3. 3
• Mfg. Support System
- procedures used to manage prod. and to
solve logistics & technical prob.
Facilities
- the equipments in factory and the way
the equipment is organized. It includes
machines, tooling, material handling
equipment, inspection equipment, comp. &
plant layout.
INTRODUCTION… cont.
6. 6
INTRODUCTION… cont.
• Industrial Automation:
• The technology by which a process or
procedure is accomplished without human
assistance.
• A technique that can be used to reduce costs
and/or to improve quality.
• Can increase manufacturing speed, while
reducing cost.
7. 7
• Can lead to products having consistent
quality, perhaps even consistently good
quality
• It is implemented using a program of
instructions combined with a control system
that executes the instructions.
INTRODUCTION…cont.
8. 8
• To automate a process, power is required,
both to drive the process itself and to
operate the program and control system.
• Automated processes can be controlled by
human operators, by computers, or by a
combination of the two.
INTRODUCTION…cont.
9. 9
Definition 1
• Automation is a technique that can be used to
reduce costs and/or to improve quality. Automation
can increase manufacturing speed, while reducing
cost. Automation can lead to products having
consistent quality, perhaps even consistently good
quality.
Definition 2
• Automation is a technology concerned with
application of mechanical, electronic and
computer-based system to operate and
control system. This technology includes;
10. 10
• Automatic assembly machines
• Automation machine tools to process
parts
• Industrial robots
• Automatic materials handling and
storage system
• Automatic inspection system and
quality control
• Feedback control and computer
process control
• Computer system for planning, data
collection and decision making to
support manufacturing activities
11. 11
• If a human operator is available to monitor
and control a manufacturing process, open
loop control may be acceptable.
• If a manufacturing process is automated, then
it requires closed loop control, also known
as feedback control.
• example of open loop control and closed loop
control.
INTRODUCTION…cont.
15. 15
Arguments in favor of Automation
• Automation is the key to shorter work week –
working hours per week reduces and , allowing
more leisure hours and a higher quality of life.
• Automation brings safer working conditions for
workers.
• Automated production results in lower prices and
better products
16. 16
Arguments against Automation
• It result in the subjugation of human being by a
machine – reduces the need for skilled labor
• There will be reduction in the labor force –
resulting un employment.
• Automation will reduce purchasing power-
markets will become saturated with products that
people cannot afford to purchase.
17. 17
SOME CONSIDERATIONS
• What automation and control technology
is available?
• Are employees ready and willing to use
new technology?
• What technology should be used?
• Should the current mfg process be
improve before automation?
• Should the product be improved before
spending millions of ringgit acquiring
equips.
18. 18
MANUAL LABOR IN PRODUCTION
SYSTEMS
• Task is too technologically difficult to
automate.
• Short product life cycle.
• Customized product.
• To cope with ups and downs in demand.
• To reduce risk of product failure.
19. 19
BASIC ELEMENT OF AN AUTOMATED
SYSTEM
• Consists of 3 basic elements:
1) The actuator (which does the work)
• Controlled by the controller.
• The actuator in a automated
process may in fact be several
actuators, each of which provides
an output that drives another in
the series of actuator.
20. 20
• Some actuators can only be on and
off. Other actuators respond
proportionally with the signal they
receive from a controller
• Actuators can be selected for the
types of inputs they require, either
DC or AC.
BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
21. 21
2)The controller (which ‘tells’ the
actuator to do work)
» A controlled system either
may be a simple digital
system or an analog system.
» Digital and analog controllers
are available ‘off the shelf’
so that systems can be
constructed inexpensive and
with little specialized
knowledge required.
BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
22. 22
3) The sensor (which provides
feedback to the controller so that
it knows the actuator is doing work)
• Obviously, controlled automation
requires devices to sense system
output.
• Sensors also can be used so that a
controller can detect and respond
to changing conditions in its
working environment.
BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
23. 23
• Switches and transducers are
another name for sensors.
• Switches can detect when a
measured condition exceeds a pre-
set level. Examples, closes when a
work-piece is close enough to work
on.
• Transducers can describe a
measured condition. Examples,
output increased voltage as a work-
piece approaches the working zone.
BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
24. 24
TYPE OF AUTOMATION
• Hard Automation
– Controllers were built for specific
purposes and could not be altered easily.
– Early analog process controllers had to
be rewired to be reprogrammed.
25. 25
– This controllers do what they are
designed and built to do, quickly and
precisely perhaps, but with little
adaptability for change (beyond minor
adjustments).
– Modification of hard automation is
time-consuming and expensive, since
modifications can only be performed
while the equipment sits idle.
TYPE OF AUTOMATION…cont.
26. 26
• Soft Automation
– Modern digital computers are
reprogrammable.
– It is even possible to reprogram them
and test the changes while they work.
– Even if hardware changes are required
to a soft automation system, the lost
time during changeover is less than for
hard automation
TYPE OF AUTOMATION…cont.
27. 27
• Automated Mfg. System can be
classified into three basic types:
Fixed Automation
– A system which the sequence of
processing (or assembly) operations
is fixed by the equipment
configurations.
– Each operations in the sequence is
usually simple.
AUTOMATED MFG. SYSTEM
28. 28
– The features of fixed automation;
• High initial investment for custom-
engineered equipment
• High production rates
• Relatively inflexible in accommodating
product variety.
• Examples, machining transfer lines and
automated assembly machines.
AUTOMATED MFG. SYSTEM… cont.
29. 29
• Programmable Automation
– The production equipment is designed
with the capability to change the
sequence of operations to accommodate
different product configurations.
– The operation sequence is controlled by
a program, which is a set of instruction
coded so that they can be read and
interpreted by the system.
AUTOMATED MFG. SYSTEM… cont.
30. 30
– New programs can be prepared and
entered into the equipment to produce
new products.
– The physical setup of the machine must
be changed for each new products.
– This changeover procedures takes time.
– Eg: numerical control (NC) machine
tools, industrial robots and PLC.
AUTOMATED MFG. SYSTEM… cont.
31. 31
– The features of programmable
automation;
• 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.
AUTOMATED MFG. SYSTEM… cont.
32. 32
• Flexible Automation
– An extension of programmable
automation.
– Capable of producing a variety of
parts/products with virtually no time
lost for changeovers from one part
style to the next.
AUTOMATED MFG. SYSTEM… cont.
33. 33
– The features of flexible automation;
• High investment for custom-
engineered system.
• Continuous production of variable
mixtures of products.
• Medium production rates.
• Flexibility to deal with product design
variations.
AUTOMATED MFG. SYSTEM… cont.
34. 34
– Examples, flexible manufacturing
systems for performing machining
operations.
The relative positions of the three
types of automation for different
production volume and product
varieties are shown below.
AUTOMATED MFG. SYSTEM… cont.
37. 37
REASON FOR AUTOMATING
• To increase labor productivity
• To reduce labor cost
• To improve worker safety
• To improve product quality
• To mitigate the effects of labor
shortages
• To reduce/eliminate routine
manual & clerical tasks.
38. 38
REASON FOR AUTOMATING… cont.
• To reduce mfg lead time
• To accomplish processes that cannot
be done manually
• To avoid the high cost of not
automating
39. 39
MANUAL LABOR IN PROD. SYSTEM
There are situations which manual labor is
usually preferred over automation:
• Task is too technologically difficult to
automate.
• Short product life cycle
• Customized product
• To cope with ups and downs in demand
• To reduce risk of product failure
40. 40
American Prod. And Inventory Control
Society(APICS) gives three principles:
• Understand the existing process
• Simplify the process
• Automate the process
PRINCIPLES AND STRATEGIES
41. 41
STRATEGIES FOR AUTO./PROD SYSTEM
• Specialization of operation
• Combined operations
• Simultaneous operations
• Integration operations
• Increased flexibility
• Improved material handling and storage
• On-line inspection
42. 42
STRATEGIES FOR AUTO./PROD
SYSTEM… cont.
• Improved material handling and storage
• On-line inspection
• Process control and optimization
• Plant operations control
• Computer-integrated manufacturing
43. 43
AUTOMATION CONTROL
• Usually implies a sequence of mechanical
steps.
• A camshaft is an automation controller
because it mechanically sequences the
steps in the operation of an internal
combustion engine.
44. 44
• Manufacturing processes are often
sequenced by special digital computers,
known as programmable logic controller
(PLC).
• PLC can detect and can switch electrical
signals on and off.
AUTOMATION CONTROL… cont.
45. 45
PROCESS CONTROL
• Usually implies that the product is
produced in a continuous stream.
• Often, it is a liquid that is being
processed.
• Early process control system consisted of
specially-designed analog circuitry that
measured a system’s output ( e.g., the
temperature of liquid leaving a tank),
46. 46
and changed that input ( e.g., changing
the amount of cool liquid mixed in) to
force the output to stay at a preset
value.
• Now, process control is accomplished
using digital computers.
PROCESS CONTROL… cont.
47. 47
MANUFACTURING
Manufacturing – the application of
physical and chemical processes to
alter the geometry, properties and /or
appearance of a given starting
material to make parts/product
- includes the joining of multiple
parts to make assembled products
48. 48
• Economic viewpoint- the transformation of
material into items of greater value…
• Eg: iron converted into steel, sand
transformed into glass, petroleum
transforms into plastic etc.
MANUFACTURING… cont.
51. 51
• Basic activities to convert raw material
into finished products:
i. Processing and assembly operations
ii. Material handling
iii. Inspection and test
iv. Coordination and control
MANUFACTURING… cont.
52. 52
Processing and assembly operations
• Processing operation transform a work
material from one state of completion to a
more advanced state that is closer to the
final desired part/product. materials is
fed into the process, energy is apply by
the machinery and tooling to transform
the material into finished products.
• Assembly operations – two or more
components combined to form a new entity
eg: welding, soldering, screws, rivets etc.
53. 53
• Moving and storing materials between
processing and/or assembly operations.
Inspection and test
• Both are quality control activities to
determine whether products meet the
design std. and spec.
Material handling & storage
54. 54
Coordination and control
• includes at process and plant levels
• Process level – manipulating input and
parameters of the process.
• Plants level – labor, maintenance, costing,
shipping, scheduling etc.
55. 55
• 4 keys parameters:
i. Quality
ii. Variety
iii. Complexity of assembled
products
iv. Complexity of individual parts.
PRODUCT/PRODUCTION
RELATIONSHIPS
56. 56
Quantity and variety
Consider: Q= prod. Quantity, P=prod. Variety
: Qj=annual quantity of prod j
: Qf= total quantity of all part
p
Qf = ∑Qj, where P = total no. of diff.
j=1 part, j = 1,2,3,…
57. 57
Product and Part complexity
• Complexity refer to the no.of components
used to produce a product-the mere parts,
the more complex.
• Let, np = the no. of part per product
no = the no. of operation/pros. Steps
The total no. of parts manufactured/year:
npf=total no.of part/yr
p
npf = ∑Qjnpj Qj= annual quantity/yr
j=1 npj= no. of parts/prod
58. 58
Product and Part complexity… cont.
• The total no. of processing operations performed
in the plant:
p npj
nof = ∑Qjnpj ∑nojk
j=1 k=1
Where; nof= total no. ofoperation cycles
nojk= no of processing operation for each part k
npj = no.of parts in product
59. 59
Product and Part complexity… cont.
Conceptualize:
Consider P = no. of product design
Q = quantities
So, the total no. of product produced,
Qf = PQ
the total no. of parts produced,
npf = PQnp
the total no. of mfg operation
performed,
nof = PQnpno
60. 60
Example
P=100 different product, each product
produced 10,000 unit/yr, each consist of
1000 components, average processing
step=10/component, each processing
step=1min. Determine:
- how many product
- how many part
- how many prod. operation
- how many workers needed
61. 61
Solution
i. Total no. of unit produced, Qf = PQ
100 x 10,000 = 1,000,000
prod./yr
ii. Total no of part produced = npf = PQnp
1.000.000 x 1000 = 1,000,000,000
parts/yr
iii. Prod. operation = nof =PQnpno
iv. Total time = 1,000,000,000 x
1/60=166,666,667 hr
v. Workers=
1666,6666,661/2000=83,333 workers
62. 62
Production rate
• Normally expressed as an hourly rate.
• Also called operation cycle time, Tc.
Tc is defined as the time that one work
unit spends being processed/assembled.
Tc = To + Th + Tth
where Tc = operation cycle time (min/pc)
To = time of actual
processing/assemb.
Th = handling time (min/pc)
Tth= tool handling time(min/pc)
63. 63
Production capacity
• Is defined as the max. rate of o.p that the
production facilities is able to produce
under a given set of assumed operation
cond.( num. of shift/day).
• Let PC = prod. Capacity, n = num. of m/c
Rp = prod. Rate, H = hr/shift, S =num. of
shift/week.
PC = n SH Rp
64. 64
Production capacity… cont.
• If no = num. of distinct operation through which
work units are routed.
• To increase/decrease prod. Capacity:
i. Short term:
changes of S and H will increase prod. Capacity
ii. Long term
to increase capacity, change n, increase Rp and
reduce no.
PC = n SH Rp / no
65. 65
MANUFACTURING OPERATION
COSTS
• Mfg costs – fixed and variable costs.
• Fixed costs-remains constant for any level
of prod.
• Variable costs-varies in proportion to the
level of prod.
• Let TC = total annual costs (RM/yr), FC =
fixed annual costs (RM/yr), VC= variable
costs (RM/pc) and Q = annual quantity
produced (pc/yr).
67. 67
MANUFACTURING OPERATION COSTS…
cont.
• Costs also depend on labor, materials and
overhead.
• Labor costs- paid to workers
• Materials costs- cost of raw materials to
produce product.
• Overhead costs- factory and corporate
o.heat
- factory o.h to operate the factory
- corporate o.h to run the factory
71. 71
MANUFACTURING OPERATION COSTS…
cont.
• Overhead rate (burden) to be calculated
and to used in the following year to
allocate overhead costs.
FOHR = FOHC / DLC
Where FOHR = factory overhead
rate
FOHC = annual factory overhead
costs
DLC = annual direct labor costs
