COURSE MATERIAL

III Year B. Tech II - Semester

MECHANICAL ENGINEERING

Smart Manufacturing Technologies

R18A0321

MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
(Autonomous Institution-UGC, Govt. of India)
Secunderabad-500100, Telangana State, India.
www.mrcet.ac.in
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
DEPARTMENT OF MECHANICAL ENGINEERING

CONTENTS

1. Vision, Mission and Quality Policy

2. POs, PSOs & PEOs

3. Blooms Taxonomy

4. Course Syllabus

5. Course Outline.

6. Mapping of Course Objectives.

7. Unit wise course Material

a. Objectives and Outcomes

b. Detailed Notes

c. Industry applications relevant to the concepts covered

d. Tutorial Questions

e. Question bank for Assignments: 05/Unit

8. Previous Question papers: 05

www.mrcet.ac.in
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)

VISION
 To establish a pedestal for the integral innovation, team spirit, originality and
competence in the students, expose them to face the global challenges and become
technology leaders of Indian vision of modern society.

MISSION
 To become a model institution in the fields of Engineering, Technology and
Management.
 To impart holistic education to the students to render them as industry ready
engineers.
 To ensure synchronization of MRCET ideologies with challenging demands of
International Pioneering Organizations.

QUALITY POLICY

 To implement best practices in Teaching and Learning process for both UG and PG
courses meticulously.

 To provide state of art infrastructure and expertise to impart quality education.

 To groom the students to become intellectually creative and professionally

competitive.
 To channelize the activities and tune them in heights of commitment and sincerity,
the requisites to claim the never - ending ladder of SUCCESS year after year.

For more information: www.mrcet.ac.in

MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering

VISION

To become an innovative knowledge center in mechanical engineering through state-of-

the-art teaching-learning and research practices, promoting creative thinking
professionals.

MISSION

The Department of Mechanical Engineering is dedicated for transforming the students

into highly competent Mechanical engineers to meet the needs of the industry, in a
changing and challenging technical environment, by strongly focusing in the
fundamentals of engineering sciences for achieving excellent results in their professional
pursuits.

Quality Policy

 To pursuit global Standards of excellence in all our endeavors namely teaching,

research and continuing education and to remain accountable in our core and
support functions, through processes of self-evaluation and continuous
improvement.

 To create a midst of excellence for imparting state of art education, industry-

oriented training research in the field of technical education.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering
PROGRAM OUTCOMES
Engineering Graduates will be able to:
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems
and design system components or processes that meet the specified needs with
appropriate consideration for the public health and safety, and the cultural, societal, and
environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and
research methods including design of experiments, analysis and interpretation of data,
and synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex
engineering activities with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent
responsibilities relevant to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and
need for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and teamwork: Function effectively as an individual, and as a member or
leader in diverse teams, and in multidisciplinary settings.
10.Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and
write effective reports and design documentation, make effective presentations, and give
and receive clear instructions.
11.Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member
and leader in a team, to manage projects and in multidisciplinary environments.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering
12.Life-long learning: Recognize the need for and have the preparation and ability to
engage in independent and life-long learning in the broadest context of technological
change.

PROGRAM SPECIFIC OUTCOMES (PSOs)

PSO1 Ability to analyze, design and develop Mechanical systems to solve the
Engineering problems by integrating thermal, design and manufacturing Domains.

PSO2 Ability to succeed in competitive examinations or to pursue higher studies or

research.

PSO3 Ability to apply the learned Mechanical Engineering knowledge for the
Development of society and self.

Program Educational Objectives (PEOs)

The Program Educational Objectives of the program offered by the department are broadly
listed below:

PEO1: PREPARATION

To provide sound foundation in mathematical, scientific and engineering fundamentals

necessary to analyze, formulate and solve engineering problems.

PEO2: CORE COMPETANCE

To provide thorough knowledge in Mechanical Engineering subjects including theoretical

knowledge and practical training for preparing physical models pertaining to Thermodynamics,
Hydraulics, Heat and Mass Transfer, Dynamics of Machinery, Jet Propulsion, Automobile
Engineering, Element Analysis, Production Technology, Mechatronics etc.

PEO3: INVENTION, INNOVATION AND CREATIVITY

To make the students to design, experiment, analyze, interpret in the core field with the help of
other inter disciplinary concepts wherever applicable.

PEO4: CAREER DEVELOPMENT

To inculcate the habit of lifelong learning for career development through successful completion
of advanced degrees, professional development courses, industrial training etc.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering

PEO5: PROFESSIONALISM

To impart technical knowledge, ethical values for professional development of the student to
solve complex problems and to work in multi-disciplinary ambience, whose solutions lead to
significant societal benefits.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering

Blooms Taxonomy
Bloom’s Taxonomy is a classification of the different objectives and skills that educators set for
their students (learning objectives). The terminology has been updated to include the following
six levels of learning. These 6 levels can be used to structure the learning objectives, lessons,
and assessments of a course.

1. Remembering: Retrieving, recognizing, and recalling relevant knowledge from long‐ term
memory.
2. Understanding: Constructing meaning from oral, written, and graphic messages through
interpreting, exemplifying, classifying, summarizing, inferring, comparing, and explaining.
3. Applying: Carrying out or using a procedure for executing or implementing.
4. Analyzing: Breaking material into constituent parts, determining how the parts relate to
one another and to an overall structure or purpose through differentiating, organizing, and
attributing.
5. Evaluating: Making judgments based on criteria and standard through checking and
critiquing.
6. Creating: Putting elements together to form a coherent or functional whole; reorganizing
elements into a new pattern or structure through generating, planning, or producing.
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution – UGC, Govt. of India)
www.mrcet.ac.in
Department of Mechanical Engineering
Course Syllabus
 UNIT - I

SMART MANUFACTURING TECHNOLOGIES

UNIT I: INTRODUCTION TO SMART MANUFACTURING

What is “smart manufacturing” really and how does it differ from conventional/legacy
manufacturing, Computer Integrated Manufacturing Systems Structure and functional areas of
CIM system, - CAD, CAPP, CAM, CAQC, ASRS. Advantages & Disadvantages of CIM.
Smart manufacturing is a broad category of manufacturing with the goal of optimizing concept
generation, production, and product transaction. While manufacturing can be defined as the
multi-phase process of creating a product out of raw materials, smart manufacturing is a subset
that employs computer control and high levels of adaptability. Smart manufacturing aims to take
advantage of advanced information and manufacturing technologies to enable flexibility in
physical processes to address a dynamic and global market. There is increased workforce training
for such flexibility and use of the technology rather than specific tasks as is customary in
traditional manufacturing

The 21st century manufacturing facilities have ushered a new wave of manufacturing with an
amalgamation of technologies from advanced robotics to fully integrated production systems.
With smart manufacturing or Industry 4.0, manufacturers are moving towards a new level of
interconnected and intelligent manufacturing system which incorporates the latest advances in
sensors, robotics, big data, and controllers.

To keep pace with the evolution of these “smart factories’ requires highly skilled and nimble
engineers to manage the increasing complexity and shorter mind-to market product cycles. The
goal of this program is to train future manufacturing engineers with basic knowledge on IT in
addition to the strong problem-solving skills that are imparted in today’s programs. Students will
be trained in manufacturing processes, manufacturing systems, systems engineering, IT,
Networks and basic shop floor communications. Experiential learning approach will be followed
and students will be gaining hands-on experience in many spheres of technology related to smart
manufacturing.

Smart Manufacturing is a specific application of the Industrial Internet of Things (IIoT).

Deployments involve embedding sensors in manufacturing machines to collect data on their
operational status and performance. In the past, that information typically was kept in local
databases on individual devices and used only to assess the cause of equipment failures after
they occurred.

Now, by analyzing the data streaming off an entire factory's worth of machines, or even across
multiple facilities, manufacturing engineers and data analysts can look for signs that particular
parts may fail, enabling preventive maintenance to avoid unplanned downtime on devices.

Manufacturers can also analyze trends in the data to try to spot steps in their processes where
production slows down or is inefficient in their use of materials. In addition, data scientists and
other analysts can use the data to run simulations of different processes in an effort to identify
the most efficient ways of doing things.

As smart manufacturing becomes more common and more machines become networked
through the Internet of Things, they will be better able to communicate with each other,
potentially supporting greater levels of automation.

For example, SM systems might be able to automatically order more raw materials as the
supplies, allocate other equipment to production jobs as needed to complete orders and prepare
distribution networks once orders are completed.

A lack of standards and interoperability are the biggest challenges holding back greater adoption
of smart manufacturing. Technical standards for sensor data have yet to be broadly adopted,
which inhibits different kinds of machines from sharing data and communicating with each other
effectively.

In the United States, the National Institute of Standards and Technology (NIST) is investigating
opportunities to develop and promote standards with various industry stakeholders, including
technology companies and manufacturers. The process is ongoing. Other challenges include the
cost of implementing sensors broadly and the complexity of developing predictive models.

History/background
It's been nearly 260 years since the beginning of the original Industrial Revolution, thought to
have started around 1760. In the United States, the latest iteration of this process, the fourth
industrial revolution, has been called "smart manufacturing," while in Europe it's known as
"Industry 4.0."

The first industrial revolution was characterized by steam power and the power loom; the
assembly line was introduced during the second industrial revolution; and automation and data-
enhanced automation came along in the 1970s during the third industrial revolution.

This fourth industrial revolution is characterized by a range of interconnected automated systems

that are fusing the physical, digital and biological worlds.

Related technologies
In addition to the Internet of Things, there are a number of technologies that will help enable
smart manufacturing, including:

 Artificial intelligence (AI)/machine learning – enables automatic decision-making

based on the reams of data that manufacturing companies collect. AI/machine
learning can analyze all this data and make intelligent decisions based on the inputted
information.
 Drones and driverless vehicles – can increase productivity by reducing the number of
workers needed to do rote tasks, such as moving vehicles across a facility.
 Blockchain – blockchain's benefits, including immutability, traceability and
disintermediation, can provide a fast and efficient way to record and store data.
 Edge computing – edge computing helps manufacturers turn massive amounts of
machine-generated data into actionable data to gain insights to improve decision-
making. To accomplish this, it uses resources connected to a network, such as alarms
or temperature sensors, enabling data analytics to happen at the data source.
 Predictive analytics – companies can analyze the use huge amounts of data they
collect from all their data sources to anticipate problems and improve forecasting.
 Digital twins – companies can use digital twins to model their processes, networks
and machines in a virtual environment, then use them to predict problems before
they happen as well as boost efficiency and productivity.
Manufacturing is an ever-evolving industry and data shows that the industry contributes to the
significant amount of revenue to any country. With said that, the industry leaders have started
to shift their focus from traditional to smart manufacturing using industry 4.0 solutions as they
offer a plethora of benefits to operators, managers, and executives of companies under this
sector. To add to that, partnering with a right IoT app development company can’t be ruled out
as well.

Industry 4.0 solutions have taken manufacturing by storm. According to a Forbes report, the new
machines, devices, and robots will help companies produce better with little human inputs.

And according to the Deloitte University Press, Industry 4.0 brings in the physical-digital-physical
link. That means the advanced technologies will pave way for connected enterprises that operate
smart and deliver unparalleled customer satisfaction.

Before getting started with here are a few challenges the industry faces with the manual-only
approach.

 Drawing information fast,

 Improving services and products,
 Marketing and selling products and services smartly,
 Improving market experience,
 Optimizing the performance and distribution,
 Communicating and analyzing process performance of humans, machines,
 Lack of real-time data extraction for faster decision making.

How Smart Manufacturing differs from traditional manufacturing approaches

Traditional manufacturing methods, developed during the age of mass production, focus on
economy of scale and machine utilization. The thinking was that if a machine was idle, it was
losing money, so companies kept them running continuously.

To achieve customer satisfaction, traditional manufacturing companies keep large inventories

on hand so they can fulfill potential orders. Consequently, these companies have to keep their
machines running with specific setups for as long as they can to reduce the costs of making the
parts.

This is known as batch-and-queue processing – a mass production approach to operations

where the parts are processed and moved to the next process, whether they're needed or not,
and wait in a line (queue).

However, this approach isn't very efficient for several reasons, including:

 A longer machine set-up time means more lost production time, because nothing is
produced while a machine is down.
 The quality of the product suffers because if parts in a batch aren't made correctly,
no one will likely notice the problem until the next operation. This means the work
has to be done again, which is expensive and ties up valuable resources.

Smart manufacturing, on the other hand, is a collaborative, fully-integrated manufacturing

system that responds in real-time to meet changing the conditions and demands in the factory,
in the supply network, and in the needs of the customers.

The goal of smart manufacturing is to optimize the manufacturing process using a technology-
driven approach that utilizes Internet-connected machinery to monitor the production process.
Smart manufacturing enables organizations to identify opportunities for automating operations
and use data analytics to improve manufacturing performance.

The Smart Factory Opportunity

In the next five years, smart factories may contribute as much as $500 billion in added value to
the global economy, according to Capgemini’s Digital Transformation Institute. The reason: Smart
factories can produce more with lower costs, according to a recent report. In fact, manufacturers
expect smart technologies to drive a sevenfold increase in annual efficiency gains by 2022. Some
industries can expect to nearly double their operating profit and margin with smart technologies.
Smart factories increase output, quality, and consistency. Additional benefits include:

 Streamlined and automated data: Smart technologies automate data collection and
provide advanced production analytics, so managers can make more informed decisions.
In a smart operating environment, manufacturers can tie their operations technology
 with business systems to measure their key performance indicators against business
goals.
 Predictive maintenance: With better visibility, manufacturers can predict and resolve
maintenance issues before they lead to downtime or product-quality issues. For example,
sensors affixed to machines or devices may send condition-monitoring or repair data in
real time, so manufacturers can identify problems more efficiently.
 Significant cost reductions: Manufacturers can identify waste and increase forecast
accuracy when their operations and enterprise systems are connected. They have better
insight into supply chain issues, such as inventory levels and delivery status, as well as
demand cycles. With this information, they can reduce costs related to excessive
inventory or unexpected production volume.
 Reduce workforce challenges: Automation helps manufacturers launch and complete
projects with fewer workers. Having real-time access to data across multiple platforms
frees workers to focus on their core responsibilities. This allows manufacturers to
innovate faster without investing in additional resources.
 Enhanced productivity: Smart, connected systems help factories improve throughput. In
a connected enterprise, manufacturers have seamless visibility into bottlenecks, machine
performance, and other operational inefficiencies. With this data, manufacturers can
make adjustments to increase yields, improve quality, and reduce waste

CIM WHEEL

CIMS STRUCTURE AND FUNCTIONS

CIMS Structure
The components of CIMS include both hardware and software. The hardware includes computer
hardware, network, manufacturing devices, and peripherals. The software includes operating
systems, communication software, database management systems, manufacturing planning and
control soft- ware, management information software, design software, office automation
software, and decision support software. These different hardware and software systems have
different functions and work together to fulfill the company’s business goals. To make it easier
to understand, CIMS is normally decomposed into a number of subsystems interacting with each
other. Unfortunately, no unique and standard decomposition method exists. Every company can
define a method according to its specific situation and requirements. One decomposition method
is shown in Figure 5.

From Figure 5, it can be seen that CIMS consists of four functional subsystems and two support
subsystems. The four functional subsystems are management information, CAD / CAPP / CAM,
man- ufacturing automation, and computer-aided quality management. These functional
subsystems cover the business processes of a company. The two support subsystems are
computer network and database management. They are the basis that allows the functional
subsystems to fulfill their tasks. The arcs denote the interfaces between different subsystems.
Through these interfaces, shared data are ex- changed between different subsystems.

CAD / CAPP / CAM System

CAD / CAPP / CAM stands for computer-aided design / computer-aided process planning /
computer- aided manufacturing. The system is sometimes called the design automation system,
meaning that CAD / CAPP / CAM is used to promote the design automation standard and provide
the means to design high-quality products faster.

CAD (Computer-Aided Design)

Computer-Aided Design CAD is a process that uses computers to assist in the creation,
modification, analysis, or optimization of a product design. It involves the integration of
computers into design activities by providing a close coupling between the designer and the
computer. Typical design activities involving a CAD system are preliminary design, drafting,
modeling, and simulation. Such activities may be viewed as CAD application modules interfaced
into a controlled network operation under the supervision of a computer.

A CAD system consists of three basic components: hardware, which includes computer and
input– output devices, application software, and the operating system software (Figure 7). The
operating system software acts as the interface between the hardware and the application
software system.

The CAD system function can be grouped into three categories: geometric modeling, engineering
analysis, and automated drafting.

Geometric modeling constructs the graphic images of a part using basic geometric elements such
as points, lines, and circles under the support of CAD software. Wire frame is one of the first
geometric modeling methods. It uses points, curves, and other basic elements to define objects.
Then the surface modeling, solid modeling, and parametric modeling methods are presented in
the area of geometric modeling area. Saxena and Irani (1994) present a detailed discussion of the
development of geometric modeling methods.

Engineering design completes the analysis and evaluation of product design. A number of com-
puter-based techniques are used to calculate the product’s operational, functional, and
manufacturing parameters, including finite-element analysis, heat-transfer analysis, static and
dynamic analysis, mo- tion analysis, and tolerance analysis. Finite-element analysis is the most
important method. It divides an object into a number of small building blocks, called finite
elements. Finite-element analysis will fulfill the task of carrying out the functional performance
analysis of an object. Various methods and packages have been developed to analyze static and
dynamic performance of the product design. The objectives and methods can be found in any
comprehensive book discussion of CAD techniques. After the analysis, the product design will be
optimized according to the analysis results.

The last function of the CAD system is automated drafting. The automated drafting function
includes 2D and 3D product design drafting, converting a 3D entity model into a 2D
representation.

CAPP(Computer-Aided Process Planning )

Computer-Aided Process Planning CAPP is responsible for detailed plans for the pro- duction of
a part or an assembly. It acts as a bridge between design and manufacturing by translating design
specifications into manufacturing process details. This operation includes a sequence of steps to
be executed according to the instructions in each step and is consistent with the controls
indicated in the instructions. Closely related to the process-planning function are the functions
that determine the cutting conditions and set the time standards. The foundation of CAPP is
group technology (GT),

which is the means of coding parts on the basis of similarities in their design and manufacturing
attributes. A well-developed CAPP system can reduce clerical work in manufacturing engineering
and provide assistance in production.

One of the first tasks of the CAPP system is to complete the selection of the raw workpiece.
According to the functional requirements of the designed part, it determines the attributes of
the raw workpiece, such as shape, size (dimension and weight), and materials. Other jobs for the
CAPP system are determining manufacturing operations and their sequences, selecting machine
tools, and selecting tools, fixtures, and inspection equipment. Determination of manufacturing
conditions and manufacturing times are also part of the work of CAPP. These conditions will be
used in optimizing manufacturing cost.

The CAPP system consists of computer programs that allow planning personnel interactively to
create, store, edit, and print fabrication and assembly planning instructions. Such a system offers
the potential for reducing the routine clerical work of manufacturing engineers. Figure 8 presents
the classification of various CAPP systems.

It is difficult to name all the packages available so far for process planning.

A few have been listed alone with their sources.

o CAP (Lockheed
o ACUDATA/UNIVATION (Allis Chalmers),
o AUTAP (Aachen University, Berlin),
o AUTOPLAN (Metcut),
o APPAS (Purdue University),
o CAPP(CAM-I),
o CIMS/PRO (Japan),
o COBAPP(Philips),
o COMCAPPV(MDSI),
o DCLASS (University of Utah),
o GETRUN(GE),
o GENPLAN (Lockheed),
o MIPLAN (Metal Inst.),
o XPS-1 (CAM-I),
o CAPSY(Univ.of Berlin),
o LOCAM (Logan Associates)

Retrieval Type CAPP System

 In this system, separate files for part family, machine routing and operation sequence are
created and stored. Algorithm is available which enables the user to identlfy the family to which
the component belogs whenhe/she enters the part code number. On completion of the search,
Standard routing is retrieved from the machine routing file and then the standard operation
sheet is retrieved from the operation reference file. These are edited to take care of any variation
which a particular component may have from the art family. Other application software are also
used to finajlly obtain the process plan in proper format with all the required details

Generative CAPP System

As mentioned earlier, this differs from the varient type in that in this case the process plan
is made from scratch. No standard plans exist and as such no retrieval is involved in this case. The
software inthe system is capable of taking technical and logical decisions ( based on stored
information pertaining to capabilities of machine tool available) when the user inputs description
of the part in proper coded form and thus outputs the process plan. It builds up optimal processe
sequence based on part description provided on the machine capabilities.

CAM(Computer Aided Manufacturing)

Computer-Aided Manufacturing In this section, computer-aided manufacturing (CAM) refers to
a very restricted area that does not include general production control functions. The pro-
duction control functions will be introduced in the manufacturing automation subsystem (MAS)
section. Here, CAM includes preparing data for MAS, including producing NC code for NC ma-
chines, generating tool position, planning tool motion route, and simulating tool movement.
Auto- matic NC code generation is very important for increasing work efficiency. Before the NC
code for NC machine centers can be generated, a number of parameters regarding machine tool
specification, performance, computer numerical control system behavior, and coding format
should be determined first. The manufacturing method and operations will be selected according
to these parameters, ge- ometric dimensions, solid forms, and designed part specifications. The
CAM system will calculate the tool position data. Then the data regarding the part dimension,
the tool motion track, cutting parameters, and numerical control instructions are generated in a
program file. This file, called the NC program, is used by the machine tool to process part
automatically.

The benefits of CAM

Using CAM has a number of benefits when it comes to creating components used in building
construction. Compared to manually operated machines, CAM generally offers:

 Greater speed in producing components

 Greater accuracy and consistency, with each component or finished product exactly the
same
 Greater efficiency as computer-controlled machines do not need to take breaks
 High sophistication in terms of following complex patterns like tracks on circuit boards

CAD / CAPP / CAM Integration Besides the utilization of CAD, CAPP, and CAM tech- nology alone,
the integration of CAD, CAPP, and CAM is an important way to enhance the company’s product
design standards. Three methods can be used in the integration of CAD / CAPP / CAM: exchange
product data through specific defined data format; exchange product data through standard data
format, such as STEP, IGES, and DXF; and define a unified product data model to exchange
product information.
Figure 9 is a STEP-based CAD / CAPP / CAM integration system developed at the State CIMS
Engineering Research Center of China (located at Tsinghua University, Beijing). It was developed
as a part of the CIMS application integration platform (Fan and Wu 1997) for manufacturing
enterprises. This system focuses on part-level CAD / CAPP / CAM integration. XPRESS language
and the STEP development tool ST-developer are used to define and develop the integration
interfaces. Different kinds of CAD, CAPP, and CAM systems can be integrated using the interfaces
provided.
ASRS (Automated Storage and Retrieval System:

• The conventional storage system requires a human worker to access the items in storage
in which the storage system itself is static.

• Automated storage systems are available to reduce or eliminate the amount of human
intervention

• An AS/RS is a combination of equipment and controls which handles, stores, and retrieves
materials with precision, accuracy, and speed under a defined degree of automation
• Focuses on finding a specific desired item and delivering it to the operator.

• An AS/RS consists of one or more storage aisles that are serviced by a storage/retrieval
(S/R) machine.
• The stored materials are held by storage racks of aisles.
• The S/R (storage/retrieval) machines are used to deliver and retrieve materials in and out
of the inventory.
• P/D(Pickup/deposit) stations are where inventory are transferred into and out of the
AS/RS
OBJECTIVES OF ASRS

• Increasing the storage capacity

• Increasing the stock rotation

• Maximum utilization of floor space

• Customer service is improved

• Control over inventories is improved

• Ensuring safety in storage function

• Reducing labour cost in storage operation

TYPES OF ASRS:
1.UNIT LOAD AS/RS:
(i) The unit load AS/RS is used to store and retrieve loads that are palletized or stored
in standard-sized containers
(ii) The loads are generally over 500 lb. per unit
Stacking heights are up to 130 feet Hight
2.MINI LOAD AS/RS
(i) This system is designed to handle small loads such as individual parts, tools, and
supplies that are contained in bins in the storage system.
(ii) Such a system is applicable where the availability of space is limited.
(iii) A mini load AS/RS is generally smaller than a unit load AS/RS and Stacking heights
range from 12 to 20 feet

3.DEEP-LANE AS/RS
Similar to unit load ASRS, except loads can be stored to greater depths in the storage rack for
storing large quantities of stock.
A rack-entry vehicle is used to carry loads into the racks from the storage retrieval machine and
is controlled by the machine
ASRS APPLICATIONS:
1. UNIT LOAD STORAGE AND RETRIEVAL
(i) Warehousing and distribution operations
Used AS/RS types: unit load, deep lane (food industry)
2. ORDER PICKING
Used AS/RS types: mini load, man-on-board
3. WORK-IN-PROCESS STORAGE
(i) Helps to manage WIP in factory operations
(ii) Buffer storage between operations with different production rates
(iii) Kitting of parts for assembly

CAQC(Computer Aided Quality Control)

QUALITY
• Quality in a manufacturing context can be defined as the degree to which a product or its
components conform to certain standards that have been specified by the designer.
INSPECTION
• Inspection is normally used to examine whether a product conforms to the design
standards specified for it. For a mechanical component, this would be probably concerned
with the dimensions, surface texture and tolerances specified for the part. Non-
conforming goods result in scrap, rework, and the loss of customer goodwill.
TESTING
• Testing is a process of the checking the quality by the third party tools , either the
developed component as the customer requirement or not
• Various categories of tests used for final product evaluation:
• Functional tests under normal or simulated operating conditions
• Fatigue or wear tests to determine the product’s life function until failure
• Overload tests to determine the level of safety factor built into the product
• Environmental testing to determine how well the product will perform under different
environments (e.g. humidity, temperature, vibration).
CONTACT INSPECTION METHODS
• In contact inspection, physical contact is made between the object and the measuring
and gauging the instrument.
• Typically contact is achieved using a mechanical probe or other deice that touches the
item, and allows the inspection procedure to occur.
• By this nature, contact inspection is concerned with some physical dimension of the part,
and so contact methods are widely used in manufacturing and production industries to
assess the metal parts.
TYPES OF CONTACT INSPECTION METHODS
1. Conventional instruments
2. Stylus measuring system
3. Coordinate measuring machine
1. Conventional instruments
 Scale
 Gauge bars
 Slip gauges
 Vernier calipers
 Screw gauge
2. Stylus measuring system
Stylus – type instruments are commercially available to measure surface roughness. These
electronic devices have a cone shaped diamond stylus with point radius of about 0.005mm
and a 90° tip angle that is traversed across the test surface at a constant slow speed. As the
stylus head moves horizontally, it also moves vertically to follow the surface deviations. The
vertical movements are converted in to an electronic signal that represents the topography
of the surface along the path taken by the stylus. This can be displayed as either 1. a profile
of the surface or 2. an average roughness value.
3.COORDINATE MEASURING MACHINE
A CMM consists of a constant probe that can be positioned in 3D space relative to the surface of
a work part, and the x, y, and z coordinates of the probe can be accurately and precisely recorded
to obtain dimensional data concerning the part geometry

TYPES OF CMM
NON-CONTACT INSPECTION METHODS
The noncontact methods are divided into two categories for our purposes:
1. Optical
Machine vision, Scanning laser beam devices, Photogrammetry
2. Non-Optical
Electric Field techniques, Radiation techniques, Ultrasonic.

CIM Advantages:
 Responsiveness to shorter product life cycles
 Better process control emphasizes product quality and uniformity.
 Supports and co-ordinates exchange of information
 Designs components for
o machines.
 Decreases the cost of production and maintenance

CIM Disadvantages:
 Unfamiliar technologies used.
 Requires major change incorporate culture.
 Reduction in short term profit.
 Perceived risk is high.
 High maintenance cost and expensive implementation
 UNIT – II

Industry 4.0, IIoT, and digitisation are currently some of the most-discussed and yet least understood
topics within manufacturing today. With still a lot of confusion surrounding Industry 4.0, today we’ll be
exploring the key technologies behind Industry 4.0, as well as real-world applications.

Industry 4.0 in a nutshell

Industry 4.0 is signalling a change in the traditional manufacturing landscape. Also known as the Fourth
Industrial Revolution, Industry 4.0 encompasses three technological trends driving this transformation:
connectivity, intelligence and flexible automation.

Industry 4.0 converges IT (Information Technology) and OT (Operational Technology), to create a cyber-
physical environment.

This convergence has been made possible thanks to the emergence of digital solutions and advanced
technologies, which are often associated with Industry 4.0. These include:

 Industrial Internet of Things

 Big Data
 Cloud computing
 Additive manufacturing (AM)
 Advanced robotics
 Augmented and virtual reality (AR/VR)

These technologies are helping to drive manufacturing’s digital transformation through the integration of
previously disparate systems and processes through interconnected computer systems across the value
and supply chain.

Embracing Industry 4.0, digital manufacturing and the interconnectivity that comes with it opens a myriad
of benefits for companies, including greater agility, flexibility and operational performance.

Industrial Internet of Things

At the heart of Industry 4.0 is the Internet of Things (IoT).

Put simply, IoT refers to a network of physical devices that are digitally interconnected, facilitating the
communication and exchange of data through the Internet. These smart devices could be anything from
smartphones and household appliances to cars and even buildings.

Industrial IoT is a subset of the Internet of Things, where various sensors, Radio Frequency Identification
(RFID) tags, software and electronics are integrated with industrial machines and systems to collect real-
time data about their condition and performance.

IIoT has many use cases, with asset management and tracking being one of the major applications of the
technology today.
For example, IIoT can be used is to prevent the overstocking or understocking of inventory.

One way to achieve this is to use shelf-fitted sensors and weighing devices to broadcast inventory
information to your warehouse management system. Putting such a system in place allows warehouse
managers to monitor inventory levels, thereby gaining real-time visibility and control over the inventory.

Let’s take a look at how BJC HealthCare uses an integrated inventory management solution to achieve
cost-savings in its supply chain.

BJC HealthCare adopts IoT for inventory and supply chain management

BJC HealthCare is a healthcare service provider that operates 15 hospitals in Missouri and Illinois.

The company deploys radio frequency identification (RFID) technology to track and manage thousands of
medical supplies. RFID technology uses radio waves to read and capture information stored on a tag
attached to an object, such as healthcare supplies. Previously, the process of tracking inventory involved
a lot of manual labour. However, monitoring inventory manually can be a challenge, since hospitals
purchase a variety of products from suppliers and store a lot of items on site for specific procedures.

In some cases, products’ expiration dates will need to be closely monitored, while the loss of stock can
lead to a lot of time spent on conducting inventory checks.

For these reasons, BJC decided to implement RFID tagging technology in 2015.

Since implementing the technology, BJC has been able to reduce the amount of stock kept onsite at each
facility by 23 per cent. The company predicts that it will see ongoing savings of roughly $5 million annually,
once RFID tagging is fully implemented this year. As this example demonstrates, IIoT can significantly
improve operations, increase efficiency, reduce costs and provide valuable real-time visibility across the
supply chain.

Big Data and Analytics

Big Data refers to the large and complex data sets generated by IoT devices. This data comes from a wide
range of cloud and enterprise applications, websites, computers, sensors, cameras and much more — all
coming in different formats and protocols.

In the manufacturing industry, there are many different types of data to take into consideration, including
the data coming from production equipment fitted with sensors and databases from ERP, CRM and MES
systems. But how can manufacturers convert the data collected into actionable business insights and
tangible benefits? With data analysis.

When it comes to data, the use of data analytics is essential to convert data to information that can deliver
actionable insights. Machine learning models and data visualisation can aid data analytics processes.
Broadly speaking, machine learning techniques apply powerful computational algorithms to process
massive data sets, while data visualisation tools enable manufacturers to more easily comprehend the
story the data tells. Ultimately, by taking previously isolated data sets, collecting and analysing them,
companies are now able to find new ways to optimise the processes that have the greatest effect on yield.
Big Data decision-making at Bosch Automotive factory in China

Combining IIoT and Big Data is a recipe Bosch is using to drive the digital transformation of its Bosch
Automotive Diesel System factory in Wuxi, China.

The company connects its machinery to monitor the overall production process at the core of its plant.
This is achieved by embedding sensors into the factory’s machines which are then used to collect data
about the machines’ conditions and cycle time. Once collected, advanced data analytics tools process the
data in real time and alert workers when any bottlenecks in the production operations have been
identified. Taking this approach helps to predict equipment failures, enabling the factory to schedule
maintenance operations well before any failures occur.

As a result, the factory is able to keep its machinery running and operating for longer stretches of time.
The company states that using data analysis in this way has contributed to more than 10% output increase
in certain areas, whilst improving delivery and customer satisfaction. Ultimately, a greater insight into the
plant’s operations supports better and faster decision-making throughout the entire organisation,
enabling it to reduce equipment downtime and optimise production processes.

Cloud computing

For decades, manufacturers have been collecting and storing data with the goal of improving
operations.

However, with the advent of IoT and Industry 4.0, the reality is that data is being generated at a staggering
speed and at high volumes, making it impossible to handle manually. This creates a need for an
infrastructure that can store and manage this data more efficiently.

This is where cloud computing comes in. Cloud computing offers a platform for users to store and process
vast amounts of data on remote servers. It enables organisations to use computer resources without
having to develop a computing infrastructure on premise. The term cloud computing refers to information
being stored in the “cloud”, accessed remotely via the Internet. In itself, cloud computing is not a solution
on its own, but enables the implementation of other solutions that once required heavy computing power.

The capability of cloud computing to provide scalable computing resources and storage space enables
companies to capture and apply business intelligence through the use of big data analytics, helping them
to consolidate and streamline manufacturing and business operations.

Manufacturers’ global spending on cloud computing platforms is predicted to reach $9.2 billion in 2021,
according to IDC. A key factor behind this adoption is the benefit of being able to centralise operations,
eliminating so that information can be shared across an entire organisation. According to one IDC survey,
Quality Control, Computer-Aided Engineering and Manufacturing Execution Systems (MES) are the three
most widely adopted systems in the cloud.

Clearly, cloud computing is transforming virtually every facet of manufacturing, from workflow
management to production operations – and even product qualification.

Volkswagen creates Automotive Cloud

Connected cars are a big new trend in the automotive industry, having emerged as an
opportunity to offer digital added-value services for customers. One of the first automakers to
jump on this trend is Volkswagen, which joined forces with Microsoft to develop a cloud network,
the “Volkswagen Automotive Cloud”.
The technology, planned for 2020, will offer a range of features, including smart home
connectivity, a personal digital assistant, predictive maintenance service, media streaming and
updates.
Volkswagen aims to add over 5 million Volkswagen brand offerings per year to its Internet of
Things (IoT) with the help of this cloud service.
As the automotive industry makes impressive strides in developing advanced autonomous and
electric vehicles, carmakers need to come up with an effective approach of managing and
transmitting large amounts of data to their vehicles. Incorporating cloud-based storage and
communication platform emerges as an effective way to overcoming the challenges faced by
these automakers.

Advanced Robotics
While robotics have been used in manufacturing for decades, Industry 4.0 has given new life to
this technology.
With recent advancements in technology, a new generation of advanced robotics is emerging,
capable of performing difficult and delicate tasks. Powered by cutting-edge software and sensors,
they can recognise, analyse and act upon information they receive from the environment, and
even collaborate and learn from humans.
One area of robotics gaining significant traction is collaborative robots (“cobots”), designed to
work safely around people, freeing workers from repetitive and dangerous tasks.
Fetch Robotics help DHL improve warehouse operations

California-based Fetch Robotics has developed collaborative Autonomous Mobile Robots (AMRs) for
locating, tracking, and moving inventory in warehouse and logistics facilities.

A DHL distribution centre in the Netherlands is using Fetch AMRs to perform pick and place operations.
At DHL, AMRs autonomously move across the facility alongside the workers, automatically learning and
sharing the most efficient travel routes. Using self-driving robots in this way can help reduce order cycle
time by up to 50% and provide up to twice the picking productivity gain, according to the company.

As robots become more autonomous, flexible and cooperative, they will be able to tackle even more
complex assignments, relieving the workers from monotonous tasks and increasing productivity on the
factory floor.

Additive Manufacturing
Alongside robotics and intelligent systems, additive manufacturing, or 3D printing, is a key technology
driving Industry 4.0. Additive manufacturing works by using digital 3D models to create parts with a 3D
printer layer by layer.

Within the context of Industry 4.0, 3D printing is emerging as a valuable digital manufacturing technology.
Once solely a rapid prototyping technology, today AM offers a huge scope of possibilities for
manufacturing from tooling to mass customisation across virtually all industries.

It enables parts to be stored as design files in virtual inventories, so that they can be produced on-demand
and closer to the point of need — a model known as distributed manufacturing. Such a decentralised
approach to manufacturing can reduce transportation distances, and hence costs, as well as simplify
inventory management by storing digital files instead of physical parts.

Digital Twins
The concept of a digital twin holds great promise for optimising the performance and maintenance of
industrial systems. Global research firm, Gartner, predicts that by 2021, 50% of large industrial companies
will be using digital twins to monitor and control their assets and processes.

A digital twin is a digital representation of a real-world product, machine, process, or system, that allows
companies to better understand, analyse and optimise their processes through real-time simulation.

While digital twins can be confused with simulation used in engineering, there is much more to this
concept. Unlike engineering simulations, a digital twin runs an online simulation, based on data received
from sensors connected to a machine or other device. As an IIoT device sends data almost in real time, a
digital twin is able to collect this data continuously, maintaining its fidelity with the original throughout
the lifespan of the product or system.

This enables the digital twin to predict potential issues so that preemptive measures can be taken. For
example, an operator can use a digital twin to identify why a part is malfunctioning or to predict the
lifetime of a product. This continuous simulation helps to improve designs of products as well as to ensure
equipment uptime.
This use of digital twins has long been an important tool in demanding aerospace, heavy machinery and
automotive applications. Now, advances in computing technology, machine learning and sensors are
expanding the concept of digital twinning across other industries.

Augmented reality
Despite its uptake in consumer applications, the manufacturing industry is just beginning to explore the
benefits of Augmented Reality (AR) technology. And yet, there is a huge untapped potential for the
technology, from helping with assembly processes to helping to maintain manufacturing equipment.

Augmented reality bridges the gap between the digital and physical worlds by superimposing virtual
images or data onto a physical object. For this, the technology uses AR-capable devices, such as
smartphones, tablets and smart glasses.

Let’s take a medical instance as an example — a surgeon using AR glasses during a surgical operation. The
glasses could overlay data from patient’s MRI and CT scans, such as nerves, major blood vessels and ducts,
onto the patient, and highlight them in colour. This helps the surgeon to find the safest path into the
region that needs invasion, minimising the risk of complications and improving surgeon’s precision.

In the context of manufacturing, AR could enable workers to speed up the assembly process and improve
decision-making. For example, AR glasses could be used to project data, such as layouts, assembly
guidelines, sites of possible malfunction, or a serial number of components, on the real part, facilitating
faster and easier work procedures.

AR increases productivity at GE

General Electric offers a glimpse at how AR technology can empower manufacturing. The company is
currently piloting the use of AR glasses at its jet engine manufacturing facility in Cincinnati. Before using
these smart glasses, jet engine makers often had to stop what they were doing in order to check their
manuals and ensure tasks were being performed correctly.

However, with AR glasses, they can now receive digitised instructions in their field of view. The mechanics
can also access training videos or use voice commands to contact experts for immediate assistance.

During the pilot, GE reports that the productivity of workers using smart wearables increased by up to
11%, compared to previously. Ultimately, this approach could offer a tremendous potential to minimise
errors, cut down on costs and improve product quality.

Even with this example from GE, we’re still scratching the surface when it comes to implementing AR
within the manufacturing context.

Manufacturing is changing. Quickly. Call it Industry 4.0, the Fourth Industrial Revolution, or the new
status quo, but the fact remains the same: manufacturing is experiencing an era of acceleration. To keep
up, manufacturers need to adopt an approach that welcomes change.

Increasingly, that approach has been Agile. Across industries and verticals, manufacturers apply Agile
methods to access faster time to value and increase resilience in a time of disruption. Initially designed
for software development, Agile allows manufacturers to harness a fast rate of change for competitive
advantage. By emphasizing rapid iteration, operator augmentation, operational flexibility, and bottom-up
innovation, Agile Manufacturing enables a fast response to customer demands while empowering
workers to innovate.

This guide will introduce you to Agile Manufacturing. We’ll review history, dive deep into each of the
principles, and give concrete tips on how to adopt this method of working on your shop floor.

The 4 core values of Agile Manufacturing: flexibility, rapid iteration, augmentation and bottom-up innovation

What is Agile Manufacturing?

Agile Manufacturing is an approach to manufacturing that leverages flexibility, bottom-up innovation,
and augmentation in order to adapt, through an iterative process, to changing conditions.

Four major shifts in the manufacturing landscape have made Agile methods necessary.

1. Rapidly evolving environment – Technology is driving significant changes in manufacturing. But

technology is not the only moving part. Customers are also evolving quickly. They now have higher
standards. They expect product customization, fast delivery, and cheaper production. Regulations are
changing as well, increasing in number and severity. Add to this increasingly complex supply chains and
questionable trade stability and you have an environment that demands flexibility.

2. Constant technological development – New technologies appear every day, and manufacturing is
getting its bearings in the digital age. Moving forward, manufacturers will feel the effects of new
technologies in unexpected ways. According to a report published by McKinsey in 2018, manufacturing
will experience more disruptions in the next five years than in the past twenty years combined.
3. More access to information – Connected factories product data on an unprecedented scale. Data will
enable leaps forward like predictive maintenance and supply chain optimization. Companies will be able
to act on real-time data at every level. Upper management will be able to evaluate plant-level
performance in real-time. Production managers will diagnose quality issues before they reach
downstream. And executives interested in contract manufacturer performance will gain new visibility.

4. Workforce transformation – Low unemployment rates and an enduring skills gap make it difficult for
manufacturers to recruit skilled workers. Research by Deloitte shows that this skills gap may leave over
two million manufacturing positions unfilled between 2018 and 2028.

By incorporating Agile, manufacturers can survive these shifts and remain competitive. But too often,
“agile” is a buzzword, dissociated from its real meaning and principles. Let’s go back in time and recall
the development of the now-famous approach.

The 4 major shifts in manufacturing: rapidly evolving environment, constant technological development,
workforce transformation and more access to information.
History of Agile

The Agile movement was born in 2001, when seventeen software developers gathered in a ski lodge in
Utah. They all had at least one thing in common: a deep dissatisfaction with the Waterfall model.

The Waterfall model is a development method that is linear and sequential. Practitioners must complete
each step of production before they start the next. Though structured and easy to follow, the Waterfall
model has many pitfalls.
Primarily, the Waterfall model discourages changing course until the end of the development cycle.
Because it privileges forward progress, the waterfall model delays incorporating feedback, makes it
challenging to adapt to changing requirements, and slows production as engineers go to great lengths to
avoid mistakes.

In the Waterfall model, production steps are followed one after the other, with no back-and-forth, until the
final product is obtained. In the Agile model, multiple cycles of production take place.

Agile Manufacturing Principles

The Lean and Agile approaches are both wildly popular. However, they should not be confused. On the
one hand, Lean Manufacturing is focused on increasing efficiency by reducing waste. On the other hand,
Agile Manufacturing aims to increase efficiency via flexible, parallel problem solving.

While some of the ideas of Lean Manufacturing and Agile Manufacturing overlap, the fundamental
principles are different.
 The intersection and difference between Agile Manufacturing and Lean Manufacturing.

Key principles of Agile Manufacturing:

1. Iterate Faster

The idea of delivering smaller pieces of value more frequently is central to Agile Manufacturing. Rather
than attempting to design a single, perfect product in one go, the objective is to rapidly produce multiple
versions. Each iteration, with its flaws and strengths, reveals new insights that make it possible to improve
the process. As the process improves, each new version of the product surpasses the previous.

Why does this incremental, iterative method result in a superior result? Because process engineers deal
with many variables. Iterations allow them to test different solutions, and gather data on individual
variables. Without this data, it is difficult to determine which changes are necessary at a given stage to
optimize production.

2. Flexibility

According to McKinsey, “Volatility is rising and taking its toll. Whether from increasing fluctuations in
demand, labor rates and input prices, or from disruptive events like natural disasters and financial crises,
volatility has damaged supply chains, increased costs and eroded profits. […] Companies are increasingly
recognizing that they must alter their manufacturing strategies in the face of rising volatility.”

In order not to bend under external forces, manufacturing companies need to have flexible systems. Their
internal structure needs to be dynamic enough to rebound quickly from external disruptions. Agile
manufacturers are aware that environmental factors – economic, political, environmental, social,
technological – require them to constantly stay on their toes. They make sure that every component of
their system can grow organically and adapt to changes.

3. Bottom-Up

For decades, goals and directives have passed from the top of the organization, to the bottom. The top-
down approach has its advantages, such as the quick implementation of decisions taken by upper levels
of a company. However, this comes at a cost. Employees at the bottom can feel disconnected and
disengaged. Low engagement can discourage accountability and innovation.

Agile manufacturers favor a bottom-up approach, in which ideas and directives flow seamlessly between
all layers of the company. With this approach, directors and managers give operators and shop floor
workers a voice. Agile Manufacturing supports the idea that those closest to manufacturing challenges
understand them best. The more operators, engineers, managers, and business executives collaborate,
the more effective operations will be as a whole. Collaboration across functions and seniority levels yields
higher value products and processes.

Agile organizations abandon the hierarchical, top-down approach to adopt a flexible, bottom-up approach.

4. Augmentation

Augmentation is best understood in contrast to automation. Automation consists of automating workers’

tasks – in other words, of replacing workers by machines. Augmentation, on the other hand, enhances
workers’ capabilities through technology. For years, automation was considered the solution to high labor
costs and human error in the factory. Yet automation is also expensive, difficult to maintain, and inflexible.

Agile manufacturing argues that humans will perform best if they have tools that enable them to evolve
their work. From computer-vision assisted quality checks to error-proofing work instructions, Agile
manufacturers use technology to help their people do more work, better.
How to Implement Agile Manufacturing
In order to successfully implement Agile Manufacturing, manufacturers need to apply its principles and
encourage some changes to their organization. These changes will vary depending on the organization’s
size and structure, but some underlying features are common to most successful Agile organizations.

Implementing Agile Manufacturing Through Organizational Changes

1. Culture and purpose

Agile culture puts people at the center. Agile organizations are structured in a way that team members
have ownership over their work. Leaders in an Agile organization do not rule over their employees, but
rather provide them with tools to achieve results on their own.

These autonomous Agile teams are goal-oriented. After setting their goals and deciding how to achieve
them, teams are held accountable for their progress. Even if different teams work on different goals, there
is an organization-wide cohesion: all goals fit into a greater purpose. Agile organizations understand that
purpose is essential to give meaning to the short-term goals that teams work hard to meet.

Purpose also increases productivity: when employees work with a sense of purpose, they are more
engaged and motivated. Agile organizations share their purpose with everyone so that every employee
knows why they’re doing what they’re doing. A purpose-driven mindset fuels people and boosts
motivation and engagement.

2. Network of teams

Teams hold great importance in Agile organizations. Accountability, transparency and collaboration are
crucial within teams. Team members have clear roles, but they do not necessarily have a single role and
roles can be shared among multiple people. The work environment should be open and safe. Finally,
teams should be in touch with each other, so that members can source knowledge and insights from other
teams.

3. Rapid cycles

The “Iterate Faster” principle of Agile Manufacturing encourages teams to quickly go through multiple
versions of a process or product. The ability to implement this principle is a core feature of successful Agile
organizations. In order to iterate faster, Agile teams work on concrete goals over short, predetermined
periods of time. Both the goals and the timeframe are critical to agility. Goals should be realistic and
measurable. Team members are held accountable for them. The timeframe should be fairly short – on the
order of weeks – to keep teams iterating quickly.

4. Technology

Technology is essential to all of the cornerstones of Agile Manufacturing. Without the right technologies,
it is impossible for companies to deliver value at a fast enough pace to keep up with customer demands
and market fluctuations.

Examples of enabling technologies include real-time communication and work management tools, to
improve flow and organization; hackathons, to swiftly push out new solutions and products; and
interactive digital work instructions, to easily keep employees’ skill sets up to date. But Agile isn’t about
adopting solve-it-all technologies. Rather, it is about finding the right technologies to improve their unique
processes, workers, and products.

Applications of Agile Manufacturing:

Manufacturers can bring agility to their organizations by adopting the right technologies.

To iterate faster, Agile manufacturers turn to technologies that help them collect data. To become flexible,
tools and software that enable quick turnovers are essential. To follow a bottom-up approach, Agile
manufacturers award their workers more trust and power. To augment their workers, they equip them
with the proper tools and training.

Let’s look at some examples of enabling technologies in action.

Using Real-Time Data to Guide Iteration

Contract manufacturer Jabil supports a wide variety of customers and is subject to fast-changing
requirements. Moreover, Jabil’s customers need to receive their products as fast as possible. This means
Jabil also had to increase its speed.

Thus, non-value-add steps had to be identified and eliminated quickly. The only way to achieve this is to
run processes again and again, and collect data on each iteration. Jabil started using IoT connected tools
and sensors to collect real-time data on every iteration. This data, collected through the use of a
manufacturing app platform, allowed process engineers to incorporate feedback after each process
completion. This cycle of iterative improvements stripped processes of non-value-add steps. With such
visibility into their processes, process engineers were able to take control over their operations, following
a bottom-up approach. The result: cycle times were reduced, and production yield and throughput were
significantly increased.

Using 3D Printing to Prototype Faster

3D printers have the potential to greatly accelerate designing and prototyping. Iterative cycles become
shorter as new versions of products are tested in a fraction of the time. Indeed, new prototypes no longer
need to be designed and manufactured in a process that can take months. Rather, they are simply printed
and tried immediately. Products are thus tested early and often, and improvements are made with each
version. The result: optimal end products that satisfy customer demands.

3D printing also makes mass customization realistic for manufacturers. For example, 3D printing is
transforming the jewelry industry by allowing the rapid production of highly detailed, custom parts. 3D
printing allows manufacturers to be much more flexible to changing customer demands.

Using Computer Vision to Augment Operators

Computer vision systems can assist operators through a production process. These systems track the
operator’s movements and inspect the product as it is being made. Based on ongoing context analysis of
the manufacturing environment, the computer provides assistance and performs the relevant quality
checks.
With computer vision, manufacturers can deliver a much greater array of products without sacrificing
productivity or quality. When used to assist operators in line, computer vision systems can help fatigued
workers detect defects, and provide error proofing in complex assemblies where workers or prone to miss
or mis-execute steps. With computer vision assisting with cognitively taxing tasks, operators have more
attention and focus for problem-solving and innovation.

Using Manufacturing Apps to Amplify Training Programs

At Merck, a multinational pharmaceutical and life sciences company, the complex lab equipment requires
highly skilled operators. Training used to be excruciating and expensive. The firm’s paper-based training
instructions were difficult to follow, and training programs required taking experienced operators to
supervise new hires through each step of the training process.

Interactive training apps with step-by-step work instructions were a game changer. The photos, videos
and live stream sensor data transformed the training experience, making it more interactive and
constructive. For Merck, the outcome was remarkable: training costs were reduced by 57%, and training
times by 92%. The new training program augmented workers’ capabilities: rather than using technology
to automate workers’ tasks, Merck leveraged it to simplify re-skilling and close the skills gap.

Using Digital Work Instructions to Error-Proof High-Mix Assemblies

Dentsply is the world’s largest provider of dental solutions. Their implants division receives thousands of
custom orders every day, and each requires a very specific kitting combination.

A senior process engineer at Dentsply created an app to simplify the kitting process. The app was
connected to IoT devices like pick-to-lights and break beams that would guide workers to the bin with the
right part from for each kit. Process engineers were able to improve the process by building the apps
themselves. They no longer needed to go through IT or get the change reapproved as part of their Quality
Management System. Moreover, production became as flexible as Dentsply’s customized products
required it to be.

The Agile Methodology has been in the spotlight for almost two decades. 41% of the organizations
surveyed by McKinsey say their companies have fully implemented or are in the progress of
implementing a company-wide Agile transformation. However, it is only in recent years that
technologies enabling agility in the manufacturing sector have emerged. Now, there is promising
potential for manufacturing companies to join the digital revolution and leave the past behind.

Mass Customization
Mass customization is the process of delivering market goods and services that are modified to satisfy a
specific customer's needs. Mass customization is a marketing and manufacturing technique that combines
the flexibility and personalization of custom-made products with the low unit costs associated with mass
production. Other names for mass customization include made-to-order or built-to-order.

 Mass customization is a process that allows a customer to personalize certain features of a

product while still keeping costs at or near mass production prices.
  Innovative manufacturing techniques help companies produce interchangeable parts that can be
combined in a variety of ways to build a cost-effective product that satisfies a specific customer's
needs.
 The four primary types of mass customization are collaborative customization, adaptive
customization, transparent customization, and cosmetic customization.
 Various companies employ mass customization techniques, including retail companies, software
creators, financial services companies, and modular home builders.
 Companies that offer mass customization can give themselves a competitive advantage over
other companies that only offer generic products.

Understanding Mass Customization

Mass customization allows a customer to design certain made-to-order features of a product while still
keeping costs closer to that of mass-produced products. In some cases, the components of the product
are modular. This flexibility allows the client to mix-and-match options to create a semi-custom final
product. Mass customization may apply to many fields, but many connect it to the retail industry.
Software creators may use this method to include software-based product configurations that enable end-
users to add or change specific functions of a core product. Even the financial services industry embraces
mass customization through the growth of independent, fee-only advisory firms.

The Growth of Mass Customization

B. Joseph Pine II looked at the growth of the American economy due to mass production. In his book,
Mass Customization: The New Frontier in Business Competition (Harvard Business Review Press, 1992),
he describes four primary types of mass customization which took the concept of mass production to a
new level:

Collaborative customization: companies work in partnership with clients to offer products or services
uniquely suited to each client

Adaptive customization: companies produce standardized products which the end-user may customize

Transparent customization: companies provide unique products to individual clients without overtly
stating the products are customized

Cosmetic customization: companies produce standardized products but market them in different ways to
various customers

Pine focused on the concept of creating a small number of interchangeable pieces. The individual parts
may be combined in a variety of ways producing a cost-efficient production model and still allows
consumers to choose how the pieces go together.
Robotics & Automation

Robotics is a field of engineering that deal with design and application of robots and the use of computer
for their manipulation and processing. Robots are used in industries for speeding up the manufacturing
process. They are also used in the field of nuclear science, sea-exploration, servicing of transmission
electric signals, designing of bio-medical equipments etc. Robotics requires the application of computer
integrated manufacturing, mechanical engineering, electrical engineering, biological mechanics, software
engineering.

Automation and Robotics Engineering is the use of control systems and information technologies to
reduce the need for human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization.

A specialization in robotics engineering may lead to potential career opportunities in manufacturing,

research and engineering, agriculture, mining, nuclear, power-plantmaintenances and a variety of other
areas. Besides, thereis great scope for qualified experts and researchers to associate themselves with
different segments of R & D in robotics. As the recent global career trend in robotics suggests, fields as
diverse as surgery, modern warfare and nanotechnology have registered a remarkable increase recently
in their demand for technical expertsand researches in robotics.

Benefits

A course in Robotics trains and educates an individual in the following fields,

 Artificial Intelligence
 Computer Aided Manufacturing
 Computer Integrated Manufacturing System
 Computational Geometry
 Robot Motion Planning
 Robot Manipulators

One of the great ways to learn about robotics is to take part in robotics competitions organized by GGI
every year. Students from various engineering colleges and high schools cantake part in this technical
festival. Surveys conducted by the government and private agencies reveal that the robots enhance the
job quality, productivity, productquality, profitability for those who work in hazardous environment. The
use of robots creates jobs and people who are working manually can be rehabilitated in different areas
through training. Even,robots require maintenance, programming and design change.

Robotics consists of a branch of technology that predominantly deals with the design, construction and
operation of robots. An industrial robot is typically a standard machine controlled by an internal or
external computer that is able to carry out a complex series of movements automatically. There are a
wide range of robots available; from basic robot arms through to completely autonomous vehicle
mounted robots. Robots are often equipped with audio, visual and tactile sensors. Whilst a standard
robot usually follows a pre-determined program, collaborative robots have force sensing built in and as a
result are able to follow a person’s movements and work collaboratively with them.

Robots today perform a variety of jobs within factories such as:

 Palletising
 Parts assembly
 Painting
 Welding
 Machine tool tending
 Material handling
 Pick and place
 CNC milling
Robots are also often used to substitute humans in dangerous environments including hazardous areas
environments, high temperature environments, radioactive environments and areas where there are
harmful vapours and gasses.

The main advantage of robots is their adaptability and flexibility. They are also a known component when
designing an automated system with mixed products/requirements. They can also be a very cheap way to
automate multiple tasks with a lot of variables that would otherwise need a very specialist bespoke
automated system.

Automation

There are two main types of automation; software automation and industrial automation. Software
automation performs computer based tasks that would otherwise be performed by a human, whereas
industrial automation performs physical activities that would otherwise be done by a human.

Bespoke automation is the term typically used where there is a stable and predictable production
processes that needs specialist automation designed specifically to perform that process.

Processes where bespoke automation is often used includes;

 Quality control inspection

 Liquid filling
 Parts sorting
 Box erection and sealing
 Box filling
 Repetitive tasks with few variables
 Production monitoring
 Product and carton labelling
 Safety improvements
The main advantage of bespoke automation is that it can be tailored exactly to a process in the most
efficient way. This can often result in faster production speeds, and more effective solutions for repeat
tasks with little variation in products or requirements.

Robotics or Bespoke Automation – Which do I need?

Now you understand more about robotics and automation, but you may still be wondering which you
need! Maybe you need both? This depends entirely on the process you are wishing to automate. Robotics
or bespoke automation may be used, but as they are both developed in different ways, it may often be
necessary to use both to enable the optimum automation solution to be created.

To summarise, the main difference between robotics and automation is that robots are a piece of
equipment that can perform a variety of tasks with programming, whilst bespoke automation is a term
that is used for special purpose machines or systems that are designed to perform a specific task.

But in short Robotics are just one of many methods of Automation!