Automated

Production Lines
 SECTIONS:
1. Fundamentals of Automated Production Lines
2. Applications of Automated Production Lines
3. Analysis of Transfer Lines

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 Automated Production Lines ?

high
……… multiple
………. Fixed
production processing automation

The stations are integrated by work

transport system
 What is
Automated Production Lines ?

“Fixed-routing manufacturing
system that consists of multiple
workstations linked together by a
material handling system to
transfer parts from one station to
the next”

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Where to use
Automated Production Lines ?

Advantages
High product demand
Requires large production quantities Low number of
Labor
Stable product design Low product
Difficult to change the sequence and content of processing operations once the line is cost
built
High production
rate
Long product life
Min. WIP &
lead time
Multiple operations required on product Min. factory floor
Difference operations are assigned to different workstations in the line
space
 Automated Production Lines

Slowest workstation sets the pace of the line (bottleneck)

Workpart transfer:
Palletized transfer line
Uses pallet fixtures to hold and move work parts between stations

Free transfer line

Part geometry allows transfer without pallet fixtures
 Automated Production Lines

Workpart transfer:
Palletized transfer line
Uses pallet fixtures to hold and move work parts between stations

Free transfer line

Part geometry allows transfer without pallet fixtures
 Automated Production Lines

General configuration of an automated

production line consisting of n automated
workstations that perform processing operations
 System Configurations of
Work Part Transport

»In-line - straight line arrangement of workstations

Common for machining big workpieces, since they require large number of operations.

»Segmented in-line
Two or more straight line segments, usually perpendicular to each other
Used because of unavailable workspace, need for reorientation of the
workpiece or need for returning the fixtures to the front of the line.

»Rotary indexing machine (e.g., dial indexing machine)

Limited to smaller parts and fewer workstations.
 Segmented In-Line Configurations
of Work Part Transport

L-shaped layout

U-shaped layout

Rectangular configuration
Segmented In-Line Configurations
of Work Part Transport
Rotary Indexing Machine
 Work part Transfer
Mechanisms
»Linear transfer systems:
⋄Continuous motion – not common for automated systems
⋄Synchronous motion – intermittent motion, all parts move simultaneously
⋄Asynchronous motion – intermittent motion, parts move independently

»Rotary indexing mechanisms:

⋄Geneva mechanism

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 Belt-Driven Linear Transfer System

Side view of chain or steel belt-driven conveyor

(over and under type) for linear transfer using
work carriers
 Walking Beam Transfer System

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 Storage Buffers
in Production Lines
“A location in the sequence of workstations where parts can be
collected and temporarily stored before proceeding to subsequent
downstream stations”

Reasons for using storage buffers:

▪ To reduce 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 curing time or other required delay
▪ To smooth cycle time variations
▪ To store parts between stages with different production rates
 Storage Buffers
in Production Lines

Storage buffer between two stages of a

production line

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 Control Functions in an
Automated Production Line

Sequence Safety Quality

control monitoring control
To coordinate the To avoid To detect and
sequence of hazardous possibly reject
actions of the operation for defective work units
transfer system workers and produced on the
and workstations equipment line

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Applications of
Automated Production Lines
▪ Transfer lines for machining
Synchronous or asynchronous work part transport
Transport with or without pallet fixtures, depending on
part geometry
Various monitoring and control features available
▪ Rotary transfer machines for machining
Smaller & lighter work part, fewer workstation
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
 Analysis of Transfer Lines
Three problem areas must be considered:
1. Line balancing
▪ To divide the total work load among workstations as evenly
as possible
2. Processing technology
▪ Theory and principles about the manufacturing or assembly
processes used on the line
3. System reliability - two cases:
▪ Transfer lines with no internal parts storage
▪ Transfer lines with internal storage buffers
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.
Analysis of Random
Breakdown
Downtime

Transfer Lines
The actual production cycle time of the line to
be longer than the ideal cycle time

Cycle Time Analysis 𝑇𝑝 = 𝑇𝑐 + F . 𝑇𝑑

𝑇𝑐 = 𝑀𝑎𝑥 {𝑇𝑠𝑖 } + 𝑇𝑟 𝑇𝑝 ∶ actual production cycle time

F ∶ downtime frequency
𝑇𝑐 ∶ ideal cycle time on the line -- min 𝑇𝑑 ∶ average downtime per line stop – min
𝑇𝑠𝑖 ∶ processing time at station I -- min
𝑛
𝑇𝑟 ∶ repositioning time (transfer time) -- min
𝐹 = ෍ 𝑝𝑖 𝐹 = 𝑛.𝑝
𝑖=1

𝑝𝑖 ∶ freq of station breakdown per cycle at station I

𝑛 ∶ number of workstation on the line
 Line Efficiency
Analysis of 𝐸=
𝑇𝑐
=
𝑇𝑐
𝑇𝑝 𝑇𝑐 + 𝐹. 𝑇𝑑
Transfer Lines
𝐹. 𝑇𝑑 𝐹. 𝑇𝑑
𝐷= =
𝑇𝑝 𝑇𝑐 + 𝐹. 𝑇𝑑
Performance Measures
𝐸+𝐷 =1
1
𝑅𝑝 =
𝑇𝑝 Cost / unit produced

𝑅𝑝 ∶ actual average production rate – pc/min 𝐶𝑝𝑐 = 𝐶𝑚 + 𝐶𝑜 𝑇𝑝 + 𝐶𝑡

𝑇𝑝 ∶ actual production cycle time – min
𝐶𝑝𝑐 ∶ Cost / pc -- $/pc
1 𝐶𝑚 ∶ Cost of starting material -- $/pc
𝑅𝑐 = 𝐶𝑜 ∶ Cost per minute to operate the line -- $/min
𝑇𝑐
𝑅𝑐 ∶ ideal production rate – pc/min 𝑇𝑝 ∶ Production time per piece – min/pc
𝐶𝑡 ∶ Cost per tooling – $/pc
Common Reason for downtime:
1. Mechanical failure of a workstation
2. Power outages
3. Mechanical failure of the transfer system
4. Stock outs of starting work units
5. Tool failure at a workstation
6. Insufficient space for completed parts
7. Tool adjustment at a workstation
8. Preventive maintenance on the line
9. Scheduled tool change at a station
10. Worker breaks
11. Electrical malfunctions
12. Poor-quality starting work part
 CASE PROBLEM 𝑛 ∶ 20 station
𝑅𝑐 ∶ 50 pc/hour

A machine tool builder submits a proposal for a 20-station transfer 𝑝 ∶ 0.005 breakdown/cycle

line to machine a certain component currently produced by 𝑇𝑑 ∶ 8 min

conventional methods. The proposal states that the line will operate 𝐶𝑚 ∶ 3 $

at a production rate of 50 pc/hr at 100% efficiency. On similar 𝐶𝑜 ∶ 75 /hours

transfer lines, the probability of station breakdowns per cycle is 20 cutting tool → 50 parts

equal for all stations: p = 0.005 breakdowns/cycle. It is also 1 cutting tool → 2 $

estimated that the average downtime per line stop will be 8.0 min.
The starting casting that is to be machined on the line costs $3.00
per part. The line operates at a cost of $75.00/hr. The 20 cutting
tools (one tool per station) last for 50 parts each, and average cost
per tool is $2.00 per cutting edge. Determine (a) production rate,
(b) line efficiency, and (c) cost per piece produced on the line.