to

perform intermediate quality check"
Also, manual stations may also be located
along the line to perform certain operations
that are difficult or uneconomical to
automate.
FUNDAMENTALS OF AUTOMATED
PRODUCTION LINES

Each station performs a different operation,

so that the sum total of all the operations is

required to complete one unit of work.
Multiple parts are processed simultaneously
no the line. one part at each workstation.,
FUNDAMENTALS OF AUTOMATED
PRODUCTION LINES
In the simplest form at production
line. the number of parts on the line at
any moment is equal to the number of
workstations, as indicated in our
figure.

In more complicated lines, provision is

made for temporary parts storage between
stations, in which case there is on average
more than one part per station.
FUNDAMENTALS OF AUTOMATED
PRODUCTION LINES
An automated production line operates in
cycles, Each cycle consists of
processing time plus the time to
transfer parts to their respective next
workstations.

The slowest workstation on the line sets the

pace of the line, just as in an assembly line.
IN LINE
L & U- SHAPED
RECTANGULAR
ROTARY
EXAMPLE OF PRODUCTION
LINE
Workpart Transfer
Mechanisms

to move parts between stations on the

production line, a function performed by

means of transfer mechanisms that are

either synchronous or asynchronous.

Linear Transfer Systems
walking beam system
Rotary Indexing Mechanisms
GENEVA MECHANISM
Storage Buffers

A storage buffer in a production line is a

location where parts can be collected and
temporarily stored before proceeding to
subsequent (downstream) workstations.
There are a number of reasons why storage
buffers are used on automated production
lines. The reasons include :

To reduce the effect 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 required
delay.
To smooth cycle time variations.
 ANALYSIS OF TRANSFER UNES
WITH NO INTERNAL STORAGE
Assumptions about the operation of the
transfer lines and rotary indexing machines:

The workstations perform

processing operations, such as
machining, not assembly;
Processing times at each station are
constant, though not
Necessarily equal;
synchronous transfer of parts; and
no internal storage buffers.
ANALYSIS OF TRANSFER UNES WITH
NO INTERNAL STORAGE (contd)

This interval defines the ideal cycle time Tc

of the production line. Tc is the processing
time for the slowest station on the line plus
the transfer time; that is,