ME761A - Lecture 2 Computers and Manufacturing Systems

Computers and Manufacturing systems
Dr. Janakarajan Ramkumar

Professor
Department of Mechanical & Design Program
IIT Kanpur, India.
Contents
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies
Groover, Automation, Production Systems, and Computer-Integrated Manufacturing , 2016, Pearson Education, Ltd. .
1
Production System Defined
A collection of people, equipment, and procedures organized to

accomplish the manufacturing operations of a company
Two categories:
• Facilities – the factory and equipment in the facility and the way the
facility is organized (plant layout)
• Manufacturing support systems – the procedures used by a company

to manage production and to solve technical and logistics problems
in ordering materials, moving work through the factory, and ensuring
that products meet quality standards
The Production System
2
Production System Facilities
Facilities include the factory, production machines and tooling, material

handling equipment, inspection equipment, and computer systems that
control the manufacturing operations
• Plant layout – the way the equipment is physically arranged in the

factory
• Manufacturing systems – logical groupings of equipment and workers in

the factory
– Production line
– Stand-alone workstation and worker
Manufacturing Systems
Three categories in terms of the human participation in the processes

performed by the manufacturing system:
1. Manual work system - a worker performing one or more tasks without

the aid of powered tools, but sometimes using hand tools
2. Worker-machine system - a worker operating powered equipment
3. Automated system - a process performed by a machine without direct

participation of a human
3
Categories of Manufacturing Systems
(a) Manual work system, (b) worker-machine system, and (c) fully
automated system
Manufacturing Support Systems
Manufacturing support involves a sequence of activities that consists of

four functions:
1. Business functions - sales and marketing, order entry, cost

accounting, customer billing
2. Product design - research and development, design engineering,

prototype shop
3. Manufacturing planning - process planning, production planning,

MRP, capacity planning
4. Manufacturing control - shop floor control, inventory control, quality

control
4
Sequence of Information-Processing
Activities in a Manufacturing Firm
Automation in Production Systems
Two categories of automation in the production system:
1. Automation of manufacturing systems in the factory
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)
5
Computer Integrated Manufacturing
Automated Manufacturing Systems
Examples:
• Automated machine tools
• Transfer lines
• Automated assembly systems
• Industrial robots that perform processing or assembly operations
• Automated material handling and storage systems to integrate

manufacturing operations
• Automatic inspection systems for quality control
6
Automated Manufacturing Systems
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation
Fixed Automation
A manufacturing system in which the sequence of processing (or assembly)

operations is fixed by the equipment configuration
Typical features:
• Suited to high production quantities
• High initial investment for custom-engineered equipment
• High production rates
• Relatively inflexible in accommodating product variety
7
Programmable Automation
A manufacturing system designed with the capability to change the

sequence of operations to accommodate different product
configurations
Typical features:
• High investment in general purpose equipment
• Lower production rates than fixed automation
• Flexibility to deal with variations and changes in product configuration
• Most suitable for batch production
• Physical setup and part program must be changed between jobs
(batches)
Flexible Automation
An extension of programmable automation in which the system is capable

of changing over from one job to the next with no lost time between jobs
Typical features:
• High investment for custom-engineered system
• Continuous production of variable mixes of products
• Medium production rates
• Flexibility to deal with soft product variety
8
Product Variety and Production Quantity
for Three Automation Types
Computerized Manufacturing
Support Systems
Objectives of automating the manufacturing support systems:

• To reduce the manual and clerical effort in product design, manufacturing
planning and control, and the business functions
• Integrates computer-aided design (CAD) and computer-aided
manufacturing (CAM) in CAD/CAM
• CIM includes CAD/CAM and the business functions of the firm
9
Reasons for Automating
1. Increase labor productivity

2. Reduce labor cost
3. Mitigate the effects of labor shortages
4. Reduce or remove routine manual and clerical tasks
5. Improve worker safety
6. Improve product quality
7. Reduce manufacturing lead time
8. Accomplish what cannot be done manually
9. Avoid the high cost of not automating
Manual Labor in Production Systems
Is there a place for manual labor in the modern production system?

– Answer: YES
• Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems
10
Manual Labor in Factory Operations
The long term trend is toward greater use of automated systems to

substitute for manual labor
• When is manual labor justified?
– Some countries have very low labor rates and automation cannot
be justified
– Task is technologically too difficult to automate
– Short product life cycle
– Customized product requires human flexibility
– To cope with ups and downs in demand
– To reduce risk of new product failure
Labor in Manufacturing Support Systems
• Product designers who bring creativity to the design task

• Manufacturing engineers who
– Design the production equipment and tooling
– And plan the production methods and routings
• Equipment maintenance
• Programming and computer operation
• Engineering project work
• Plant management
11
Automation Principles and Strategies
1. The USA Principle

2. Ten Strategies for Automation and Process Improvement
3. Automation Migration Strategy
U.S.A Principle
1. Understand the existing process

– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production systems
– Automation migration strategy
12
Ten Strategies for Automation and Process
Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
Automation Migration Strategy For

Introduction of New Products
1. Phase 1 – Manual production

– Single-station manned cells working independently
– Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
– Single-station automated cells operating independently
– As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
– Multi-station system with serial operations and automated transfer
of work units between stations
13
Automation Migration Strategy
Production System
- Technological categories
14
Glossary of Terms :
• Batch Processing: A manufacturing operation in which a specified

quantity of material is subject to a series of treatment steps. Also, a mode
of computer operations in which each program is completed before the
next is started.
• Flow Processing: This processing involves moving one work unit at a time
between each step of the process with no breaks in time, sequence,
substance or extent.
Glossary of Terms :
• Computer-aided design (CAD): It is the use of computers

(or workstations) to aid in the creation, modification, analysis, or
optimization of a design. CAD software is used to increase the productivity
of the designer, improve the quality of design, improve communications
through documentation, and to create a database for manufacturing.
• Computer-aided engineering (CAE): It is the broad usage of computer

software to aid in engineering analysis tasks. It includes finite element
analysis (FEA), computational fluid dynamics(CFD), multibody
dynamics (MBD), durabilityand optimization.
15
Glossary of Terms :
• Computer-aided manufacturing (CAM): CAM is the use of software to

control machine tools and related ones in the manufacturing of
workpieces. It may also refer to the use of a computer to assist in all
operations of a manufacturing plant, including planning, management,
transportation and storage.
• Computer-aided process planning (CAPP) : It is the use of computer

technology to aid in the process planning of a part or product, in
manufacturing. CAPP is the link between CAD and CAM in that it provides
for the planning of the process to be used in producing a designed part.
Glossary of Terms :
• Computer-aided quality assurance (CAQ): CAQ is the engineering

application of computers and computer-controlled machines for the
definition and inspection of the quality of products.
• Enterprise resource planning (ERP): ERP is the integrated management of

main business processes, often in real-time and mediated by software and
technology. It is usually referred to as a category of business management
software — typically a suite of integrated applications—that an
organization can use to collect, store, manage, and interpret data from
these many business activities.
16
Glossary of Terms :
• Computer Numerical Control (CNC)): It is the automated control of

machining tools (drills, boring tools, lathes) and 3D printers by means of
a computer.
• Direct numerical control (DNC), also known as distributed numerical

control (also DNC): It is a common manufacturing term for
networking CNC machine tools. On some CNC machine controllers, the
available memory is too small to contain the machining program (for
example machining complex surfaces), so in this case the program is
stored in a separate computer and sent directly to the machine, one block
at a time.
Glossary of Terms :
• Programmable logic controller (PLC) or programmable controller: It is an

industrial digital computer which has been ruggedized and adapted for the
control of manufacturing processes, such as assembly lines,
or robotic devices, or any activity that requires high reliability control and
ease of programming and process fault diagnosis.
• Controller: It is a chip, an expansion card, or a stand-alone device

that interfaces with a peripheral device. This may be a link between two
parts of a computer (for example a memory controller that manages
access to memory for the computer) or a controller on an external device
that manages the operation of (and connection with) that device.
17
Glossary of Terms :
• Computer network: It is a digital telecommunications network which

allows nodes to share resources. In computer networks, computing
devices exchange data with each other using connections between nodes.
• Automatic guided vehicle (AGV): It is a portable robot that follows along

marked long lines or wires on the floor, or uses radio waves, vision
cameras, magnets, or lasers for navigation.
Glossary of Terms :
Automatically Guided Vehicle
https://www.consoveyo.com/en/products/agvs.html
18
Glossary of Terms :
• Automated storage and retrieval system (ASRS or AS/RS): It consists of a

variety of computer-controlled systems for automatically placing and
retrieving loads from defined storage locations.
https://www.westfaliausa.com/products/automated-storage-retrieval-systems
Glossary of Terms :
• Flexible manufacturing system (FMS): It is a manufacturing system in

which there is some amount of flexibility that allows the system to react in
case of changes, whether predicted or unpredicted.
19
Glossary of Terms :
https://www.latestquality.com/flexible-manufacturing-system/
Glossary of Terms :
https://www.latestquality.com/flexible-manufacturing-system/
20
References
1. Groover, Automation, Production Systems, and Computer-Integrated

Manufacturing , 2016, Pearson Education, Ltd. .
2. Lee, K., 1999. Principles of CAD/CAM/CAE systems. Addison-Wesley
Longman Publishing Co., Inc.
Thank you!!
21

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Computers and Manufacturing systems

Dr. Janakarajan Ramkumar

2. Automation in Production Systems

3. Manual Labor in Production Systems

4. Automation Principles and Strategies

A collection of people, equipment, and procedures organized to

• Manufacturing support systems – the procedures used by a company

The Production System

Facilities include the factory, production machines and tooling, material

• Plant layout – the way the equipment is physically arranged in the

• Manufacturing systems – logical groupings of equipment and workers in

Three categories in terms of the human participation in the processes

1. Manual work system - a worker performing one or more tasks without

2. Worker-machine system - a worker operating powered equipment

3. Automated system - a process performed by a machine without direct

Manufacturing Support Systems

Manufacturing support involves a sequence of activities that consists of

1. Business functions - sales and marketing, order entry, cost

2. Product design - research and development, design engineering,

3. Manufacturing planning - process planning, production planning,

4. Manufacturing control - shop floor control, inventory control, quality

Automation in Production Systems

Two categories of automation in the production system:

1. Automation of manufacturing systems in the factory

2. Computerization of the manufacturing support systems

• The two categories overlap because manufacturing support systems

– Computer-Integrated Manufacturing (CIM)

Automated Manufacturing Systems

• Automated assembly systems

• Industrial robots that perform processing or assembly operations

• Automated material handling and storage systems to integrate

• Automatic inspection systems for quality control

Three basic types:

A manufacturing system in which the sequence of processing (or assembly)

A manufacturing system designed with the capability to change the

An extension of programmable automation in which the system is capable

Objectives of automating the manufacturing support systems:

1. Increase labor productivity

Manual Labor in Production Systems

Is there a place for manual labor in the modern production system?

The long term trend is toward greater use of automated systems to

Labor in Manufacturing Support Systems

• Product designers who bring creativity to the design task

1. The USA Principle

1. Understand the existing process

Automation Migration Strategy For

1. Phase 1 – Manual production

• Batch Processing: A manufacturing operation in which a specified

• Computer-aided design (CAD): It is the use of computers

• Computer-aided engineering (CAE): It is the broad usage of computer

• Computer-aided manufacturing (CAM): CAM is the use of software to

• Computer-aided process planning (CAPP) : It is the use of computer

• Computer-aided quality assurance (CAQ): CAQ is the engineering

• Enterprise resource planning (ERP): ERP is the integrated management of

• Computer Numerical Control (CNC)): It is the automated control of

• Direct numerical control (DNC), also known as distributed numerical

• Programmable logic controller (PLC) or programmable controller: It is an

• Controller: It is a chip, an expansion card, or a stand-alone device

• Computer network: It is a digital telecommunications network which

• Automatic guided vehicle (AGV): It is a portable robot that follows along

Automatically Guided Vehicle

• Automated storage and retrieval system (ASRS or AS/RS): It consists of a