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The document discusses automation in manufacturing, detailing three types: rigid, programmable, and flexible automation, each with distinct characteristics and applications. It also covers Flexible Manufacturing Systems (FMS) and computer-aided technologies like CAD, CAM, and CAPP, emphasizing their roles in enhancing production efficiency. Additionally, it touches on lean manufacturing principles, waste reduction, and the evolution towards Industry 4.0 and 5.0, highlighting the importance of collaboration and sustainability in modern manufacturing.

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Ali Tavakoli
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14 views5 pages

1 6 7 8 9

The document discusses automation in manufacturing, detailing three types: rigid, programmable, and flexible automation, each with distinct characteristics and applications. It also covers Flexible Manufacturing Systems (FMS) and computer-aided technologies like CAD, CAM, and CAPP, emphasizing their roles in enhancing production efficiency. Additionally, it touches on lean manufacturing principles, waste reduction, and the evolution towards Industry 4.0 and 5.0, highlighting the importance of collaboration and sustainability in modern manufacturing.

Uploaded by

Ali Tavakoli
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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11/01/2025, 13:51 ChatGPT

Automation in Manufacturing
Automation refers to technology and processes that reduce human intervention in production. It is
categorized into three types:

Rigid Automation
Definition: Fixed systems designed for repetitive tasks with high production volume.
Characteristics:

High initial investment.


Limited adaptability to product or volume changes.
Used in transfer lines and assembly lines.
Example: A car factory producing the same model repeatedly on an assembly line.
Drawbacks:

Poor adaptability to market changes.


Expensive modifications if production needs to shift.

Programmable Automation
Definition: Systems capable of changing their operations via programming, making them more
adaptable than rigid automation.
Tools Used: Numerical Control (NC) Machine Tools operated by hardwired control units.
Applications:

Aerospace: Adjusting machines to fabricate parts with different dimensions.


Furniture manufacturing: Program changes for custom designs.
Advantage: Greater flexibility than rigid automation, allowing batch production of varied
products.

Flexible Automation
Definition: Advanced automation with the ability to adjust seamlessly between products and
volumes without downtime.
Core Technologies:

Computer Numerical Control (CNC) machines.


Industrial robots.
Material handling systems.

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Example: A production line capable of making smartphones and tablets alternately without
manual intervention.
Advantages:

Eliminates downtime during retooling or reprogramming.


Adapts quickly to new market demands.

Flexible Manufacturing Systems (FMS)


FMS integrates machinery, robots, and handling systems to create adaptive production lines.

Components of FMS:
1. CNC Machines: Perform precise machining operations on diverse components.
2. Robots: Assist in loading, unloading, and assembly tasks.
3. Material Handling Systems: Include Automated Guided Vehicles (AGVs) for transferring parts.
4. Computerized Control Systems: Oversee the entire process to ensure coordination.

Benefits of FMS:
Reduced setup times and manual labor.
High flexibility in handling different products.
Increased productivity and equipment utilization.

Categories of FMS:
1. Flexible Manufacturing Modules (FMM):

Single CNC machine tool with automated loading/unloading.


Suitable for small batch production.
2. Production Cells:

Small groups of machines connected for varied production tasks.


3. Flexible Transfer Lines:

Fixed sequence systems with multifunctional machines.


Example: Tire production lines in the automotive industry.
4. Flexible Offline Systems:

Independent systems with non-cyclical connections.

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Example: Customizing furniture with different finishes.

Computer-Aided Technologies
Computer-Aided Design (CAD)
CAD systems streamline the design process with tools for 2D and 3D modeling.
Techniques:

Wireframe Modeling: Basic geometric representation using points and lines.


Surface Modeling: Adds shading and texture, useful for complex surfaces like car bodies.
Solid (Robust) Modeling: Provides volume and internal geometry, essential for finite element
analysis (FEA).
Benefits:

Enhanced design accuracy.


Quicker design iterations.
Data storage for future reuse.

Computer-Aided Manufacturing (CAM)


CAM involves automated control of production processes via computers.
Key Features:

Integration with CAD for seamless design-to-production transition.


Real-time adjustments based on process feedback.
Example: CNC milling machines producing parts based on CAD designs.

Computer-Aided Process Planning (CAPP)


CAPP defines the sequence of operations for manufacturing a product.
Functions:

Selection of tools and equipment.


Determination of operation order.
Benefits:

Streamlined workflows.
Reduced errors in process planning.

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Lean Manufacturing and Waste Reduction


Lean Principles
1. Value: Define what the customer values.
2. Value Stream: Map the steps from raw material to finished product to identify waste.
3. Flow: Ensure uninterrupted progression of value-adding steps.
4. Pull: Produce based on customer demand (Just-in-Time).
5. Perfection: Continuously improve processes.

Waste Categories (3M):


1. Muda (Uselessness):

Activities not adding value, e.g., overproduction, excess motion.


2. Mura (Unevenness):

Variability in workloads, leading to inefficiencies.


3. Muri (Overburden):

Overloading equipment or workers, risking breakdowns or errors.

Waste Types (DOWNTIME):


Defects: Reworking or scrapping faulty products.
Overproduction: Producing items without immediate demand.
Waiting: Delays due to bottlenecks or material shortages.
Non-utilized Talent: Ignoring workers' skills.
Transportation: Unnecessary movement of materials.
Inventory Excess: Holding more stock than needed.
Motion: Inefficient movements of workers or machines.
Extra Processing: Unneeded steps or features.

Industry 4.0 and Industry 5.0


Industry 4.0
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Core Elements:

IoT: Connecting devices for real-time data sharing.


AI and Machine Learning: Predictive maintenance and production optimization.
Digital Twin: Virtual replicas of physical systems for simulation and planning.
Cloud Computing: Centralized data storage and processing.
Edge Computing: On-site data processing for real-time decision-making.

Industry 5.0
Key Features:

Collaboration between humans and machines.


Emphasis on sustainability and worker well-being.
Examples: Augmented reality for training, robots assisting in hazardous tasks.

Push vs. Pull Systems


Push System:

Produces based on forecasts.


Risk of overproduction.
Suitable for stable demand environments.
Pull System:

Production triggered by customer orders.


Minimizes inventory.
Example: Toyota's Just-in-Time system.

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