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Lec.02 Advanced Manufacturing Systems

The document discusses various types of manufacturing systems including continuous-flow, mass production, batch production, and job-shop production. It also covers manufacturing support systems that help manage production operations and the role of automation in production systems, detailing fixed, programmable, and flexible automation. The benefits of automation include increased productivity, reduced labor costs, and improved product quality.

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Mariem Saleh
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Download as PPTX, PDF, TXT or read online on Scribd
4 views

Lec.02 Advanced Manufacturing Systems

The document discusses various types of manufacturing systems including continuous-flow, mass production, batch production, and job-shop production. It also covers manufacturing support systems that help manage production operations and the role of automation in production systems, detailing fixed, programmable, and flexible automation. The benefits of automation include increased productivity, reduced labor costs, and improved product quality.

Uploaded by

Mariem Saleh
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Misr International Technological University

Faculty of Industry and Energy Technology in Fayoum

Bachelor of Technology in Industrial Automation

Advanced manufacturing systems


(TP_12)
Lecture 02
Dr. Sabry Said Youssef
Assistant professor
Mechanical Engineering Department
Faculty of Engineering
Fayoum University
Introduction

 Types of Manufacturing Systems

 Manufacturing Support Systems

 Automation in Production Systems

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Types of Manufacturing Systems
 Continuous-flow processes. Continuous dedicated production of large amount of bulk product.

Continuous manufacturing is represented by chemicals, plastics, petroleum, and food industries.

 Mass production of discrete products. Dedicated production of large quantities of one product (with

perhaps limited model variations). Examples include automobiles, appliances and engine blocks.

 Batch production. Production of medium lot sizes of the same product. The lot may be produced once

or repeated periodically. Examples: books, clothing and certain industrial machinery.

 Job-shop production. Production of low quantities, often one of a kind, of specialized products. The

products are often customized and technologically complex. Examples: prototypes, aircraft, machine

tools and other equipment.


Types of Manufacturing Systems
Types of Manufacturing Systems
Manufacturing Support Systems
 To operate the production facilities efficiently, a

company must organize itself to design the processes

and equipment, plan and control the production

orders, and satisfy product quality requirements.

 These functions are accomplished by manufacturing

support systems—people and procedures by which a

company manages its production operations.

 Most of these support systems do not directly

contact the product, but they plan and control its

progress through the factory.


Manufacturing Support Systems
Manufacturing support involves a sequence of activities

 Business functions: the principal means by which the company communicates with the customer.
 Product Design: If the product is manufactured to customer design, the design has been provided by the customer, and
the manufacturer’s product design department is not involved. If the product is to be produced to customer
specifications, the manufacturer’s product design department may be contracted to do the design work for the product
as well as to manufacture it.
 Manufacturing planning include process planning, master scheduling, material requirements planning, and capacity
planning.
 Manufacturing control Include shop floor control, inventory control, and quality control.
Manufacturing Support Systems
Automation in Production Systems
What is Automation?
A technology concerned with the application of mechanical, electronic, and computer-based systems to
operate & control production

The automated elements of the production


system can be separated into two categories:
(1) automation of the manufacturing systems
in the factory, and
(2) computerization of the manufacturing
support systems.

The two categories overlap because manufacturing support


systems are connected to the factory manufacturing systems
 Computer-Integrated Manufacturing (CIM)
Automated Manufacturing Systems
Automated manufacturing systems: In this system operations such as processing, assembly, inspection, and material
handling, or more than one of these operations in the same system are performed with a reduced level of human
participation compared with the corresponding manual process.

Examples of automated manufacturing systems include:

• Automated machine tools that process parts

• Transfer lines that perform a series of machining operations

• Automated assembly systems

• Manufacturing systems that use industrial robots to perform processing or assembly operations

• Automatic material handling and storage systems to integrate manufacturing operations

• Automatic inspection systems for quality control.


Automated Manufacturing Systems
Automated manufacturing systems can be classified into three basic types:
Fixed automation is a system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration (high
production rates, and inflexibility of the equipment to accommodate
product variety).
Programmable Automation. In programmable automation, the
production equipment is designed with the capability to change the
sequence of operations to accommodate different product
configurations (lower production rates than fixed automation, and
flexibility to deal with variations and changes in product).

Flexible automation is an extension of programmable automation. A


flexible automated system is capable of producing a variety of parts
or products with virtually no time lost for changeovers from one
design to the next (medium production rates, flexibility to deal with
product design variations)
Types of Automation
 Fixed Automation (transfer lines)
– Hard automation, automation for mass production
– Produces large numbers of nearly identical parts
– High initial investment for custom engineered equipment
– Product design must be stable over its life
– Advantages: equipment fine tuned to application - decreased cycle time,
infrequent setups, automated material handling - fast and efficient movement
of parts, very little WIP
– Disadvantage: inflexible
Types of Automation
 Programmable Automation (NC, CNC, robots)
– Sequence controlled by a program
– High investment in general purpose equipment
– Lower production rates
– Flexibility to deal with variation
– Suitable for batch production
– Smaller volumes (than fixed) of many different parts
– More flexible than fixed automation
– Major disadvantage: setup prior to each new part
– Large batch size (due to setups)
– Speed sacrificed for flexibility
Types of Automation
 Flexible Automation (FMS)
– Extension of programmable automation
– No time lost for change over
– High investment in custom-engineered systems
– Production of product mix
– Flexibility to deal with design variations
– Low to medium quantities
– Compromise between fixed and programmable automation in speed and flexibility
– Advantage: programming and setup performed off-line
– More expensive - size and tool change capabilities
– Small batch sizes are justified - reduced WIP and lead time
– Typical parts are expensive, large and require some complex machining
Reasons for Automating
Companies undertake projects in automation and computer-integrated manufacturing for good reasons, some
of which are the following:

 Increase labor productivity

 Reduce labor cost

 Mitigate the effects of labor shortages

 Reduce or eliminate routine manual and clerical tasks

 Improve worker safety

 Improve product quality

 Reduce manufacturing lead time

 Accomplish processes that cannot be done manually

 Avoid the high cost of not automating


Thanks

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