DQ047-01 Manufacturing Systems Week 12 / Lecture 2

Single Station Manufacturing Cells

Single stations (Type I) constitute the most common
manufacturing system in industry.

Two forms of type I systems:

Single station manned cell (type I M)

Single station automated cell (type I A)

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 1

Single Station Manned Cells

n=1, w=1

Most widely used production method today

Requires shortest amount of time to implement
Requires the least capital investment
Easiest system to install and operate
For low quantities, results in the lowest cost per unit produced
Most flexible manufacturing system

How about CNC machine tools?

Variation: n=1, w>1

Two workers at one machine

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 2

1
 Single Station Automated Cell
n=1, w=0

Characteristics
Labor cost < manned station
Easiest and least expensive among automated systems
Production rate > manned station
First step in implementing automated system

Robot loading/unloading: n>1?

Robot plays a supporting role

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 3

Enablers for Unattended Cell Operation

For single model/batch model

Programmed cycle
Part storage subsystem
Automatic transfer of work parts
Periodic attention of a worker
Built-in safeguards

For mixed model

Work identification subsystem
Program downloading capacity
Quick setup changeover capability

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 4

2
 Part Storage Subsystem
UT = npTc
UT = Unattended time of operation of the manufacturing cell (min)
np = designed part storage capacity (pc)
Tc = cycle time of the automated workstation (min/pc)

Objective of Part Storage

Fixed time interval that allows a worker to tend multiple machines
Time between scheduled tool change (to change tool during
downtime)
One complete shift
Overnight operation

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 5

Storage Capacity of One Part

Automatic Pallet Change (APC)

Tc = Tm + Ts
Tc= Cycle time, Tm= machining process time, Ts= worker service time
One part storage: Tc = Max{Tm, Ts} + Tr
Tr= responding time
If Ts>Tm, machine experiences forced idle time

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 6

3
Application of Single Station Cells
Manned Cells Automated Cells
CNC machining center for + Part carousel + APC
single products
Worker: Execute part program,
load/unload part
CNC turning center single for + Part storage + robot
products
Worker: Execute part program,
load/unload part
Above for mixed products + Automatic part program
Worker: Select part program download
Cluster of two CNC turning + Part storage + robot
center
One worker can work on both machines
Assembly by worker Assembly by robot

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 7

Examples of Automated Machines

Automated Stamping Press Machines

CNC Turing Center

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 8

4
Mill-Turn Center

DQ047-01 Manufacturing Systems Week 12 / Lecture 2 9