Computer Integrated Manufacturing (CIM)

Unit 3
RRV
 General Terminology & Analysis

 There are two problem areas in analysis of automated flow lines

which must be addressed

Process Technology
System Technology
 Process Technology.

 Process Technology refers to the body of knowledge about the theory &
principles of the particular manufacturing process used on the production line
• In the manufacturing process, process technology includes the metallurgy &
machinability of the work material, the correct applications of the cutting tools,
chip control, economics of machining, machine tools alterations & a host of
other problems.
• Many problems encountered in machining can be overcome by application of
good machining principles.
 In each process, A Technology is developed by many years of research and
practice.
 Systems Technology.

 It refers to design of flow lines and overall flow line operation.

 System technology also refers to the manufacturing process
that are carried out on the flow lines.
 The problem related to design of flow lines is called “ Reliability
problems”
 Reliability problems refers that failure of any one component in
a flow line may stop entire system.
 Systems Technology.

 This can be solved by proper design of automated flow lines.

 The problems related to overall flow line operation is called as
“Line balancing problems”
 Line balancing refers that the total machining work that must be
accomplished on the automated flow lines must be evenly
distributed between workstations.
 General Terminology and Analysis of Automated flow lines

• During the analysis of automated flow lines the following

assumptions are made.
1. Workstation performs processing operations and not assembly
operations
2. Processing time at each workstation is constant and may not be
equal to other workstations
3. All parts are synchronously transferred
4. Automated flow lines without internal buffers are in the topic ( no
internal storage of buffer)
 General Terminology and Analysis of Automated flow lines

 In the operation of an automated production line, parts are

introduced into the first workstation & are processed and
transported at regular intervals to the succeeding stations.
 This interval defines the ideal cycle time, Tc of the production line.
Tc is the processing time for the slowest station of the line plus
the transfer time; i.e. :
 Tc = max (Tsi) + Tr ---------------- (1)
 Tc = ideal cycle on the line (min)
 Tsi = processing time at station (min)
 Tr = repositioning time, called the transfer time (min)
 General Terminology and Analysis of Automated flow lines

 In equation 1, we use the max (Tsi) because the longest service

time establishes the pace of the production line. The remaining
stations with smaller service times will have to wait for the
slowest station. The other stations will be idle.
 In the operation of a transfer line, random breakdowns &
planned stoppages cause downtime on the line.
Common reasons for downtime on an Automated Production
line

1.Tool failures at workstations.

2. Tool adjustments at workstations
3. Scheduled tool changes
4. Limit switch or other electrical malfunctions.
5. Mechanical failure of a workstation.
6. Mechanical failure of a transfer line.
7. Stock outs of starting work parts.
8. Insufficient space for completed parts.
9. Preventive maintenance on the line worker breaks
 Actual average production time: Tp

 The actual average production time Tp:

 Tp = Tsi+ Tr+ F.Td
 Tp = Tc + FTd ------------------------ 2
 F = downtime frequency, line stops / cycle
 Td = downtime per line stop in minutes
 The downtime Td includes the time for the repair
crew to swing back into action, diagnose the cause
of failure, fix it & restart the drive.
 Actual average production time: Tp

 FTd = downtime averaged on a per cycle basis

 Production can be computed as a reciprocal of Tp
 Rp = ----------------------------- 3
 Where, Rp = actual average production rate (pc / min)
 Tp = the actual average production time
 The ideal production rate is given by
 Rc = (without breakdown)------------------------------ 4
 Where Rc = ideal production rate (pc / min)
 Ideal Production rate: R c

 Production rates must be expressed on an hourly basis on

automated production lines.
 The machine tool builders uses the ideal or theoretical
production rate, Rc, in their proposal for the automated transfer
line.
 By considering this theoretical production rate, they claim the
machines has100%.
 The machine tool builder may ignore the effect of downtime on
production rate but it should be stated that the amount of
downtime experienced on the line is the responsibility of the
company using the production line and not the manufacturer.
 Line efficiency or Proportion of uptime: E

 Line efficiency refers to the proportion of uptime on the line & is

a measure of reliability more than efficiency.
 Line efficiency can be calculated as follows:
 E = = ----------------- 5
 E = The proportion of uptime on the production line
 Analysis of Automated flow lines without internal storage

 Process Technology
 System Technology
 Process Technology

 Process Technology : refers to theory and principles of

particular manufacturing process. Concepts like metallurgy and
machinability of work parts, proper application of cutting tools,
chip control, machining economics, machine tool vibrations etc.
 Such problems can be solved by application of good machining
principles.
 System Technology

 Refers to design of flow lines and overall flow line operation

 Manufacturing process that are carried out on the flow lines
 Reliability problems refers to that failure of any one component
in a flow line which may stop entire system
 Solution proper design of automated flow lines
 Problems related to the overall flow line operation is called “Line
balancing problems”
 Assumptions made

 Work station perform processing operation and not assembly

are made
 Processing time at each workstation is constant and may not be
equal to other workstations
 All parts are synchronously transferred
 Automated flow lines without internal buffers
 Terminology & Analysis of transfer lines with no Internal
storage

 Tc = max (Tsi) + Tr ---------------- (1)

• Tc = ideal cycle on the line (min)
• Tsi = processing time at station (min)
• Tr = repositioning time, called the transfer time (min)
 Actual average production time Tp = Tc + FTd ------------------------ 2
• F = downtime frequency, line stops / cycle
• Td = downtime per line stop in minutes
• The downtime Td includes the time for the repair crew to swing back into
action, diagnose the cause of failure, fix it & restart the drive.
 Terminology & Analysis of transfer lines with no Internal
storage

 Average down time per cycle = Frequency of breakdowns X

down time = F X Td
 Production time, Tp= Tsi+ Tr + F. Td-------------------------------- 3
 Ideal cycle time Tc=Tsi + Tr
 Therefore Tp= Tc+ F. Td
 Production rate is given by Rp =1/Tp-------------------------------4
 If there is no break down Td = 0
 Then Tp=Tc
 Terminology & Analysis of transfer lines with no Internal
storage

 Theoretical production rate is given by Rc =1/ Tc

 Line efficiency or proportion of uptime E = Tc/Tp--------(6)
 E = -------------------------------(7)
 Proportion of down time D = -----------(8)
 D= ------------------------(9)
 Terminology & Analysis of transfer lines with no Internal
storage

 In general, the time lost due to breakdowns is compensated by

the time gained by using automation and extra features i.e.,
Proportion of down time is compensated by proportion of
uptime. From equation 7 and 9
 E + D= + = 1-------------(10)
 Terminology & Analysis of transfer lines with no Internal
storage

 An important economic measure of the performance of an automated

production line is the cost of the unit produced. The cost of 1 piece
includes the cost of the starting blank that is to be processed, the cost
of time on the production line & the cost of the tool consumed.
 The cost per unit can be expressed as the sum of three factors
 Cpc = Cm +Co Tp +C------------------(11)
 Terminology & Analysis of transfer lines with no Internal
storage

• Where Cpc = cost per piece (Rs / pc)

• Cm = cost per minute to operate the time (Rs / min)
• Tp = average production time per piece (min / pc)
• Ct = cost of tooling per piece (Rs / pc)
• Co = the allocation of capital cost of the equipment over the
service life, labour to operate the line, applicable overheads,
maintenance, & other relevant costs all reduced to cost per min.
 Analysis of Automated Transfer line without storage during
break down

 Upper bound
 Lower bound approach
 Upper bound: The workstation breakdown will not have any
effect on the part
 The part can remain on the transfer line for subsequent
processing at remaining stations
 Applied in situations such as minor electrical or mechanical
failures at stations, tool change, tool adjustments, preventive
maintenance and so on
 Upper bound approach

 In case of upper bound approach the frequency of breakdown is

given by F= np-------------(12)
n= number of workstations
p= probability of failure in each workstation
 Production rate is given by Rp= 1/Tp
 If probability of failure is different for individual work stations,
then frequency of breakdown is given by,
 F = P1 + P2 + P3 +…….Pn
 Lower bound approach

 In this case the station breakdown results in the damage of the

part and it must be removed from the line
 Arises in situation such as tool breaks down during the process
resulting in damage of the part.
 In such case the broken tool must be replaced at the
workstation and the part must be removed from the line and
cannot proceed to the next station for further processing.
 The frequency of breakdowns is given as F= 1 – (1 - p) n
n= number of workstations, p= probability of failure in each work station
 Lower bound approach

 The production rate

 Rp =1- F/ Tp-----------------------------------(16)
 The frequency of breakdown is given as
 F=1 – [ (1-p1) (1-p2) (1-p3)…..(1-pn)]-----------------------(17)
 Lower bound approach

 The production rate

 Rp =1- F/ Tp-----------------------------------(16)
 The frequency of breakdown is given as
 F=1 – [ (1-p1) (1-p2) (1-p3)…..(1-pn)]-----------------------(17)
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 Analysis of Transfer line with Storage

 In automated production line with no internal storage, the

workstation are dependent on each other.
 If one workstation break downs, then all the remaining stations
are affected.
 Two reasons workstations stop working
1. Starving of stations
2. Blocking of stations
 Starving of stations

 Starving of stations: In this case, the workstation is prevented

from performing its operation as there are no work parts to flow
in.
 The workstation must wait for the parts to flow in, to start the
operation
 This concept is called as starving of station.
 Blocking of stations

 Blocking of stations: In this case, the workstation have

performed the operations, but the parts cannot move to the next
workstation as the conveyor is blocked with the parts or may be
the next workstation has not yet finished its operation.
 To avoid such effects, Transfer lines with intermediate storage
points called as storage buffers are introduced.
 The storage buffer divides the line into stages and makes each
stage to work independently
Blocking of stations
 Blocking of stations

 Blocking of stations: In general there will be one storage

buffer in between each workstation. i.e., for a n stage line there
will be (n-1) storage buffers.
 Storage buffers does not store raw materials or finished
products. They will store the parts that are being processed on
the transfer line.
 Storage buffer effectiveness

 There are two extreme cases of determining storage buffer

effectiveness.
 No storage buffer capacity at all.
 Infinite capacity storage buffer
 Storage buffer effectiveness

No storage buffer capacity at all.

 In this case the transfer line acts as a single stage.
 The concept will be similar to concept of no internal storage.
 When a station breakdowns, the entire line will stop.
 Line efficiency is given by
 E= Tc/Tp= Tc / (Tc +F Td)
 Storage buffer effectiveness

Infinite capacity storage buffer.

 In this case the storage buffers with maximum capacity will be
used between the workstations.
 Line efficiency at each stage is given by
 E= Tc/Tp= Tc / (Tc +FK TdK) where K=number of stages
 Line efficiency at stage 1 is given by E1= Tc / (Tc +F1 Td1)
 Line efficiency at stage 2 is given by E2= Tc / (Tc +F2 Td2)