HIGH VOLUME PRODUCTION SYSTEM

AUTOMATED FLOW LINES

An automated flow line consists of several machines or workstations which are linked together by
work handling devices that transfer parts between the stations. The transfer of workparts occurs
automatically and the workstations carry out their specialized functions automatically. A raw
workpart enters one end of the line and the processing steps are performed sequentially as the part
moves from one station to the next. It is possible to incorporate buffer storage zones into the flow
line, either al a single location or between every workstation. It is also possible to include inspection
stations in the line to automatically perform intermediate checks on the quality of the workparts.
Manual stations might also be located along the flow line to perform certain operations which are
difficult or uneconomical to automate.

The objectives of the use of flow line automation are, therefore:

• To reduce labor costs
• To increase production rates
• To reduce work-in-process
• To minimize distances moved between operations
• To achieve specialization of operations
• To achieve integration of operations

Configurations of automated flow line.

1) In-line type
The in-line configuration consists of a sequence of workstations in a more-or-less straight-line
arrangement as shown in figure. An example of an in-line transfer machine used for metal-cutting
operations

2) Segmented In-Line Type

The segmented in-line configuration consists of two or more straight-line arrangement which are
usually perpendicular to each other with L-Shaped or U-shaped or Rectangular shaped. The flow of
work can take a few 90° turns, either for workpieces reorientation, factory layout limitations, or
 other reasons, and still qualify as a straight-line configuration.

3) Rotary type
In the rotary configuration, the workparts are indexed around a circular table or dial. The
workstations are stationary and usually located around the outside periphery of the dial. The parts ride on
the rotating table and arc registered or positioned, in turn, at each station for its processing or assembly
operation. This type of equipment is often referred to as an indexing machine or dial index machine and
the configuration is shown in Figure .

Figure Rotary configuration

METHODS OF WORKPART TRANSPORT

The transfer mechanism of the automated flow line must not only move the partially completed
workparts or assemblies between adjacent stations, it must also orient and locate the parts in the
correct position for processing at each station. The general methods of transporting workpieces on flow
lines can be classified into the following three categories:
1. Continuous transfer
2. Intermittent or synchronous transfer
3. Asynchronous or power-and-free transfer

The most appropriate type of transport system for a given application depends on such factors as:
 The types of operation to be performed
 The number of stations on the line
 The weight and size of the work parts
 Whether manual stations are included on the line
  Production rate requirements
 Balancing the various process times on the line

1) Continuous transfer
With the continuous method of transfer, the workparts are moved continuously at Constant speed.
This requires the workheads to move during processing in order to maintain continuous registration
with the workpart. For some types of operations, this movement of the workheads during processing
is not feasible. It would be difficult, for example, to use this type of system on a machining transfer
line because of inertia problems due to the size and weight of the workheads. In other cases,
continuous transfer would be very practical. Examples of its use are in beverage bottling operations,
packaging, manual assembly operations where the human operator can move with the moving flow
line, and relatively simple automatic assembly tasks. In some bottling operations, for instance, the
bottles are transported around a continuously rotating drum. Beverage is discharged into the moving
bottles by spouts located at the drum's periphery. The advantage of this application is that the liquid
beverage is kept moving at a steady speed and hence there are no inertia problems.

Continuous transfer systems are relatively easy to design and fabricate and can achieve a high rate of
production.
2) Intermittent transfer
As the name suggests, in this method the workpieces are transported with an intermittent or
discontinuous motion. The workstations are fixed in position and the parts are moved between
stations and then registered at the proper locations for processing. All workparts are transported at
the same time and, for this reason, the term "synchronous transfer system" is also used to describe
this method of workpart transport.

3) Asynchronous transfer
This system of transfer, also referred to as a "power-and-free system," allows each workpart to move
to the next station when processing at the current station has been completed. Each part moves
independently of other parts. Hence, some parts are being processed on the line at the same time that
others are being transported between stations.

Asynchronous transfer systems offer the opportunity for greater flexibility than do the other two
systems, and this flexibility can be a great advantage in certain circumstances. In-process storage of
workparts can be incorporated into the asynchronous systems with relative ease. Power-and-free
systems can also compensate for line balancing problems where there are significant differences in
process times between stations. Parallel stations or several series stations can be used for the longer
operations, and single stations can be used for the shorter operations. Therefore, the average
production rates can be approximately equalized. Asynchronous lines are often used where there are one
or more manually operated stations and cycle-time variations would be a problem on either the
continuous or synchronous transport systems. Larger workparts can be handled on the asynchronous
systems. A disadvantage of the power- and-free systems is that the cycle rates are generally slower
than for the other types.
 TRANSFER MECHANISMS
There are various types of transfer mechanisms used to move parts between stations. These
mechanisms can be grouped into two types: those used to provide linear travel for in-line machines,
and those used to provide rotary motion for dial indexing machines.

Linear transfer mechanisms

We will explain the operation of three of the typical mechanisms; the walking beam transfer bar
system, the powered roller conveyor system, and the chain-drive conveyor system. This is not a
complete listing of all types, but it is a representative sample.

Walking beam systems

With the walking beam transfer mechanism, the work-parts are lifted up from their workstation
locations by a transfer bar and moved one position ahead, to the next station. The transfer bar
then lowers the pans into nests which position them more accurately for processing. For speed
and accuracy, the motion of the beam is most often generated by a rotating camshaft powered
by an electric motor or a roller movement in a profile powered by hydraulic cylinder. Figure.
shows the working of the beam mechanish.

Powered roller conveyor system

 This type of system is used in general stock handling systems as well as in automated flow
lines. The conveyor can be used to move pans or pallets possessing flat riding surfaces. The
rollers can be powered by either of two mechanisms. The first is a belt drive, in which a flat
moving belt beneath the rollers provides the rotation of the rollers by friction. A chain drive is the
second common mechanism used to power the rollers. Powered roller conveyors are versatile
transfer systems because they can be used to divert work pallets into workstations or alternate
tracks.

Chain-drive conveyor system

In chain-drive conveyor system either a chain or a flexible steel belt is used to transport the
work carriers. The chain is driven by pulleys in either an "over-and- under" configuration, in
which the pulleys turn about a horizontal axis, or an "around-the-corner" configuration, in which
the pulleys rotate about a vertical axis. Figure 14 shows the chain conveyor transfer system.

Figure 14 Chain drive conveyor

This general type of transfer system can be used for continuous, intermittent, or nonsynchronous
movement of workparts. In the nonsynchronous motion, the workparts are pulled by friction or
ride on an oil film along a track with the chain or belt providing the movement. It is necessary to
provide some sort of final location for the workparts when they arrive at their respective stations.
Rotary transfer mechanisms
There are several methods used to index a circular table or dial at various equal angular positions
corresponding to workstation locations.
Rack and pinion
This mechanism is simple but is not considered especially suited to the high-speed operation
often associated with indexing machines. The device is pictured in Figure
4.6 and uses a piston to drive the rack, which causes the pinion gear and attached indexing table
 to rotate, A clutch or other device is used to provide rotation in the desired direction.

Ratchet and pawl:

A ratchet is a device that allows linear or rotary motion in only one direction, while preventing
motion in the opposite direction.
Ratchets consist of a gearwheel and a pivoting spring loaded finger called a pawl that engages the
teeth. Either the teeth, or the pawl, are slanted at an angle, so that when the teeth are moving in one
direction, the pawl slides up and over each tooth in turn, with the spring forcing it back with a 'click'
into the depression before the next tooth. When the teeth are moving in the other direction, the angle
of the pawl causes it to catch against a tooth and stop further motion in that direction. This drive
mechanism is shown in Figure 16.

Figure 16 Rachet and pawl mechanism

Geneva mechanism:
The previous mechanisms convert a linear motion into a rotational motion. The Geneva
mechanism uses a continuously rotating driver to index the table, as pictured in Figure 17. If the
 driven member has six slots for a six-station dial indexing machine, each turn of the driver will
cause the table to advance one-sixth of a turn. The driver only causes movement of the table
through a portion of its rotation. For a six-slotted driven member, 120° of a complete rotation of
the driver is used to index the table. The other 240° is dwell. during which the processing
operation must be completed on the work unit. In general.
θ =360 / ns
where θ is angle of rotation of worktable during indexing and ns number of slots in the geneva.
Total cycle time as Tc =1 / N where Tc is cycle time (min) & N= rotational speed of driver
(rev/min).
Dwell time Ts =(180+ θ) /(360N) (min)
Indexing time Tr =(180- θ)/360 N

For a four-slotted driven member, the ratio would be 90° for index and 270° for dwell. The usual
number of indexings per revolution of the table is four, five, six, and eight.

EXAMPLE

A rotary worktable is driven by a Geneva mechanism with six slots. The driver rotates at 30 rev/min. Determine
the cycle time, available process time, and the lost time each cycle indexing the table.

Solution: With a driver rotational speed of 30 rev/min, the total cycle time is given by

Tc= 1/N=1/ (30)= 0.0333 min= 2.0 sec.

The angle of rotation of the worktable during indexing for a six-slotted .

θ =360/6 =60°

the available service time and indexing time, respectively, as:

Ts =(180+ θ) /(360N)= (180 +60)/360*30 =0.0222 min=1.33 sec

Tr =(180- θ)/360 N =(180 -60)/360*30 =0.0111 min=0.667 sec

CAM Mechanisms:
Various forms of cam mechanism, an example of which is illustrated in Figure 18, provide
probably the most accurate and reliable method of indexing the dial. They are in widespread use in
industry despite the fact that the cost is relatively high compared to alternative mechanisms. The
cam can be designed to give a variety of velocity and dwell characteristics.

CONTROL FUNCTIONS
Controlling an automated flow line is a complex problem, owing to the sheer number of sequential
steps that must be carried out. There are three main functions that are utilized to control the operation
of an automatic transfer system. The first of these is an operational requirement, the second is a safety
requirement, and the third is dedicated to improving quality.

Sequence control.
The purpose of this function is to coordinate the sequence of actions of the transfer system and its
workstations. The various activities of the automated flow line must be carried out with split-second
timing and accuracy.Sequence control is basic to the operation of the flow line.

Safety monitoring:
This function ensures that the transfer system does not operate in an unsafe or hazardous condition.
Sensing devices may be added to make certain that the cutting tool status is satisfactory to continue to
process the workpart in the case of a machining-type transfer line. Other checks might include
monitoring certain critical steps in the sequence control function to make sure that these steps have all
been performed and in the correct order. Hydraulic or air pressures might also be checked if these are
crucial to the operation of automated flow lines.

Quality monitoring:
The third control function is to monitor certain quality attributes of the workpart. Its purpose is to
identify and possibly reject defective workparts and assemblies. The inspection devices required to
perform quality monitoring are sometimes incorporated into existing processing stations. In other cases,
separate stations are included in the line for the sole purpose of inspecting the workpart as shown in
figure 19.

Figure 19 Inspection station with feedback

Conventional thinking on the control of the line has been to stop operation when a malfunction
occurred. While there are certain malfunctions representing unsafe con-ditions that demand shutdown
of the line, there are other situations where stoppage of the line is not required and perhaps not even
desirable. There are alternative control strategies 1.Instantaneous control and 2. Memory control.

Instantaneous control:
This mode of control stops the operation of the flow line immediately when a malfunction is detected.
It is relatively simple, inexpensive, and trouble-free. Diagnostic features are often added to the system
to aid in identifying the location and cause of the trouble to the operator so that repairs can be quickly
made. However, stopping the machine results in loss of production from the entire line, and this is the
system's biggest drawback.

Memory control:
In contrast to instantaneous control, the memory system is designed to keep the machine operating. It
works to control quality and/or protect the machine by preventing subsequent stations from processing
the particular workpart and by segregating the part as defective at the end of the line. The premise
upon which memory-type control is based is that the failures which occur at the stations will be
random and infrequent. If, however, the station failures result from cause and tend to repeat, the
memory system will not improve production but, rather, degrade it. The flow line will continue to
operate, with the consequence that bad parts will continue to be produced. For this reason, a counter is
sometimes used so that if a failure occurs at the same station for two or three consecutive cycles, the
memory logic will cause the machine to stop for repairs.

BUFFER STORAGE
Automated flow lines are often equipped with additional features beyond the basic transfer mechanisms
and workstations. It is not uncommon for production flow lines to include storage zones for collecting
banks of workparts along the line. One example of the use of storage zones would be two intermittent
transfer systems, each without any storage capacity, linked together with a workpart inventory area. It is
possible to connect three, four, or even more lines in this manner. Another example of workpart storage
on flow lines is the asynchronous transfer line. With this system, it is possible to provide a bank of
workparts for every station on the line.

There are two principal reasons for the use of buffer storage zones. The first is to reduce the effect of
individual station breakdowns on the line operation. The continuous or intermittent transfer system
acts as a single integrated machine. When breakdowns occur at the individual stations or when
preventive maintenance is applied to the machine, production must be halted. In many cases, the
proportion of
time the line spends out of operation can be significant, perhaps reaching 50% or more. Some of the
common reasons for line stoppages are:
Tool failures or tool adjustments at individual processing stations Scheduled tool changes
Defective workparts or components at assembly stations, which require that the
Feed mechanism be cleared
Feed hopper needs to be replenished at an assembly station Limit switch or other
electrical malfunction
Mechanical failure of transfer system or workstation

Figure 20 Storage buffer between two stages of a production

When a breakdown occurs on an automated flow line, the purpose of the buffer storage zone is to
allow a portion of the line to continue operating while the remaining portion is stopped and under
repair. For example, assume that a 20- station line is divided into two sections and connected by a
parts storage zone which automatically collects parts from the first section and feeds them to the
second section. If a station jam were to cause the first section of the line to stop, the second section
could continue to operate as long as the supply of parts in the buffer zone lasts. Similarly, if the
second section were to shut down, the first section could continue to operate as long as there is room
in the buffer zone to store parts. Hopefully, the average production rate on the first section would be
about equal to that of the second section. By dividing the line and using the storage area, the average
production rate would be improved over the original 20-station Mow line. Figure 20 shows the
Storage buffer between two stages of a production line
Reasons for using storage buffers:

 To reduce effect of station breakdowns

 To provide a bank of parts to supply the line
 To provide a place to put the output of the line
 To allow curing time or other required delay
 To smooth cycle time variations
 To store parts between stages with different production rates

The disadvantages of buffer storage on flow lines are increased factory floor space, higher
in-process inventory, more material handling equipment, and greater complexity of the
overall flow line system. The benefits of buffer storage are often great enough to more than
compensate for these disadvantages.