Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
By:
Prof. Afzal Alad
Mechanical Engineering Dept.
INTRODUCTION
“A manufacturing philosophy in which similar parts are identified and grouped
together to take advantage of their similarities in design and production”
“Group Technology is the realization that many problems are similar, and
that by grouping similar problems, a single solution can be found to a set
of problems thus saving time and effort.” (Solaja 73)
Conti…
It was first proposed and developed in Russia by Mitrofanov in 1966 and
originally translated as ‘family planning’ during his studies, Mitrofanov
classified different parts based on their similarity of shapes in to several
group cells (part families)
OVER VIEW OG GROUP TECHNOLOGY
Parts in the medium production quantity range are usually made
in batches.
GT can be implemented by manual or automated techniques
When automated, the term flexible manufacturing system is often
applied.
An approach to manufacturing in which similar parts are identified
and grouped together in order to take advantage of their
similarities in design and production.
Conti…
Similarities among parts permit them to be classified into part
families.
In each part family, processing steps are similar.
The improvement is typically achieved by organizing the
production facilities into manufacturing cells that specialize in
production of certain part families.
Conti…
Conti…
PROCESS-TYPE LAYOUT
CELLULAR LAYOUT
PART FAMILY
“Part family is collection of parts which are similar because of geometric
shape and size, or in the processing steps used in their manufacturing”
The group of similar parts is known as part family and the group of
machines used to process an individual part family is known as machine
cell.
Part families are a central feature of group technology.
There are always differences among parts in a family.
But the similarities are close enough that the parts can be grouped
into the same family.
Conti…
Two parts that are identical in shape and size but quite different in
manufacturing:
(a) 1,000,000 units/yr, tolerance = + or - 0.010 inch, 1015 CR steel,
nickel plate;
(b) 100/yr, tolerance = + or - 0.001 inch, 18-8 stainless steel
32XX
321X 323X
Mechanical
Transmission
3231 3233
322X
UNF thread 3232
3221 3223
3222
Conti…
Polycode , or Attribute code, or Chain type code
The Polycode is not structure like logic tree.
The meaning of each character in an attribute code is independent of all other digit.
The interpretation of each symbol in the sequence is fixed and represents one
feature.
The value of any given digits (or position) within the code does not depend on the
preceding digits. Another name of this type of symbol is poly-code.
The problem associated with poly-code is that the code tends to be relatively long.
The use of poly-code allows for convenient identification of specific part attribute.
This can be helpful in recognizing parts with similar processing requirements.
Conti…
Table shows, each digit and each value in the specific digit has a specific
meaning.
Thus, for example, the first digit may always describe external shape of the
part.
The second digit describe internal shape, the third digit describe there is
internal hole, the fourth digit describe the type of hole and so on.
Conti…
Advantages
Easy to formulate.
Limitations
Less information is stored per digit; therefore to get a meaningful comparison
of, say, shape, very long codes will be required.
Comparison of coded parts (to check for similarity) requires
Hybrid Code or Mixed code
Most of the commercial parts coding system in industries are a combination of the
two pure structure (i.e. poly codes and mono codes).
The hybrid is an attempt to achieve the best feature of both poly-codes and mono-
codes.
Hybrid codes are typically constructed as a series of short poly codes.
Conti…
Within each of these shorter chains, the digits are independent, but one or more of
symbols in the complete code number are used to classify the part population into
groups, as in the hierarchical structure.
This hybrid coding seems to best serve the need of both design and production.
Conti…
2
Machining Other holes
3 Main shape Rotational teeth and
of plane
machining forming
surfaces
4
Dimensions
Accuracy
Material
6
Non-rotational
The general code gives a general description of the part, the type of
operation it performs, and other specifications that uniquely identify
the product.
The specific code gives us a more detailed description about a part by
classifying it into subclasses.
Some parts do not needs all 12 digits.
CODE System
Developed by Manufacturing Data Systems Incorporated (MDSI). Use of
an eight-digit code similar to Optiz system.
It has a mixed code structure in which each digit is represented by a
hexadecimal value that allows more information to be represented with
the same number of digits.
production flow analysis
Production flow analysis (PFA) is a method for identifying part
families based on the sequence of operation and machine routing
needed to produce the part.
PFA uses manufacturing attributes rather than design attributes to
identify and form part families.
Part Order: A – H – D – B – F – G – I – C - E
Step – 4: Repeat above steps until there no further change in position of
each element in each row & column.
To
From 1 2 3 4 5
1 0 10 80 0 0
2 0 0 0 85 0
3 0 0 0 0 0
4 70 0 20 0 0
5 0 75 0 20 0
FACTORY FLOW ANALYSIS
If the group technology & FFA are combined during the plant
lay out, efficient manufacturing routes can be established and
maintained, as long as there is no change in design of the part.
This method require very through knowledge of the part spectrum
which can be grouped together, and the available processes.
DIRECT CLUSTERING METHOD
Step 1 : Count the number of entries 1(x) in each column & row. Record these
numbers.
Step 2: Rearrange the matrix with column with decreasing order
& rows in increasing order.
Step 3: Take the first column of the new matrix and move all
rows that have an entry 1(x) in this column to the top. Repeat this
procedure with succeeding columns until all rows are rearranged.
Step 4 : If the current matrix & the one that preceded it are
identical, go to 7; other wise go to step 5.
Step 5 : Take the first row of the new matrix and move all
columns that have an entry 1(x) in this row to the left most
position. Repeat this procedure with succeeding rows until all
columns are rearranged.
Step 6 : If the current matrix & the one that preceded it are
identical, go to 7; other wise go to step 3.
Step 7 : Stop
COMPOSITE PART
The composite part for a given part family is a hypothetical
part that includes all of the design and manufacturing
attributes of the family.
An individual part in the family have some of the features that
characterize the family, but not all of them.
Design Feature Operation
External Cylinder Turning
Face of Cylinder Facing
Cylindrical step Turning
Smooth surface Cylindrical grinding
Axial hole Drilling
Counter bore Counter boring
Internal threads Tapping
Composite part consisting all seven
design and manufacturing
attributes
A machine cell designed for the part family would include
those machines required to make the composite part.
Such a cell would be capable of producing any member of the
family, simply by omitting those operations corresponding to
feature possessed by the particular part.
The cell would be design to allow for size variation within the
family as well as feature variation
MACHINE CELL
In group technology production machines are grouped into machine
cells, each machine cell specializes in the production of one family
called cellular manufacturing.
Cellular machine is an application of group technology in which
dissimilar machines or processes are arranged into cells, each of
which is dedicated to production of a part family
Manned Unmanned
Types of Machine Cell
Afzal Alad
Introduction
It is
“digital electronic apparatus”
with a “programmable memory”
for
storing instruction to implement specific function,
such as
logic,
sequencing,
timing,
counting,
and arithmetic functions to control machines and processes.
- NEMA (National Electrical Manufacturer Association-USA)
PLC Architecture
Processor: It is the CPU of the programmable controller.
Provides intelligence to command and govern the
activities of the entire PLC systems.
PLC memory (EEPROM/RAM): Unit is connected with
processor, which contains the program of logic, sequencing, and
I/O operations.
Programming Device: Used to enter the desired program that
will determine the sequence of operation and control of process
equipment or driven machine.
It is detachable from the PLC cabinet so that it can be shared
among different controller.
Power Supply: The power supply convert 230V A.C into 24 OR
48 V Direct Current.
I/O Module: purpose of the I/O interface is to condition the
various signals received from or sent to the external input and
output devices.
o Input modules converts signals from discrete or analog input
devices to logic levels acceptable to PLC’s processor.
o Output modules converts signal from the processor to levels
capable of driving the connected discrete or analog output
devices.
Relay
In General, Relays Transform a Control Signal into a Control
Action
Relays Provide:
Isolation Between Input and Output
Leverage (Small Signal Can Control Large Action)
Automation (Minimize Human Interaction with a Control
Process)
Relay Symbol use for
ladder diagram
Counter
Counter Relays must “Count” a pre-determined number
of events before changing contact status.
Three types of counters are available.
UP Counter
DOWN Counter
UP-DOWN Counter
UP Counter
The up counter can be used to signal when a count has
reached a maximum value (Pre-set).
DOWN Counter
The down counter can be used to signal when a count has
reached zero, on counting down from a pre-set value.
Timer
It is an instruction that waits a set amount of time before
doing something.
When TD Relay Pick-Up Coil is Energized, a Delay is
Initiated
Normally Open Contacts Wait to Close until Delay is
Completed
Normally Closed Contacts Wait to Open until Delay is
Completed
There are three types of PLC timer delays
ON-delay timer
OFF-delay timer
Retentive timer on
ON-delay timer
An ON delay timer is used where we need a time delay
before instruction becomes true.
i.e. once sensor (input) turns on it wait x-seconds (pre-set
value) before activating a solenoid valve (output)
OFF-delay timer
An Off-Delay timer will keep the output energized for a pre-set
time after the rung signal has gone false.
i.e. once sensor (input) sees a target we turn on a solenoid
(output). When the sensor no longer sees the target it hold the
solenoid on for x-seconds before turning it off
Retentive or Accumulating timer
It retain accumulated time value through the power loss or
the change in the rung state.
A retentive timer accumulates time whenever the device
receives power, and it maintains the current time should
power be removed from the device.
Logic Gates
AND Gate
OR Gate
NOT Gate
NAND Gate
NOR Gate
Problem:
An emergency stop system is to be designed for a certain automatic
production machine. A single ‘start’ push button is used to turn on
the power to the machine at the beginning of the day. In addition,
there are three “emergency stop” buttons located at different
locations around the machine, any one of which can be pressed to
immediately turn off power to the machine.
(a)Write the truth table for this system.
(b) Write the Boolean logic expressions (Sum – Of- Product) for
the system.
(c) Construct the logic network diagram for the system.
(d) Construct the ladder logic diagram for the system.
Sr.No Start Stop-1 Stop-2 Stop-3 Latching Power to Machine
1 0 0 0 0 0 0
2 0 0 0 0 1 1
3 0 0 0 1 0 0
4 0 0 0 1 1 0
5 0 0 1 0 0 0
6 0 0 1 0 1 0
7 0 0 1 1 0 0
8 0 0 1 1 1 0
9 0 1 0 0 0 0
10 0 1 0 0 1 0
11 0 1 0 1 0 0
12 0 1 0 1 1 0
13 0 1 1 0 0 0
14 0 1 1 0 1 0
15 0 1 1 1 0 0
16 0 1 1 1 1 0
17 1 0 0 0 0 1
18 1 0 0 0 1 1
19 1 0 0 1 0 0
20 1 0 0 1 1 0
21 1 0 1 0 0 0
22 1 0 1 0 1 0
23 1 0 1 1 0 0
24 1 0 1 1 1 0
25 1 1 0 0 0 0
26 1 1 0 0 1 0
27 1 1 0 1 0 0
28 1 1 0 1 1 0
29 1 1 1 0 0 0
30 1 1 1 0 1 0
31 1 1 1 1 0 0
32 1 1 1 1 1 0
Boolean Expression:
P = (X1 + L) + (X2 + X3 + X4)
Afzal Alad
Production Planning and Control
The planning process within an organization is dynamic &
continuous.
It is deciding future courses of action in advance.
In any organization following type of decisions are taken.
o Strategic Decisions- Taken at top level management
o Tactical Decisions - Taken at middle level management
o Operational decisions- Taken at bottom level management
Strategic Decisions
Warehouse location
Distribution Systems
Building a new plant
New product planning
R&D Planning
Quality Assurance Planning
Dropping a product from existing product mix
Social responsibility planning etc.
Tactical Decisions
Estimating & Costing of a product
Product improvement through value analysis
Maintenance Policy
Budget Analysis
Short term forecasting
Make or buy decision
Plant layout
Project Scheduling
Buying Equipment etc.
Operational Decisions
Designing sampling plan for inspection
Deciding price discount at salesman level
Scheduling of maintenance man power
Machine loading
Production scheduling
Inventory Control etc.
Production Control
In reality, most of the decisions may not be implemented as
per the plans.
This is due to uncertainty involved in many business processes
o Raw material quality is not as per assessed level
o Sudden breakdown of machine
o Operator efficiency is not with time standards
Thus, a careful system with a proper feedback mechanism is a
must to correct the whole business process a appropriate time.
Function of PPC
Material Requirement Planning
Problem:
Master Production Schedule for P1 & P2 is given in the table.
1 2 3 4 5
P1 50 100
P2 70 80 25
The detail of bill of material along with EOQ and stock on hand
for final product and sub assemblies are shown in the table.
Problem:
Material requirement planning are to be planned for component
C2, given the master schedule for P1 and P2 in Fig 1, and the
product structure in fig 2 and 3 (next slide). Assembly lead time
for products and subassemblies (P and S levels) is 1 week,
manufacturing lead time for component (C level) is 2 weeks, and
ordering lead time for raw materials (M level) is 3 weeks.
Determine the MRP plan for M2, C2, S1 and S4. All on-Hand
inventories are zero.
Week 1 2 3 4 5 6 7 8 9 10
Model P1 50 100
Model P2 70 80 25
P1
S1 S2
(1) (2)
C1 C2 C3 C4 C5 C6
(1) (4) (1) (2) (2) (1)
M1 M2 M3 M4 M5 M6
(1) (1) (1) (1) (1) (5)
P2
S3 S4 C7
(1) (1) (2)
C4 C6 C2 C8
(1) (2) (2) (1)
M4 M6 M2 M8 M7
(1) (0.5) (1) (1) (1)
Manufacturing Resource Planning
(MRP-II)
A method for the effective planning of all resources of a
manufacturing company.
it addresses operational planning in units, financial planning in
rupees, and has a simulation capability to answer what-if
questions.
It is made up of a variety of processes, each linked together:
business planning, production planning (sales and operations
planning), master production scheduling, material
requirements planning, capacity requirements planning, and
the execution support systems for capacity and material.
Just in Time
JIT as a management philosophy, rather than another production
technique.
Monden Y. (1993) defines JIT as “producing the necessary items,
in the necessary quantity at the necessary time.”
The primary objective of JIT is to eliminate waste which Toyota
President, Shoichiro Toyoda has referred to as “ anything other
than the minimum amount of equipment, materials, parts,
space, and worker’s time, which are absolutely essential to add
value to the product.”
Type of waste
Waiting
Overproduction
Rework / Rejection
Motion
Over Processing
Inventory
Transportation
Expert System
Expert System is an information system that is capable of
mimicking human thinking and making considerations during
the process of decision-making.
It is an information system that has been used to solve a
problem that usually requires an expert to solve.
Expert System comes from the Knowledge-Based Expert
System terminology.
Why Expert System?
Expert System Architecture
Forward Chaining
Backward Chaining