Advance Manufacturing Processes

Unit No.6
Industrial Automation &Robotics

Prepared
By

Prof. Nilesh C. Gaikwad

Department of Mechanical Engineering

Rajarambapu Institute of Technology,

Rajaramnagar
Diploma 2nd Shift
 Definition: Automation is the technology by which a process or procedure is performed with
minimal human assistance.

 Need of Automation:
1. To Reduction in production time
2. To Increase in accuracy and repeatability
3. To Less human error
4. To Less employee costs
5. To Increased safety
6. To Higher volume production
7. Labor shortages
8. Reduced manufacturing lead time

 Examples of Automation:
1. Automated machine tools that process parts
2. Transfer lines
3. Automated Assembly Systems
4. Manufacturing Systems that uses industrial robots
5.Automatic material handling and storage systems to integrates manufacturing operations
6. Automatic inspection systems

 High and Low Cost Automation:

1. High Cost Automation: It is technology that creates all around automation around the
existing equipment’s, tool, methods and people, using programmable components available
in the market which can sustain any market demand.

2. Low Cost Automation: It is technology that creates some degree of automation around
the existing equipment’s, tool, methods and people , using mostly standard components
available in the market.

 Types of Automation System

Automated production systems can be classified into three basic types:

i. Fixed automation,
ii. Programmable automation, and
iii. Flexible automation.

i. FIXED AUTOMATION

It is a system in which the sequence of processing (or assembly) operations is fixed by the
equipment configuration. The operations in the sequence are usually simple. It is the integration
and coordination of many such operations into one piece of equipment that makes the system
complex. The typical features of fixed automation are:

a. High initial investment for custom–Engineered equipment;

b. High production rates; and
c. Relatively inflexible in accommodating product variety

The economic justification for fixed automation is found in products with very high demand rates
and volumes. The high initial cost of the equipment can be spread over a very large number of
units, thus making the unit cost attractive compared to alternative methods of production.
Examples of fixed automation include automated assembly and machining transfer lines.
ii. PROGRAMMABLE AUTOMATION

In this the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations. The operation sequence is
controlled by a program, which is a set of instructions coded so that the system can read and
interpret them. New programs can be prepared and entered into the equipment to produce new
products. Some of the features that characterize programmable automation are:
a. High investment in general-purpose equipment;
b. Low production rates relative to fixed automation;
c. Flexibility to deal with changes in product configuration; and
d. Most suitable for batch production.
Programmable automated production systems are used in low and medium volume production.
The parts or products are typically made in batches. To produce each new batch of a different
product, the system must be reprogrammed with the set of machine instructions that correspond
to the new product. The physical setup of the machine must also be changed over: Tools must be
loaded, fixtures must be attached to the machine table also be changed machine settings must be
entered. This changeover procedure takes time. Consequently, the typical cycle for given product
includes a period during which the setup and reprogramming takes place, followed by a period in
which the batch is produced.
Examples of programmed automation include numerically controlled machine tool, industrial
robots and logic controllers.

iii. FLEXIBLE AUTOMATION

It is an extension of programmable automation. A flexible automated system is one that is capable

of producing a variety of products (or parts) with virtually no time lost for changeovers from one
product to the next. There is no production time lost while reprogramming the system and
altering the physical setup (tooling, fixtures, and machine setting). Consequently, the system can
produce various combinations and schedules of products instead of requiring that they be made
in separate batches. The features of flexible automation can be summarized as follows:
1. High investment for a custom-engineered system.
2. Continuous production of variable mixtures of products.
3. Medium production rates.
4. Flexibility to deal with product design variations.
The essential features that distinguish flexible automation from programmable automation are:
1. the capacity to change part programs with no lost production time; and
2. the capability to changeover the physical setup, again with no lost production time.
These features allow the automated production system to continue production without the
downtime between batches that is characteristic of programmable automation. Changing the part
programs is generally accomplished by preparing the programs off-line on a computer system
and electronically transmitting the programs to the automated production system. Therefore, the
time required to do the programming for the next job does not interrupt production on the
current job. Advances in computer systems technology are largely responsible for this
programming capability in flexible automation. Changing the physical setup between parts is
accomplished by making the changeover off-line and then moving it into place simultaneously as
the next part comes into position for processing. The use of pallet fixtures that hold the parts and
transfer into position at the workplace is one way of implementing this approach. For these
approaches to be successful; the variety of parts that can be made on a flexible automated
production system is usually more limited than a system controlled by programmable
automation.
The relative positions of the three types of automation for different production volumes and
product varieties are depicted in the following figure.
 Group Technology

Group technology (GT) signifies a philosophical tool, which attempts to analyze and to
arrange the parts into groups to take advantage of their similarities according to design and
production process.
Group technology is based on a general principle that many problems are similar and by
grouping similar problems, a single solution can be found to a set of problems, thus saving time
and effort.
The group of similar parts is known as Part Family and the group of machineries used to
process an individual part family is known as Machine Cell.
On the basis of groups, families can be established for rationalizing the manufacturing process
in the area of small and medium batch sizes of mass production of a large product mix.
It is reasonable to believe that the processing of each member of a given family is similar and
this should result in manufacturing efficiencies.
Organizing the production equipment’s into cells (machine group) to facilitate work flow.
Organizing production equipment’s in to machine cell were each cell is specialized in the
production of apart family is called Cellular Manufacturing.
Group Technology and Cellular manufacturing are applicable to a wide variety of production
situations.
 The plant currently uses traditional batch production and process type layout, which
result in much material handling, high in process inventory and long manufacturing lead
times.
 It is possible to group the parts in families.

There are two major tasks that a company must undertake when it implements group technology.
 Identifying the part families. If the plant makes 10,000 different parts, reviewing all of the
part drawing and grouping the parts into families is a substantial and time consuming
task.
 Rearranging production machines in to manufacturing cells. It is time consuming and costly
to plan and accomplish this rearrangement and the machines are not producing the
changeover.

 Advantage of GT

 GT promotes standardization of tooling, fixturing and setups.

 Material handling is reduced
 Process planning and production scheduling are simplified.
 Setup times are reduced
 Work in process is Reduced
 Higher quality work is accomplished
 Disadvantages of GT Manufacturing :
 Involves less manufacturing flexibility
 Increases the machine down time as machines are grouped as cells which may not be
functional throughout the production process.
 PART FAMILIES (Similarity groupings are called Part Families)

 A part family is a collection of parts that are similar either because of geometric shape and
size or because similar processing steps are required in their manufacture.

 The parts within a family are different, but their similarities are close enough to merit their
inclusion as members of the part family.

a
b

A. Grouping Part Families

There are three general methods for solving part families grouping. All the three are time
consuming and involve the analysis of much of data by properly trained personnel.
The three methods are:
i. Visual inspection.
ii. Parts classification and coding.
iii. Production flow analysis.
i. Visual Inspection Method
The visual inspection method is the least sophisticated and least expensive method. It
involves the classification of parts into families by looking at either the physical parts or their
photographs and arranging them into groups having similar features.
ii. Parts classification and Coding

 In parts classification and coding, similarities among parts are identified, and these
similarities are related in a coding system.
 Two categories of part similarities can be distinguished:
1. Design attributes, which concerned with part characteristics such as geometry, size and
material.
2. Manufacturing attributes, which consider the sequence of processing steps required to
make a part.
• A part coding system consists of a sequence of symbols that identify the part’s design and/or
manufacturing attributes.
• The symbols are usually alphanumeric, although most systems use only numbers.
The three basic coding structures are:
1] Chain-type Structure, also known as a polycode, in which the interpretation of each symbol in
the sequence is always the same, it does not depend on the value of the preceding symbols.

2] Hierarchical Structure, also known as a monocode, in which the interpretation of each

successive symbol depends on the value of the preceding symbols.

3] Hybrid structure, a combination of hierarchical and chain-type structures

Opitz Classification and Coding System

The code number has a maximum of 13 positions. Each position may assume 10 different values
(Attributes).

It is intended for machined parts and uses the following digits sequence
Form Code 1 2 3 4 5 for design attributes
Supplementary Code 6 7 8 9 for manufacturing attributes
Secondary Code A B C D for production operation type & Sequence
Basic structure of the Opitz system
Example: Opitz part coding System

Given the rotational part design below, determine the form code in the Optiz parts classification
and coding system.

Solution
Length-to-diameter ratio: L/D = 1.5 Digit 1 = 1

External shape: both ends stepped with screw thread on one end Digit 2 = 5

Internal shape: part contains a through hole Digit 3 = 1

Plane surface machining: none Digit 4 = 0

Auxiliary holes, gear teeth, etc.: none Digit 5 = 0

The form code in the Optiz system is 15100

iii. Production Flow Analysis (PFA)

• Production flow analysis (PFA) is a method for identifying part families and associated machine
groupings that uses the information contained on process plans rather than on part drawings.
• Work parts with identical or similar process plans are classified into part families. These
families can then be used to form logical machine cells in a group technology layout.
• The procedure in production flow analysis must begin by defining the scope of the study, which
means deciding on the population of parts to be analyzed.
• The procedure of Production flow analysis (PFA) consists of the following steps:
- Data Collection. The minimum data needed in the analysis are the part number and operation
sequence, which is obtained from process plans.
- Sortation of process plans. A sortation procedure is used to group parts with identical process
plans.
- PFA Chart. The processes used for each group are then displayed in a PFA chart as shown
below.
 Flexible Manufacturing System (FMS)
Introduction

Definition: A flexible manufacturing system (FMS) is a highly automated GT machine cell

consisting of one or more processing stations (usually CNC machine tools), interconnected by an
automated material handling and storage system and controlled by a distributed computer
system.
A flexible manufacturing system (FMS) is a type of machine cell to implement cellular
manufacturing. It is the most automated and technologically sophisticated of the group
technology (GT) cells.
Its product variety allows it to cope with soft product variety.
An FMS typically possesses multiple automated stations and is capable of variable routings
among stations.
Need:
Globalization, flicking market requirements and modern lifestyle trends has put up
tremendous challenge to manufacturing industries. In the current business scenario the
competitiveness of any manufacturing industry is determined by its ability to respond quickly to
the rapidly changing market and to produce high quality products at low costs. However, the
product cost is no longer the predominant factor affecting the manufacturers’ perception. Other
competitive factors such as flexibility, quality, efficient delivery and customer satisfaction are
drawing the equal attention. Manufacturing industries are striving to achieve these capabilities
through automation, robotics and other innovative concepts such as just-in-time (JIT), Production
planning and control (PPC), enterprise resource planning (ERP) etc
Sub Systems or Elements of FMS:
The three basic components of flexible manufacturing system are
1) Workstations
2) Material Handling and Storage System
3) Computer Control System
1. Workstations
It consists of NC machines, machine-tools; inspection equipment’s, loading and unloading
operation, and machining area.
Following are types of workstations typically found in FMS
a. Load Unload Stations: The loading and unloading station is the physical interface between
the FMS and the rest of the factory. It is where raw work parts enter the system and finished
parts exit the system. Loading unloading can be done either by manually or by automated
handling system.
b. Machining Stations: The most common application of FMS are machining operations. The
workstation used in these systems is therefore predominantly CNC machine tools. Most
common are CNC machining centers along with automatic tool changing and storage system,
and pallets.
c. Assembly: Some FMS are designed to performed assembly operations. Industrial robots are
often used as the automated workstations in these flexible assembly systems.
d. Other Stations & Equipment’s: Inspections can be incorporated into FMS. To do this
coordinate measuring machine, special inspection probes that can be used in a machine tool.
In addition to above FMS can include changing parts and pallet fixtures, central coolant
delivery system and centralized chip removal system.
2. Material Handling and Storage System
The second major component of FMS is its material handling and storage system. This section
covers the function of the handling system, various types of handling equipment’s and types of
FMS layout.

3) Computer Control System

The FMS includes a distribute computer control system that is interfaced to the workstations,
material handling systems and other hardware components. Typical computer numerical
systems in FMS consist of central computer and microcomputer controlling the individual
machines and other components.
Computer Control System can be categorized as follows:
i. Workstation Control
ii. Distribution of control instruction to workstations
iii. Production control
iv. Traffic control
v. Shuttle control
vi. Tool control
vii. Performance monitoring
viii. Diagnostic

Production control—management of the mix and rate at which various parts are launched into
the system is important; alongside data input of a number of essential metrics, such as: daily
desired production rates, number of raw work parts available, work-in-progress etc.

Traffic control—management of the primary handling system is essential so that parts arrive at
the right location at the right time and in the right condition

Shuttle control—management of the secondary handling system is also important, to ensure the
correct delivery of the work part to the station’s work head

Workpiece monitoring—the computer must monitor the status of each cart or pallet in the
primary and secondary handling systems, to ensure that we know the location of every element
in the system

Tool control—this is concerned with managing tool location (keeping track of the different tools
used at different workstations, which can be a determinant on where a part can be processed),
and tool life (keeping track on how much usage the tool has gone through, so as to determine
when it should be replaced)

Performance monitoring and reporting—the computer must collected data on the various
operations on-going in the FMS and present performance findings based on this

Diagnostics—the computer must be able to diagnose, to a high degree of accuracy, where a

problem may be occurring in the FMS
 Comparison between FMS and Conventional Manufacturing Systems

Sr.No Attribute FMS Convectional

1 Set-up Defined Varies

2 Volume Low-Medium Medium-High

3 WIP (work-in-process) Low High

4 Flexibility High Low

5 Scrap Low Unpredictable

6 Labor Low High

7 Equipment cost High (short term) Low (short term)

8 Automation High level Low level

9 Quality Controlled Varies

10 Inspection Automatic tie-in Doesn’t flow

11 Tooling and fixturing Flexible Rigid

12 Market changes Flexible Rigid

13 Lead time Low High

Equipment and time
14 Engineering changes Easier
constraints
 ROBOTICS

 Definition:
a. Robot: “An industrial Robot is a reprogrammable multifunctional manipulator designed to
move materials, parts tools or specialized devices through various programmed motions for the
performance of variety of tasks”.

b. Robotics: It the branch of technology that deals with the design, construction, operation, and
application of robots.

 Advantage of Robotics
i. Cost Effectiveness
ii. Improved Quality Assurance
iii. Increased Productivity
iv. Can work in hazardous environment

 Disadvantage of Robotics:
i. High initial cost
ii. Potential Job Losses
iii. Robots don’t have emotions or logic so they cannot go beyond their defined limit.

 Application of Robots
Following are some of the applications of Robots
i. In manufacturing industry
ii. In agricultural field
iii. In medical field
iv. In automotive industries
v. In military application
 Basic Components of Robotics

a) Control System–This is the major governing system of the robot. Every system that is
present inside the robot and functioning can be represented in form of a control system
(open-loop and closed-loop).
A robot's control system uses feedback just as the human brain does. However,
instead of a collection of neurons, a robot's brain consists of a silicon chip called a central
processing unit, or CPU, that is similar to the chip that runs your computer. Our brains
decide what to do and how to react to the world based on feedback from our five senses. A
robot's CPU does the same thing based on data collected by devices called sensors.
b) Sensor System- In order for the robot to interact with the physical world, we need to
introduce sensors (which can measure physical parameters like temperature, pressure,
heat, radio waves, IR waves, etc). These sensor systems provide a feedback from the real
world to the digital world (embedded electronics), which are processed and the robot
takes the decision accordingly.
c) Actuator System- As described actuators are devices which bring about the locomotion
of the robot. There are many actuators used like DC Motors, Stepper Motors, Servo
Motors, etc. The way they are connected together, their circuit diagram, their location,
orientation, position, etc. everything comes under Actuator System
d) Manipulator- Just like the human arm, the robot consists of what is called a manipulator
having several joints and links. A robot manipulator is an electronically controlled
mechanism, consisting of multiple segments, that performs tasks by interacting with its
environment. They are also commonly referred to as robotic arms.
e) End Effectors- In robotics, an end effector is the device at the end of a robotic arm,
designed to interact with the environment. The exact nature of this device depends on the
application of the robot. The end effector means the last link (or end) of the robot. At this
endpoint, the tools are attached. In a wider sense, an end effector can be seen as the part
of a robot that interacts with the work environment.
f) Signal Processing System-The data from the sensors and other electrical and digital
signals need to be processed, so that the robot analyzes the situation and makes its
moves. For this, we introduce electronic components to process the signals. The
components can be any analog/digital device, or even a microcontroller.