01.automated Production Lines

Automated Production Lines
Sections:
1. Fundamentals of Automated Production Lines
2. Applications of Automated Production Lines
3. Analysis of Transfer Lines
2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved. This material is protected under all copyright laws as
they currently exist.
No portion of this material may be reproduced, in any form or by
any means, without permission in writing from the publisher. For
the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated
Manufacturing, Third Edition, by Mikell P. Groover.
High production of parts requiring multiple processing

operations
Fixed automation
Applications:
Transfer lines used for machining
Robotic spot welding lines in automotive final
assembly
Sheet
No portion metal
of this stamping
material may be reproduced, in any form or by
Electroplating
any means, of metals
without permission in writing from the publisher. For
Where to Use
High product demand
Requires large production quantities
Stable product design
Difficult to change the sequence and content of
processing operations once the line is built
2008
LongPearson
productEducation,
life Inc., Upper Saddle River, NJ. All rights
At least several years
NoMultiple operations
portion of required
this material may beon product in any form or by
reproduced,
The different
any means, operationsinare
without permission assigned
writing to different
from the publisher. For
workstations
the exclusive in the line
use of adopters of the book
Benefits of
Low direct labor content
Low product cost
High production rates
Production lead time and work-in-process are minimized
Factory floor space is minimized
Automated Production Line - Defined
Fixed-routing manufacturing system that consists of multiple

workstations linked together by a material handling system
to transfer parts from one station to the next
Slowest workstation sets the pace of the line
Workpart transfer:
Palletized
2008 transfer line
Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved. This material
Uses is protected
pallet fixtures under
to hold andallmove
copyright laws as
workparts
they currently exist.stations
between
No portion
Free of this material
transfer line may be reproduced, in any form or by
Part geometry allows transfer without pallet fixtures
Automated Production Line
General
they configuration
currently exist. of an automated production line
consisting
No portion ofofthis
n automated
material mayworkstations that
be reproduced, in perform
any form or by
processing
any operations
means, without permission in writing from the publisher. For
System Configurations
In-line - straight line arrangement of workstations

Segmented in-line two or more straight line segments,
usually perpendicular to each other
Rotary indexing machine (e.g., dial indexing machine)
Segmented In-Line Configurations
L-shaped layout
2008 PearsonU-shaped
Education,layout
Inc., Upper Saddle River, NJ. All rights
anyRectangular configuration
means, without permission in writing from the publisher. For
Two Machining Transfer Lines
Rotary Indexing Machine
Workpart Transfer Mechanisms
Linear transfer systems:

Continuous motion not common for automated
systems
Synchronous motion intermittent motion, all
parts move simultaneously
2008 Pearson Education,
Asynchronous Inc., Upper
motion Saddle River,
intermittent NJ. parts
motion, All rights
reserved.move
This material is protected under all copyright laws as
independently
they
currently exist. mechanisms:
Rotary indexing
Geneva mechanism
Others
Belt-Driven Linear Transfer System
No portion
Side viewofofthis material
chain maybelt-driven
or steel be reproduced, in any (over
conveyor form or
andby
any means,
under without
type) permission
for linear in using
transfer writingwork
fromcarriers
the publisher. For
Walking Beam Transfer System
Geneva Mechanism with Six Slots
Cam Mechanism to Drive
Dial Indexing Table
Storage Buffers in Production Lines
A location in the sequence of workstations where parts

can be collected and temporarily stored before
proceeding to subsequent downstream stations
Reasons for using storage buffers:
To reduce effect of station breakdowns
To provide a bank of parts to supply the line
ToThis
reserved. provide a place
material to put under
is protected the output of the line
all copyright laws as
To allow
they currently curing time or other required delay
exist.
To of
No portion smooth cycle time
this material variations
may be reproduced, in any form or by
any means,
To without
store partspermission
between in writing
stages from
with the publisher. For
different
production
the exclusive rates of the book
use of adopters
Storage Buffer
reserved. This
Storage material
buffer is protected
between under all
two stages of acopyright lawsline
production as
Control Functions in an
Automated Production Line
Sequence control
To coordinate the sequence of actions of the transfer
system and workstations
Safety monitoring
To avoid hazardous operation for workers and
2008equipment
reserved.
QualityThis material is protected under all copyright laws as
control
To detect and possibly reject defective work units
produced
any means, on permission
without the line in writing from the publisher. For
Applications of
Transfer lines for machining
Synchronous or asynchronous workpart transport
Transport with or without pallet fixtures, depending on
part geometry
Various monitoring and control features available
2008 Pearson
Rotary Education,
transfer Inc.,for
machines Upper Saddle River, NJ. All rights
machining
Variations include center column machine and trunnion
machine
System Design Considerations
Building block approach: machine tool companies

specialize in transfer lines and indexing machines
User contracts for custom-engineered line
Standard modules such as workheads, feed units,
transfer mechanisms, and bases
2008 Pearson
Called Education,
a unitized Inc., Upper Saddle
production line River, NJ. All rights
Link line: uses standard machine tools connected by
specialized
of this handling system
No portion material may be reproduced, in any form or by
Specialized
any means, withoutprocesses
permissionoften engineered
in writing from theby the userFor
publisher.
company
Standard Feed Units used with
In-Line or Rotary Transfer Machines
any(a) Horizontal
means, withoutfeed drive unit,
permission (b) angular
in writing feed
from the drive unit,
publisher. For
the exclusiveand (c)adopters
use of verticalof
column feed drive unit
the book
Standard Milling Head
any means,
Milling without
head permission
unit that in writing
attaches to one from
of thethe publisher.
feed For
drive units
in the previous slide
Rotary Transfer Machine (Plan View)
Center Column Machine (Plan View )
Analysis of Transfer Lines
Three problem areas must be considered:

1. Line balancing
To divide the total work load among workstations
as evenly as possible
2. Processing technology
Theory and principles about the manufacturing or
assembly processes used on the line
3. System
No portion reliability
of this material -may
twobecases:
reproduced, in any form or by
Transfer
any means, lines with in
without permission nowriting
internal parts
from thestorage
publisher. For
the exclusive use of adopters
Transfer of internal
lines with the book storage buffers
What the Equations Tell Us
Lines with No Storage Buffers
As the number of workstations increases

Line efficiency and production rate are adversely
affected
As reliability of individual workstations decreases
Line
2008 efficiency
Pearson and production
Education, rate are
Inc., Upper Saddle adversely
River, NJ. All rights
affected
What the Equations Tell Us
Lines with Storage Buffers
If E0 and E are nearly equal
Then little advantage is gained by adding a storage
buffer
If E is much greater than E0
Then adding a storage buffer may improve line
2008performance
significantly
reserved.
StorageThis material is protected under all copyright laws as
buffers should be located so that production rates
of the stages are about equal
anyDuring
means,operation, if any buffers
without permission are always
in writing from theempty or For
publisher.
thealways full,
exclusive usethen the buffer
of adopters is serving
of the book little purpose
What the Equations Tell Us -
Lines with Storage Buffers
The maximum possible efficiency is achieved by:
Setting the number of stages = number of stations
Using large buffer capacities
The law of diminishing returns operates in multi-stage
automated lines:
As the number of storage buffers is increased, line
efficiency improves at an ever-decreasing rate
As storage
No portion buffer capacity
of this material is increased,
may be reproduced, line form
in any efficiency
or by
improves
any means, at an
without ever-decreasing
permission in writing rate
from the publisher. For

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Automated Production Lines

High production of parts requiring multiple processing

Fixed-routing manufacturing system that consists of multiple

In-line - straight line arrangement of workstations

Linear transfer systems:

A location in the sequence of workstations where parts

Building block approach: machine tool companies

Three problem areas must be considered:

As the number of workstations increases

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