EXCEL ENGINEERING COLLEGE

(Autonomous)
Department of Information technology
VI Semester
20ECO06 – ROBOTICS AND ITS INDUSTRIAL APPLICATION
Regulation 2020
QUESTION BANK
UNIT – 3 MANUFACTURING SYSTEMS

PART-A

1. List the components of a manufacturing system.

(1) Production Machines
(2) Material Handling System
(3) Computer Control System
(4) Human Resources

2. Mention the functions of a computer control system.

Typical computer system functions include the following:
• Communicate instructions to workers.
• Download part programs.
• Control material handling system.
• Schedule production.
• Diagnose failures.
• Monitor safety.
• Maintain quality control.
• Manage operations.

3. What are the three categories of work transport systems in production lines?
(1) In-line
(2) Segmented in-line
(3) Rotary.

4. Define starving.
Starving is the situation in which the assembly operator has completed the
assigned task on the current work unit, but the next unit has not yet arrived at the
station. The worker is thus starved for work.

5. Define blocking.
Blocking means that the operator has completed the assigned task on the current
work unit but cannot pass the unit to the downstream station because that worker is not
yet ready to receive it. The operator is therefore blocked from working.

6. List the types of segmented inline work transport systems in automated

production lines.
 i) L-shaped
ii) U-shaped
iii) Rectangular

7. List the basic control functions of an automated production line.

(1) Sequence control
(2) Safety monitoring
(3) Quality control.

8. Distinguish synchronous and asynchronous transport system.

In Synchronous transport systems, all work units are moved simultaneously
between stations with a quick, discontinuous motion, and then positioned at their
respective stations.
In an Asynchronous transport system, a work unit leaves a given station when the
assigned task has been completed and the worker releases the unit. Work units move in
dependently, rather than synchronously.

9. Mention the types of work transport in manual assembly lines.

(a) Continuous transport
(b) Synchronous transport
(c) Asynchronous transport.

10. What is a storage buffer?

A storage buffer is a location in the production line where parts can be collected
and temporarily stored before proceeding to downstream workstations. The storage
buffers can be manually operated or automated.

11. Define a manufacturing system.

A manufacturing system is defined as a collection of integrated equipment and

human resources, whose function is to perform one or more processing and/or assembly
operations on a starting raw material, part, or set of parts.

12. List the types of production machines.

(1) Manually operated

(2) Semi automated
(3) Fully automated.

13. Define manually operated machines with example.

Manually operated machines are controlled or supervised by a human worker. The
machine provides the power for the operation and the worker provides the control.
Conventional machine tools (such as lathes, milling machines, and drill presses) fit into this
category.
14. What is Semi automated machine?
Semi automated machine performs a portion of the work cycle under some form
of program control, and a worker tends to the machine for the remainder of the cycle.
An example of this category is a computer numerical control (CNC) machine tool or
other programmable production machine that is controlled for most of the work cycle
by the part program, but requires a worker to unload the finished part and load the next
workpiece during each cycle.

15. Define fully automated machine?

Fully automated machine has the capability to operate with no human attention
for periods of time longer than one work cycle. Although a worker’s attention is not
required during each cycle, some form of machine tending may be needed periodically.
For example, after a certain number of cycles, a new supply of raw material must be
loaded into the automated machine.

16. List the material handling functions.

(1) Loading work units at each station
(2) Positioning the work units at the station
(3) Unloading the work units from the station.
(4) Transporting work units between stations.
(5) Temporary storage.

17. List the operations of human resources in production.

Human workers are also needed in automated manufacturing systems to manage
or support the system as computer programmers, computer operators, part
programmers for computer numerical control (CNC) machine, maintenance and repair
personnel, and similar indirect roles.

18. Mention the types of manufacturing systems.

(1) Single-station cells
(2) Multistation systems with fixed routing
(3) Multistation systems with variable routing.

19. Define synchronous transport systems.

In Synchronous transport systems, all work units are moved simultaneously
between stations with a quick, discontinuous motion, and then positioned at their
respective stations.

20. What are the types of line pacing?

(1) Rigid pacing
(2) Pacing with margin
(3) No pacing.
 PART - B

1. Describe in detail about the manufacturing system.

Manufacturing Systems:
 A manufacturing system is defined as a collection of integrated equipment
and human resources, whose function is to perform one or more
processing and/or assembly operations on a starting raw material, part, or
set of parts.
 The integrated equipment includes production machines and tools,
material handling and work positioning devices, and computer systems.
 Human resources are required either full time or periodically to keep the
system running.
 The manufacturing system is where the value-added work is
accomplished on the parts and products.
 The position of the manufacturing system in the larger production system
is shown in Figure

Examples of manufacturing systems include:

•one worker tending one machine, which operates on semi-automatic cycle

•a cluster of semi-automatic machines, attended by one worker

•a fully automated assembly machine, periodically attended by a human worker

•a group of automated machines working on automatic cycles to produce a family

of similar parts

•a team of workers performing assembly operations on a production line.

 2. Explain in detail about the components of a manufacturing
system.

COMPONENTS OF A MANUFACTURING SYSTEM:

A manufacturing system typically consists of the following components:

(1) Production Machines

(2) Material Handling System

(3) Computer Control System

(4) Human Resources

(1) Production Machines :

In terms of worker participation, the machines can be classified as

(1) Manually operated

(2) Semi automated

(3) Fully automated.

Manually operated machines are controlled or supervised by a human

worker. The machine provides the power for the operation and the worker provides
the control. Conventional machine tools (such as lathes, milling machines, and drill
presses) fit into this category.

Semi automated machine performs a portion of the work cycle under some
form of program control, and a worker tends to the machine for the remainder of the
cycle. An example of this category is a computer numerical control (CNC) machine
tool or other programmable production machine that is controlled for most of the
work cycle by the part program, but requires a worker to unload the finished part
and load the next workpiece during each cycle.

Fully automated machine has the capability to operate with no human

attention for periods of time longer than one work cycle. Although a worker’s
attention is not required during each cycle, some form of machine tending may be
needed periodically. For example, after a certain number of cycles, a new supply of
raw material must be loaded into the automated machine.

(2) Material Handling System :

In most processing and assembly operations the following material handling

functions must be performed:
 (1) Loading work units at each station

(2) Positioning the work units at the station

(3) Unloading the work units from the station.

(4) Transporting work units between stations.

(5) Temporary storage.

Loading, positioning, and Unloading.

These three material handling functions occur at each workstation. Loading

involves moving the work units into the production machine or processing
equipment from a source inside the station. Positioning means that the part is
placed in a fixed location and orientation relative to the work head or tooling that
performs the operation. When the production operation has been completed, the
work unit must be unloaded, that is, removed from the production machine and
either placed in a container at the workstation or prepared for transport to the next
workstation in the processing sequence.

Work transport between stations.

Two general categories of work transport distinguished, according to the type

of routing between stations are:

(1) Fixed routing

(2) Variable routing.

In fixed routing, the work units always flow through the same sequence of
workstations. This means that the work units are identical, or similar enough that
the processing sequence is the same.

In variable routing, work units are transported through a variety of different

station sequences. This means that the manufacturing system processes or assembles
different styles of work units.
(3) Computer Control system :

In modern automated manufacturing systems, a computer system is required

to control the automated and semi automated equipment and to participate in the
overall coordination and management of the system.

Typical computer system functions include the following:

• Communicate instructions to workers.

• Download part programs.

• Control material handling system.

• Schedule production.

• Diagnose failures.

• Monitor safety.

• Maintain quality control.

• Manage operations.

(4) Human Resources :

In many manufacturing systems, humans perform some or all of the value-

added work on the parts or products. In these cases, the human workers are referred
to as direct labor.

Human workers are also needed in automated manufacturing systems to

manage or support the system as computer programmers, computer operators, part
programmers for computer numerical control (CNC) machine, maintenance and
repair personnel, and similar indirect roles.
 3. Elaborate the classification of manufacturing systems.

CLASSIFICATION OF MANUFACTURING SYSTEMS:

Three basic types of manufacturing systems are:

(1) Single-station cells

(2) Multistation systems with fixed routing

(3) Multistation systems with variable routing.

Each type can be implemented as a manned system or an automated system,

as depicted in the Figure. In the case of multistation systems, hybrids consisting of
manned and automated stations are also possible.

(1) Single-Station Cells.

Applications of single-station cells are widespread. The typical case is a

worker-machine cell. Two categories are distinguished:

(1) Manned cells, in which a worker must be present each work cycle.

(2) Automated cells, in which periodic attention is required less frequently

than every cycle.

In either case, these systems are used for processing as well as assembly operations.

Examples of single-station cells include the following:

• Worker operating an engine lathe (manually operated machine)

• Worker loading and unloading a CNC lathe (semiautomated machine)

• Welder and fitter working in an arc-welding operation (manually operated

equipment)

• CNC turning center with parts carousel operating unattended using a robot to
load and unload parts (fully automated machine)

This type of manufacturing system is popular because

(1) it is the easiest and least expensive manufacturing system

(2) it is arguably the most adaptable, adjustable, and flexible manufacturing system

(3) a manned single workstation can be converted to an automated station.

(2) Multistation systems with Fixed routing. :

A multistation manufacturing system with fixed routing is a production line,

which consists of a series of workstations laid out so that the work unit moves from
one station to the next, and a portion of the total work content is performed on it at
each station. Transfer of work units from one station to the next is usually
accomplished by a conveyor or other mechanical transport. However, in some cases
the work is simply pushed between stations by hand.

Examples of multistation systems with fixed routing include the following:

• Manual assembly line that produces small power tools (manually operated
workstations)

• Machining transfer line (automated workstations)

• Automated assembly machine with a carousel system for work transport (auto
mated workstations)

• Automobile final assembly plant, in which many of the spot welding and
spray painting operations are automated while general assembly is manual (hybrid
system).

(3) Multistation systems with Variable routing.

A multiple-station system with variable routing is a group of workstations

organized to produce a limited range of part or product styles in medium
production quantities (typically 100–10,000 units annually). The differences in part
or product styles mean differences in operations and sequences of operations that
 must be performed. The system must possess flexibility in order to cope with this
variety.

Examples of multiple-station systems with variable routing include the

following:

• Manned machine cell designed to produce a family of parts with similar

geometric features (manually operated machines)

• Flexible manufacturing system with several CNC machine tools connected by

an automated conveyor system and operating under computer control (automated
workstations).

4. Discuss in detail about the fundamentals of manual assembly

lines.

FUNDAMENTALS OF MANUAL ASSEMBLY LINES

A manual assembly line is a production line that consists of a sequence of
workstations where assembly tasks are performed by human workers, as depicted in
Figure 15.1.

 Products are assembled as they move along the line.

 At each station, a worker performs a portion of the total work on the unit. The
common practice is to “launch” base parts onto the beginning of the line at regular
intervals.
 Each base part travels through successive stations and workers add components that
progressively build the product.
 A mechanized material transport system is typically used to move the base parts
along the line as they are gradually transformed into final products.
 The production rate of an assembly line is determined by its slowest station. Stations
capable of working faster are ultimately limited by the slowest station.

1. ASSEMBLY WORKSTATIONS:

A workstation on a manual assembly line is a designated location along the

work flow path at which one or more work elements are performed by one or more
workers. The work elements represent small portions of the total work that must be
accomplished to assemble the product. A given workstation also includes the tools
(hand tools or powered tools) required to perform the task assigned to the station.

Some workstations are designed for workers to stand, while others allow the
workers to sit. When the workers stand, they can move about the station area to
perform their assigned task. This is common for assembly of large products such as
cars, trucks, and major appliances. The product is typically moved by a conveyor at
constant velocity through the station. The worker begins the assembly task near the
upstream side of the station and moves along with the work unit until the task is
completed, then walks back to the next work unit and repeats the cycle.

For smaller assembled products (such as small appliances, electronic devices,

and subassemblies used on larger products), the workstations are usually designed
to allow the workers to sit while they perform their tasks. This is more comfortable
and less fatiguing for the workers and is generally more conducive to precision and
accuracy in the assembly task.

2. WORK TRANSPORT SYSTEMS:

There are two basic ways to accomplish the movement of work units along a
manual as sembly line:

(i) Manual methods of work transport

(ii) Mechanized work transport

(i) Manual methods of work transport:

 In manual work transport, the units of product are passed from station to
station by the workers themselves.
 Two problems result from this mode of operation: starving and blocking.
 Starving is the situation in which the assembly operator has completed the
assigned task on the current work unit, but the next unit has not yet arrived at
the station. The worker is thus starved for work.
 Blocking means that the operator has completed the assigned task on the
current work unit but cannot pass the unit to the downstream station because
 that worker is not yet ready to receive it. The operator is therefore blocked
from working.
 To mitigate the effects of these problems, storage buffers are sometimes used
between stations.
 In some cases, the work units made at each station are collected in batches
and then moved to the next station.

(ii) Mechanized Work transport:

 Powered conveyors and other types of mechanized material handling
equipment are widely used to move units along manual assembly lines.
 Three major categories of work transport systems in production lines are
(a) Continuous transport
(b) Synchronous transport
(c) Asynchronous transport.
A Continuous transport system uses a continuously moving conveyor that
operates at constant velocity. This method is common on manual assembly
lines. The conveyor usually runs the entire length of the line. However, if the
line is very long, such as the case of an automobile final assembly plant, it is
divided into segments with a separate conveyor for each segment.
Continuous transport can be implemented in two ways: (1) work units are
fixed to the conveyor, and (2) work units are removable from the conveyor. In
the first case, the product is large and heavy (e.g., automobile, washing
machine) and cannot be removed from the conveyor. The worker must
therefore walk along with the product at the speed of the conveyor in order to
accomplish the assigned task. In the case where work units are small and
lightweight, they can be removed from the conveyor for the physical
convenience of the operator at each station.

In Synchronous transport systems, all work units are moved simultaneously

between stations with a quick, discontinuous motion, and then positioned at
their respective stations. Synchronous transport is not common for manual
lines, due to the requirement that the task must be completed within a certain
time limit. This can cause undue stress on the assembly workers and result in
 incomplete products. Despite its disadvantages for manual assembly lines,
synchronous transport is often ideal for automated production lines, in which
mechanized workstations operate on a constant cycle time.

In an Asynchronous transport system, a work unit leaves a given station

when the assigned task has been completed and the worker releases the unit.
Work units move in dependently, rather than synchronously. At any moment,
some units are moving between workstations while others are positioned at
stations. With asynchronous transport systems, small queues of work units
are permitted to form in front of each station.

(iii) Line Pacing:

Manual assembly lines can be designed with three alternative levels of pacing:
(1) Rigid pacing
(2) Pacing with margin
(3) No pacing.
In Rigid pacing, each worker is allowed only a certain fixed time each cycle
to complete the assigned task. The allowed time is implemented by a
synchronous work transport system and is (usually) equal to the cycle time of
the line. In a Rigidly paced operation, if the task has not been completed
within the fixed cycle time, the work unit exits the station incomplete. This
may inhibit completion of sub sequent tasks at downstream stations.
In Pacing with margin, the worker is allowed to complete the task at the
station within a specified time range. The maximum time of the range is
 longer than the cycle time, so that a worker is permitted to take more time if a
problem occurs or if the task time required for a particular work unit is longer
than the average (this occurs when different product styles are produced on
the same assembly line).
The third level of pacing is when there is No pacing, meaning that no time
limit exists within which the task at the station must be finished. In effect,
each assembly operator works at his/her own pace. This case can occur when
(1) manual work transport is used on the line, (2) work units can be removed
from the conveyor (3) an asynchronous conveyor is used.

(iv) Coping with product Variety:

Three types of assembly line can be distinguished:
(1) Single model
(2) Batch model
(3) Mixed model.

A single-model line produces only one product in large quantities. Every

work unit is identical, so the task performed at each station is the same for all
products. This line type is intended for products with high demand.
Batch-model and mixed-model lines are designed to produce two or more
products or models, but different approaches are used to cope with the model
variations.
A Batch model line produces each product in batches. Workstations are
set up to produce the required quantity of the first product, then the stations
are reconfigured to produce the next product, and so on. Products are often
assembled in batches when demand for each product is medium.
A mixed-model line also produces more than one model; however, the
models are not produced in batches; instead, they are made simultaneously
on the same line. While one station is working on one model, the next station
is processing a different model. Each station is equipped to perform the
variety of tasks needed to produce any model that moves through it. Final
assembly of many consumer products is accomplished on mixed-model lines.
 5. Discuss in detail about the fundamentals of automated
production lines.

FUNDAMENTALS OF AUTOMATED PRODUCTION LINES

Each processing operation is performed at a workstation, and the stations
are physically integrated by means of a mechanized work transport system to
form an automated production line.

(i) Work Part Transport:

The work part transport system moves parts between stations on the
line. Transport mechanisms used on automated production lines are usually
either synchronous or asynchronous but rarely continuous.
Depending on the geometry of the work part to be processed, the line may
utilize pallet fixtures for part handling. A pallet fixture is a work-holding
device that is designed to (1) fixture the part in a precise location relative to its
base and (2) be moved, located, and accurately clamped in position at
successive workstations by the transfer system.

System Configurations:

The work flow can take different forms like:

(1) In-line
(2) Segmented in-line
(3) Rotary.

The in-line configuration consists of a sequence of stations in a straight line

arrangement, as in Figure.

This configuration is common for machining big workpieces, such as

automotive engine blocks, engine heads, and transmission cases. Because these parts
require a large number of operations, a production line with many stations is
needed. The in-line configuration can accommodate a large number of stations. In-
line systems can also be designed with integrated storage buffers along the flow
path.
 The Segmented in-line configuration consists of two or more straight-line
transfer sections, where the segments are usually perpendicular to each other. Figure
shows several possible layouts of the segmented in-line category. There are a
number of reasons for designing a production line in these configurations rather
than in a pure straight line:

(1) available floor space may limit the length of the line

(2) a workpiece in a segmented in-line configuration can be reoriented to

present different surfaces for machining

(3) the rectangular layout provides for swift return of work-holding fixtures to
the front of the line for reuse.

L-shaped

U-shaped

Rectangular
 In the Rotary configuration, the work parts are attached to fixtures around
the periphery of a circular worktable, and the table is indexed (rotated in fixed
angular amounts) to present the parts to workstations for processing. A typical
arrangement is illustrated in the Figure. The worktable is often referred to as a dial,
and the equipment is called a dial-indexing machine.

(ii) Storage Buffers:

Automated production lines can be designed with storage buffers. A storage

buffer is a location in the production line where parts can be collected and
temporarily stored before proceeding to downstream workstations. The storage
buffers can be manually operated or automated.

(iii) Control of the production Line:

Control Functions:

Three basic control functions can be distinguished in the operation of an

automated production line:

(1) Sequence control

(2) Safety monitoring

(3) Quality control.

 The purpose of sequence control is to coordinate the sequence of actions of

the trans port system and associated workstations.
 The safety monitoring function ensures that the production line does not
operate in an unsafe manner.
 In the quality control function, certain quality attributes of the work parts are
monitored. The purpose is to detect and possibly reject defective work units
produced on the line.
Line Controllers:

Programmable logic controllers (PLCs) are the conventional controllers used

on automated production lines today. Personal computers (PCs) equipped with
control software and designed for the factory environments are also widely used.