Automation

Automated Storage and Retrieval Systems Advantages

-Automated placement and withdrawal of parts and products -Reduced errors and labor -Particularly useful in inventory and test areas of manufacturing firms

2 arrangements for power heads

-Circular Pattern -Linear Pattern

Flexible Manufacturing Systems Advantages

-Computer controls both the workstation and the material handling equipment -Enhance flexibility and reduced waste -Can economically produce low volume at high quality -Reduced changeover time and increased utilization -Stringent communication requirement between components -Completely manufactures a range of components (sometimes whole simple products) without significant human intervention during processing.

Automated Guided Vehicle (AGVs) Advantages

-Electronically guided and controlled carts -Used for movement of products and/or individuals

Computer Integrated Manufacturing Advantages

-Extension of flexible manufacturing systems -Reducing the distinction between low-volume/high-variety, and high-volume/low-variety production -Coordinates the whole process of manufacturing and manufactures a part, component or product.

Automatic Identification Systems Advantages

-Improved data acquisition -Reduced data entry errors -Increased speed -Increased scope of process automation ex. bar codes and RFID

Machine Technology Advantages

-Increased precision -Increased productivity -Increased flexibility -Improved environmental impact -Reduced changeover time -Decreased size -Reduced power requirements ex. CNC machine: Performs the same types of metal-cutting and forming operations which have always been done, but with control provided by computer through pre-programmed instructions.

Factors that influence the selection of robots:

-Load-carrying capacity -Speed of movement -Reliability -Repeatability -Arm configuration -Degrees of freedom -The control system -Program memory

Automation of Manufacturing Processes

-Machine technology -Automatic identification systems (AISs) -Process control -Vision system -Robot -Automated storage and retrieval systems (ASRSs) -Automated guided vehicles (AGVs) -Flexible manufacturing systems (FMSs) -Computer-integrated manufacturing (CIM)

Vision-Based Systems Advantages

-Particular aid to inspection -Consistently accurate -Never bored -Modest cost -Superior to individuals performing the same tasks

Robots Advantages

-Perform monotonous or dangerous tasks -Perform tasks requiring significant strength or endurance -Generally enhanced consistency and accuracy

Advantages of Automation

-Robots reduces both your direct and overhead costs -No requirement for minimum lighting or heating -Potential saving of 8% for every 1 degree C reduction in heating levels, while 20% can be achieved by turning off unnecessary lighting -Reduces other costs such as training, health and safety, and employee administration -Produce a consistently high quality finishing -Employees no longer have to work in dusty, hot or hazardous environments -Robots can be left running overnight and during weekends with little supervision = increase output -A robotic solution will not need time away from production for breaks, sickness, distractions or lapses of concentration.

Playback Robot-

-the operator teaches the robot by showing it what to do -movements can be registered in the memory of the controller and are re-enacted automatically

Classification of Robots

1. Fixed-sequence Robots 2. Variable-sequence Robots 3. Playback Robot

Group Technology Benefits

1. Improved design 2. Reduced raw material and purchases 3. Simplified production planning and control 4. Improved layout, routing, and machine loading 5. Reduced tooling setup time, work-in-process, and production time

Reasons for Automation of Manufacturing Processes

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

Are there activities in manufacturing operations that cannot be automated? Explain.

Although most operations can be automated, there are many applications where automation is not cost effective. Greatly dependent on production quantity and the nature of the operation. The impact of automation on the work force should also be considered carefully.

Explain the difference between an automated guided vehicle and a self-guided vehicle.

An automatic guided vehicle follows a pre-programmed path, using tape or embedded wires as guides for determining its path. Self-guided vehicles calculate in real-time their own paths and correct for deviations as necessary. Capability of detecting obstacles in their path and taking preventing measures.

Do you think automation is generally regarded as evolutionary rather than revolutionary?

Automation can be considered evolutionary because it basically assists in the completion of tasks that have been carried out manually.

Linear Pattern-

Convenient because the movement of the part takes place along with the manufacturing sequence. Modifications are easier to implement, where as with the circular pattern it is very difficult to add one or several more power heads. Furthermore, the linear transfer line can accommodate larger workpieces and a larger number of operations can be included in the line.

Circular Pattern-

Process starts and ends at the same location. Part return to the same location is not always desirable if the part has to be moved further to another machine for subsequent processing.

Industrial Automation-

Technique, method, or system of operating or controlling a process by highly automatic means, as by electronic devices, reducing human intervention to a minimum.

Variable-sequence Robots-

can be reprogrammed to perform a different sequence of operations

Industrial Robots-

is a machine having degrees of freedom to hold a tool, a workpiece or an inspection device Applications for robots are described as dull, dirty, dangerous, demeaning, hot, heavy, and hazardous

Fixed-sequence Robots-

movements are from point to point and the cycle is repeated continuously