Automation

Automation

1. systems have a mix of manual and automation

   • human load machine, head of press line
     • robots move part down press line

2. some elements = automated, other = manual, clerical

3. automated elements = split into two

   • automation of manufacturing systems in factory
   • computerisation of the manufacturing support systems
     • reduces manual effort in product design
       • CAD/CAM

4. variety of piece of equipment

   • can perform
     • processing
     • assembly
     • inspection
     • material handling
   • CNC machines
     • Engine blocks
   • automated assembly lines
     • JLR welding robots
     • single mode or multi mode
   • robotic arms
     • material handling
       • reduce risk or person dropping parts
       • faster
       • less error
       • clean room - intel
   • CMM machine
     • Renishaw probe
       • plots co-ordinates
         • overlay CAD model, check dimensions

5. Three types

   • fixed automation
     • mass manufacture
       • fixed by process
       • fixed by the equipment
       • high initial investment
         • justified, parts produced at high rate, spread cost over many parts
         • costs a lot why do it?
           • improve quality
           • mass runs spread costs
       • complicated coordination
   • programmable
     • equipment must accommodate change in operation sequence
     • can re program, sequence of operations can be changed
       • every time we want something new
     • suits batch production
       • Paper, blanks
     • can be re configured
       • cost associated with this, down time
       • PLC - programmable logic controller
     • investment in general purpose equipment
     • industrial robots
   • flexible
     • can re-program without downtime
     • Machinery is flexible, can manufacture more parts
     • Extension of programmable automation
     • Can make changes and variation, as long as they are soft variety
     • can use general equipment
     • Can produce various combinations of products
     • came into being in 1960
       • initial automation, Ford 1912
     • EXAM
       • Tell me about flexible manufacuring, discuss the date, what it is , who it was broght in by, an example of flexible, product variety, variation
     • Ball point pen?

6. why do we Automate

   • Speed
   • reduce labour costs
   • efficiency
   • Accuracy
   • increase labour productivity
   • mitigate labour shortage
   • improve worker safety
   • improve product quality
   • reduce lead time
   • avoid costs of automating

7. Human automation

   • humans = necessary for management and maintenance
   • manual labour can be preferredover automation because:
     • task is technologically to difficult to automate
       • hand eye coordination
     • product life cycle = short
     • product is highly customised
     • cope with variation in demand
     • reduce risk of product failure
       • Cadscan
     • sometimes much less expensive

8. Manual labour

   • routine / manual / clerical tasks = automated using computer systems like materials requirement planning MRP and CAD
     • still require manual input / creativity
   • required in maintenance
   • programming
     • always need someone to code computers

9. EXAM

   • Humans Vs Automated Machines
     • human
       • develop new solutions
       • cope with abstract problems
       • adapt to change
       • generalise from observation
       • learn from experience
       • make difficult decisions based on incomplete data
     • machine
       • perform repetitive tasks
       • store large amounts of data
       • reliably retrieve data
       • multiple tasks at once
       • perform simple computations quickly
       • make quick decisions

10. Approaches to automation

    • USA PRINCIPLE - EXAM
      • U = understand the existing process
        • comprehend the process
        • write all details
        • take and understand all detaisl
        • set relationship between input and output
      • S - simplyify the process
        • does the step need to be there?
        • what is it doing?
        • is the technology for each step suitable?
        • can you combine steps? do them simultaniously?
        • once simplified you may not need to automate!
      • A - Automate the process
        • only do once simplified
          • There is ten stratergies for automatin
            • the following ten = a good road map to automation
              • 1) Specialisation of operations
              • 2) combined operations
              • 3) simultaneous operations
              • 4) integration of operations
              • 5) increased flexibilty
              • 6) improved material handling and storage
              • 7) on-line inspection
              • 8) process control and optimization
              • 9) plant operations control
              • 10) computer intergrated manufacutring

11. Migration strategy

    • company
      • new product
        • release in a short time period
          • quickest / least expensive way to release product =manual production
            • use a sequence of work stations
              • operate independently
            • tooling = low cost, fabricate quickly
            • product requires more than one work cell to meet demand, replicate manual cell
            • product = success = automate
              • migration strategy
                • Phase 1
                  • manual production
                  • single station manned cells
                    • operate independently
                  • quick product intro to market
                  • quick to make / low cost tooling
                • Phase 2
                  • automatic production using single station automated cells, operating independently
                  • Demand for product grows = will become clear automation can be justified
                    • automate single stations to reduce labour, increasing production rate. Units = still moved between workstations manually
                • Phase 3
                  • automated integrated production
                  • multi-station automated system with serial operations and automated transfer of work units between
                    • Know product will be produced for several years in mass quantities
                      • integration of single station automation cells is warranted to increase production rate

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