CHAPTER 1

CIM

Hawassa University Institute Of Technology

Department of Mechanical Engineering
([email protected])

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 Contents
1. Production system
1.1 production system facilities
Low Quantity Production
Medium Quantity Production
Mass Production
1.2 Manufacturing support systems
2. Automation
Automation in production systems
Automated manufacturing systems
Reasons for automation
Automation Principles and strategies
Basic Elements of an Automated System
Levels of Automation

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 Introduction
1. Production system
 The production system is the collection of people, equipment, and
procedures, organized to accomplish the manufacturing operations
of a company.

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1.1 Production system facilities
 The facilities in the production system are the factory, production
machines and tooling, material handling equipment, inspection
equipment, and the computer systems that control the
manufacturing operations.
 A manufacturing company attempts to organize its facilities in the
most efficient way to serve the particular mission of that plant.
 The annual product quantities produced in a given factory can be
classified into three ranges:

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a) Low Quantity Production
 production facility usually associated with the quantity range of 1 to
100 units/year is the job shop,
 Makes low quantities of specialized and customized products. The
products are typically complex, such as space capsules, aircraft, and
special machinery.
 Workers and processing equipment are brought to the product, rather
than moving the product to the equipment. This type of layout is
referred to as a fixed–position layout

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b) Medium Quantity Production
 quantity range (100–10,000 units annually), distinguished between two
different types of facility, depending on product variety.
 When product variety is hard, the traditional approach is batch
production, in which a batch of one product is made, after which the
facility is changed over to produce a batch of the next product, and so
on.
 The equipment is usually arranged in a process layout

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 When product variety is soft, extensive changeovers between one
product style is not required.

 groups of similar parts are made on the same equipment without

significant los of time for changeovers.

 The term cellular manufacturing is often associated with this type of

production. Each cell is designed to produce a limited variety of part
configurations. The layout is called a cellular layout

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c) High Production
 The high quantity range (10,000 to millions of units per year) is
often referred to as mass production.
 Two categories of mass production can be distinguished as:
 Quantity production involves the mass production of single parts on
single pieces of equipment. The typical layout used in quantity
production is the process layout
 Flow line production involves multiple workstations arranged in
sequence, and the parts are physically moved through the sequence.
The layout is called a product layout

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1.2 Manufacturing support systems
 Manufacturing support systems are not directly contact the product,
but ,they plan and control its progress through the factory, to operate
the production facilities efficiently,
 Manufacturing support involves a cycle of information processing
activities, as illustrated bellow.
a. Business functions,
b. Product design,
c. Manufacturing planning, and
d. Manufacturing control.

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2. AUTOMATION
 It is a technology concerned with the application of mechanical,
electronic, and computer based systems to operate and control
production
2.1 Automation in production systems
 Can be separated into two categories:
a) Automated manufacturing systems
b) Computerized Manufacturing Support Systems

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a. Automated manufacturing systems
 Automated manufacturing systems operate in the factory on the
physical product.
 They perform operations such as processing, assembly, inspection, or
material handling,
 Examples of automated manufacturing systems include:
 Automated machine tools that process parts
 Transfer lines that perform a series of machining operation
 Automated assembly systems
 Manufacturing systems that use industrial robots that perform
processing or assembly operations
 Automatic material handling and storage systems to integrate
manufacturing operations
 Automatic inspection systems for quality control
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 Automated manufacturing systems can be classified into three basic
types,
I. Fixed automation
II. Programmable automation, and
III. Flexible automation.

I. Fixed Automation.
 Fixed automation is a system in which the sequence of processing
operations is fixed by the equipment configuration.
 Typical features of fixed automation are:
 high initial investment for custom engineered equipment
 high production rates
 relatively inflexible in accommodating product variety

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ii. Programmable Automation
 In this automation, production equipment is designed with the
capability to change the sequence of operations to accommodate
different product configurations.
 The operation sequence is controlled by a program, which is a set
of instructions coded so that they can be read and interpreted by
the system
 Features that characterize programmable automation include:
 High investment in general purpose equipment
 Lower production rates than fixed automation
 Flexibility to deal with variations and changes in product
 Most suitable for batch production
 Examples: NC machine tools, industrial robots, and programmable
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iii. Flexible Automation.
 It is an extension of programmable automation
 Flexible automated system is capable of producing a variety of
parts with virtually no time lost for changeovers from one part style
to the next.
 Features that characterize Flexible automation include:
 high investment for a custom engineered system
 continuous production of variable mixtures of products
 medium production rates
 flexibility to deal with product design variations

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b. Computerized Manufacturing Support Systems
 Automation of the manufacturing support systems is aimed at
reducing the amount of manual and office effort in-
 product design,
 manufacturing planning and control
 the business functions of the firm.

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2.2 Reasons for automating
 Some of the reasons used to justify automation are the
following:
1. To increase labor productivity
2. To mitigate the effects of labor shortages
3. To reduce or eliminate routine manual and clerical tasks
4. To improve worker safety.
5. To improve product quality
6. To reduce manufacturing lead time
7. To accomplish processes that cannot be done manually.
8. To avoid the high cost of not automating

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2.3 Automation principles and strategies
 A certain care and respect must be observed in applying automation
technologies.
 The three approaches dealing with automation are:-
1) The USA Principle,
2) Ten Strategies for Automation and Production Systems
3) Automation Migration Strategy.

1.USA Principle
 The USA Principle is a common approach to automation. USA stands
for:
 U-Understand the existing process,
 S-Simplify the process and
 A-Automate the process

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U-Understand the Existing Process.
 The first step in the USA approach is to understand the current process
in all of its details.
 What are the inputs?
 What are the outputs?
 What exactly happens to the work unit between input and output?
 What is the function of the process?
 How does it add value to the product?
 What are the upstream and downstream operations
 can they be combined?
 Some of the basic charting tools used in methods analysis are useful
in this regard, such as the operation process chart and the flow process
chart.
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 Application of these tools to the existing process provides a model of
the process that can be analyzed and searched for weaknesses and
strengths.
 The number of steps in the process, the number and placement of
inspections, the number of moves and delays experienced by the work
unit, and the time spent in storage can be ascertained by these charting
techniques.
 Mathematical models of the process may also be useful to indicate
relationships between input parameters and output variables.

 This information may be valuable in identifying what output variables

need to be measured for feedback purposes and in formulating
algorithms for automatic process control.

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S-Simplify the Process.
 Once the existing process is understood, then the search can begin for
ways to simplify.
 This often involves a checklist of questions about the existing process
 What is the purpose of this step or this transport?
 Is this step necessary?
 Can this step be eliminated?
 Is the most appropriate technology being used in this step?
 How can this step be simplified?
 Are there unnecessary steps in the process that might be eliminated
without distracting from function?
 Can steps be combined?
 Can steps be performed simultaneously?
 Can steps be integrated into a manually operated production line?
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A-Automate the Process.
 Once the process has been reduced to its simplest form, then
automation can be considered.
 The possible forms of automation include those listed in the ten
strategies discussed in the following topic.

Strategies for Automation

1. Specialization of operations.
 It involves the use of special—purpose equipment designed to perform
one operation with the greatest possible efficiency.
 This is analogous to the concept of labor specialization, which is
employed to improve labor productivity.

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2. Combined operations
 The strategy of combined operations involves reducing the number of
distinct production machines or workstations through which the part
must be routed.
 This is accomplished by performing more than one operation at a
given machine, thereby reducing the number of separate machines
needed
3. Simultaneous operations
 It is a logical extension of the combined operations strategy in which,
two or more processing operations are being performed
simultaneously on the same work part, thus reducing total
processing time.

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4. Integration of operations.
 Linking of several workstations together into a single integrated
mechanism, using automated work handling devices to transfer parts
between stations
5. Increased flexibility.
 This strategy attempts to achieve maximum utilization of equipment
for job shop and medium volume situations by using the same
equipment for a variety of parts or products
6. Improved material handling and storage
 A great opportunity for reducing nonproductive time exists in the use
of automated material handling and storage systems.
 Typical benefits include reduced work in process and shorter
manufacturing lead times.
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7. Online inspection.
 Incorporating inspection into the manufacturing process permits
corrections to the process as the product is being made.
 This reduces scrap and brings the overall quality of product closer to
the nominal specifications intended by the designer.
8. Process control and optimization.
 By this strategy, the individual process times can be reduced and
product quality improved.
9. Plant operations control.
 this strategy is concerned with control at the plant level. Its
implementation usually involves a high level of computer networking
within the factory.

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10. Computer integrated manufacturing (CIM)
 Integration of factory operations with engineering design and the
business functions of the firm.
 CIM involves extensive use of computer applications, computer data
bases, and computer networking throughout the enterprise.
 The ten strategies constitute a checklist of the possibilities for
improving the production system through automation or simplification.

Automation Migration Strategy

 Many companies have an automation migration strategy, that is, a
formalized plan for evolving the manufacturing systems used to
produce new products as demand grows.
 A typical automation migration strategy is the following:-
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 Phase 1: Manual production using single station manned cells
operating independently. This is used for introduction of the new
product for reasons already mentioned: quick and low cost tooling to
get started.

 Phase 2: Automated production using single station automated cells

operating independently. As demand for the product grows.

 Phase 3: Automated integrated production using a multi station

automated system with serial operations and automated transfer of
work units between stations. When certain that the product will be
produced in mass quantities and for several years

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 Details of the automation migration strategy vary from company to
company, depending on the types of products they make and the
manufacturing processes they perform.

 Advantages of such a strategy include:

 It allows introduction of the new product in the shortest possible time
 It allows automation to be introduced gradually (in planned phases), as
demand for the product grows
 It avoids the commitment to a high level of automation from the start,
since there is always a risk that demand for the product will not justify
it.

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2.4 Basic elements of an automated system
 An automated system consists of three basic elements:
1) Power (to accomplish the process and operate the system)
2) program of instructions (to direct the process)
3) control system (to actuate the instructions)

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1. Power (to accomplish the process and operate the system)

 An automated system is used to operate some process, and power is

required to drive the program and process; as well as the controls.

 The principal source of power in automated systems is electricity.

 Electric power has many advantages in automated processes.

 Electrical power can be readily converted 6 alternative energy forms: mechanical,
thermal, light, acoustic, hydraulic, and pneumatic.
 Electrical power at low levels can be used to accomplish functions such as signal
transmission, information processing, and data storage and communication.
 Electrical energy can be stored in long life batteries for use in locations where an
external source of electrical power is not conveniently available.

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2. program of instructions (to direct the process)

 The particular processing steps for the work cycle are specified in a
work cycle program. Work cycle programs are called part programs
in numerical control..
 In the simplest automated processes, the work cycle consists of
essentially one step, which is to maintain a single process parameter at
a defined level,
 for example, maintain the temperature of a furnace at a designated value for the
duration of a heat treatment cycle.
 In more complicated systems, the process involves a work cycle
consisting of multiple steps that are repeated with no deviation from
one cycle to the next.
 for example(1) load the part into the production machine, (2) perform the
process, and (3) unload the part

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3. control system (to actuate the instructions)

 The control system causes the process to accomplish its defined

function. The controls in an automated system can be either closed
loop or open loop.
 A closed loop control system, also known as a feedback control
system. is one in which the output variable is compared with an
input parameter, and any difference between the two is used to drive
the output into agreement with the input.
 It contains six basic elements: (1) input parameter, (2) process, (3)
output van. able, (4) feedback sensor. (5) controller. and (6) actuator.

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 open loop control system operates without the feedback loop.
 In this case, the controls operate without measuring the output
variable.
 so no comparison is made between the actual value of the output and
the desired input parameter

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2.5 Levels of automation
 The concept of automated systems can be applied to various
levels of factory operations
 There are five possible levels of automation in a production plant.

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1) Device level.
 This is the lowest level in our automation hierarchy. It includes the
actuators, sensors, and other hardware components that comprise the
machine level.
 example, the feedback control loop for one axis of a CNC machine or
one joint of an industrial robot.
2) Machine level.
 Hardware at the device level is assembled into individual machines.
Examples include CNC machine tools and similar production
equipment, industrial robots, powered conveyors, and automated
guided vehicles.
 Control functions at this level include performing the sequence of
steps in the program of instructions in the correct order and making
sure that each step is properly executed.
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3) Cell or system level.
 A manufacturing cell or system is a group of machines or
workstations connected and supported by a material handling system,
computer and other equipment appropriate to the manufacturing
process.
 functions include part dispatching and machine loading,
coordination among machines and material handling system, and
collecting and evaluating inspection data.
4) Plant level.
 This is the factory or production systems level.
 functions include: order processing, process planning, inventory
control, purchasing, material requirements planning, shop floor
control, and quality control.

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5) Enterprise level
 This is the highest level. consisting of the corporate information
system.
 It is concerned with all of the functions necessary to manage the
company: marketing and sales, accounting, design, research, aggregate
planning, and master production scheduling

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 End of CHAPTER 1
Production system & Automation

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