CHAPTER -3: AUTOMATED MANUFACTURING SYSTEMS

3.1 Overview of manufacturing systems , Components and Classification

manufacturing cells, GT and cellular manufacturing,

3.2 . FMS, FMS and its planning and implementation

3.3 . Quality control systems: traditional and modern quality control

methods, SPC tools, inspection principles and practices.

3.1 Overview of manufacturing systems , Components and Classification
manufacturing cells, GT and cellular manufacturing,

Manufacturing System;
• A collection of integrated equipment and human resources, whose function is to perform one or
more processing and/or assembly operations on a starting raw material, part or set of parts.
Examples of Manufacturing Systems
• Single-station cells
• Machine clusters
• Manual assembly lines
• Automated transfer lines
• Automated assembly systems
• Machine cells (cellular manufacturing)
• Flexible manufacturing systems
Conti…
Components of a Manufacturing System
a) Production machines
b) Material handling system
c) Computer system to coordinate and/or control the preceding components
d) Human workers to operate and manage the system
Classification of Manufacturing Systems
Factors that define and distinguish manufacturing systems:
1) Types of operations
2) Number of workstations
3) System layout
4) Automation and manning level
5) Part or product variety
Conti…
 Group Technology (GT) and Cellular Manufacturing
Group Technology (GT) ; is a manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of their similarities in design and
production to part families.

Traditional Process Layout

Conti…
GT Cellular Layout
• A similar production shop
organized for a part family,
result in reduced workpiece
handling, lower setup times
and steps (may be change),
less in-process inventory,
and shorter lead times.
• Each cell specializes in
producing one or limited no
of part families

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Conti…
Cellular Manufacturing
Application of GT in which dissimilar machines or processes are
aggregated into cells, each dedicated to production of limited group part
family or families
Typical objectives of cellular manufacturing:
• To shorten manufacturing lead times, setup, handling, waiting, and batch sizes
• To reduce work-in-process inventory. batch sizes , lead times,
• To improve quality. each cell specializes in part family, less process variations.
• To simplify process plan and scheduling. scheduling complexity reduces by part
similarity.
• To reduce setup times. tooling designed to for part family.
• Standardization of tooling, fixtures, and setups
• Improved worker satisfaction in a GT cell
• Higher quality work

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Conti…
Quantitative Analysis in Cellular Manufacturing
Grouping Parts and Machines - Rank Order Clustering
• The rank order clustering technique is specifically applicable in production flow analysis. It is an efficient and
easy-to-use algorithm for grouping machines into cells.
• Rank order clustering works by reducing the part-machine incidence matrix to a set of diagonalized blocks
that represent part families and associated machine groups.
Rank Order Clustering algorithm steps are:
1. In each row of the matrix, read the series of 1s and 0's (blank entries = 0's) from left to right as a binary
number. Rank rows in order of decreasing. In case of a tie, rank rows in the same order as they appear in the
current matrix
2. Numbering from top to bottom, is current order of rows the same as the rank order in previous step? If yes,
go to step 7, If no, go to step 3.
3. Reorder the rows in the part-machine incidence matrix by listing them in decreasing rank order, starting from
the top
4. In each column, read the series of 1's and 0's (blank entries = (0's) from top to bottom as a binary number.
Rank columns in order of decreasing value, In case of a tie, rank the columns in the same order as they
appear.
5. Numbering from left to right, is the current order of columns the same as the rank order determined in the
previous step? If yes, go to step 7. If no, go to 6.
6. Reorder the columns in the part-machine incidence matrix by listing them in decreasing rank order, starting
with the left column. Go to step 1.
7. Stop 7
Conti…
EXAMPLE 3.1 Rank Order Clustering Technique
• Apply the rank order clustering technique to the part-machine incidence matrix in
Table 1. Solution: Step 1 consists of reading the series of 1's and 0's in each row
as a binary number, Table 1 (a). Converting the binary value for each row to its
decimal equivalent, rank ordered in the far right hand column. In step 2, the row
order is different from the starting matrix. Therefore, reorder the rows in step 3.
In step 4, read the series of 1's and 0's in each column from top to bottom as a
binary number (converted to the decimal equivalent, and the columns are ranked
in order of decreasing value, Table 1 (b). ln step 5, the column order is different
from the preceding matrix. Proceeding from step 6 back to steps 1 and 2, see that
a reordering of the columns provides a row order that is in descending value, and
the algorithm is concluded (step 7).
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Conti… TABLE 1. (a) 1st Iteration (Step 1) in Rank
Parts
Order Clustering Applied to Example 3.1.
Machi A H D B F G I C E
Binary 28 27 26 25 24 23 22 21 20
values
nes
Parts Decimal Ran 1 1 1 1
Machines A B C D E F G H I equivalent k
1 1 1 1 290 1 5 1 1
2 1 1 17 7 7 1 1 1
3 1 1 1 81 5
4 1 1 136 4 4 1 1
5 1 1 258 2 3 1 1 1
6 1 1 65 6
7 1 1 1 140 3 6 1 1
2 1 1

Parts Binary TABLE 1 (c) Solution of Ex 3.1

Machines A B C D E F G H I values
Note:
1 1 1 1 26
5 1 1 25 • This ideal case segregated the
7 1 1 1 24 part families and associated
4 1 1 23
3 1 1 1 22
machine cells (3 exclusive part-
6 1 1 21 machine groups).
2 1 1 20 • However, there may be overlap
Decimal 96 24 6 64 5 24 16 98 7
equivalent in processing requirements by a
Rank 1 4 8 3 9 5 6 2 7 part (i.e. need for more than one
m/c group process), See example
TABLE 1 (b) 2nd Iteration (Steps 3 and 4) in Rank Order 9
Clustering Technique Applied to Example 3.1
Conti…
EXAMPLE 3.2. Overlapping Machine Requirements
• Consider the part-machine incidence matrix in Table 2. This is the same as Table 1 except that part B
requires processing on m1.4, and 7 (1 is additional machine) and part D now requires processing on m1 and
m4 (4 is additional).
• Use rank order clustering technique to arrange parts and machines into groups.
Solution: The technique converges to a solution in two iterations, Tables 2 (a) and 2(b), with the final
solution in Table 2(c).
• Parts B and D could be included in either of two machine groups. This solution includes them in machine
group (-1.7); however, they must also be processed in machine group (1.5) matrix elements B1 and D1 are
exceptional elements, they each are treated as zeros when applying the rank order clustering technique. The
effect of this approach would be to organize the machines exactly as have been done in final solution in
Table 2(c).
• Another way of dealing with the overlap is simply to duplicate the machine that is used by more than one
part family. Here, this would mean that two machines of type 1 would be used in the two cells. The result is
shown in the matrix of Table [Link] the two machines are identified as 1a and 1b.
• there may be economic considerations that inhibit machine redundancy.
Other approaches to the problem of overlapping machines, include:
(1) Change routing so that all processing are done in the primary machine group.
(2) Redesign the part to eliminate processing outside the primary machine group,
(3) purchase the part from an outside supplier. 10
Conti… EXAMPLE 3.2. Overlapping Machine Requirements

Parts
Machines A B C D E F G H I Binary 28 27 26 25 24 23 22 21 20
values
Parts Decimal Ran
1 1 1 1 1 Machine A B C D E F G H I equivalent k
2 1 1 s
1 1 1 1 1 418 1
3 1 1 1 2 1 1 17 7
4 1 1 1 3 1 1 1 81 5
5 1 1 4 1 1 1 168 3
5 1 1 258 2
6 1 1 6 1 1 65 6
7 1 1 1 7 1 1 1 140 4

Parts Binary values

Machines
1
A
1
B C D
1
E F G H
1
I
26 TABLE 1 (a) First Iteration of Rank Order
5
4
1
1 1
1
1
1 25
24
Clustering Applied to Example 3.2
7 1 1 1 23
3 1 1 1 22
6 1 1 21
2 1 1 20
Decimal equivalent 96 88 6 80 5 24 8 96 7
Rank 1 3 8 4 9 5 6 2 7

TABLE 2(b) Second Iteration of Rank Order

Clustering Applied to Example 3.2 11
Conti… Machines
Parts
A H B D F G I C E TABLE 3 (c) Solution of
1 1 1 1 1 Example 3.2
5 1 1
7 1 1 1
4 1 1 1
3 1 1 1
6 1 1
2 1 1

Parts
Machines A H B D F G I C E

1a 1 1 1 1
TABLE 4 Solution to Example 5 1 1
3.2 Using Duplicate 4 1 1 1
Machines of Type 1 (Shown 1b 1 1
as Machines 1a and 1b in the 7 1 1 1
Matrix) 3 1 1 1
6 1 1
2 1 1

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3.2. FMS and its planning and implementation
Flexible Manufacturing System :- is a highly automated GT machine cell, consisting
of a group of processing stations (usually CNC machine tools), interconnected by an
automated material handling and storage system, and controlled by an integrated computer
system.

Flexibility Criteria
1. Part variety test - Can it machine different part configurations in a mix rather than in
batches?
2. Schedule change test - Can production schedule and part mix be changed?
3. Error recovery test - Can it operate if one machine breaks down?
• Example: while repairs are being made on the broken machine, can its work be temporarily reassigned
to the other machine?
4. New part test - As new part designs are developed, can NC part programs be written
off‑line and then downloaded to the system for execution?
Conti… Alternative flexibility criteria
Flexibility type Definition Factors
Machine Adaptability to range of Set up, reprogramming, skill
flexibility prdn oprn and part styles versatility, tool storage
capacity
Production Range of part styles Individual m/c flexibility,
flexibility system flexibilty
Mix flexibility Product mix without Part similarity, work content
change in quantity time
Product Design change, New part design off-line
Flexibility programming
Route Alternative workstation Similarity of product mix, WS
Flexibility sequence on breakdown duplication, common tooling
Volume working on high & low Level of manual labor,
Flexibility quantity (= investment)
Expansion Expansion to increase Expansion cost, layout
flexibility production expansion, MHS,
Conti…
FMS Applications
• Machining – most common application of FMS technology
• Assembly
• Inspection
• Sheet metal processing (punching, shearing, bending, and forming)
• Forging
FMS Benefits
• Increased machine utilization
• Reasons:
• 24 hour operation likely to justify investment
• Automatic tool changing
• Dynamic scheduling of production to account for changes in demand
• Fewer machines required
• Reduction in factory floor space required
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Conti…
FMS Planning and Implementation Issues

FMS Planning and Design Issues

• FMS planning initial phase like GT cell, include:

• Part family considerations: a limited range of product styles,

• Processing requirements. to determine types of processing equipment.

• Physical characteristics of the workparts: size and weight of the parts determine
the size of the machines and MHS
• Production volume: to determine number machines and MH.

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Conti…
FMS Operational Issues
• FMS resources must be optimized to achieve operational objectives related to profit, quality,
and customer satisfaction:
• Scheduling (based on master prdn schedule) and dispatching
• Machine loading- allocating and tooling among the machines
• Part routing: selecting routes to maximize use of workstation
• Part grouping: group selection for simultaneous production, given limitations on available
tooling and other resources.
• Tool management: decisions when to change tools, allocation of tooling, and similar issues.
• Pallet and fixture allocation - Limits on fixture types may limit part types that can be
processed.
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3.3. Quality control systems: traditional and modern quality control methods, SPC
tools, inspection principles and practices
QUALITY :- Quality as "conformance to requirements". Juran summarizes it a, "fitness for use" and "quality is
customer satisfaction". The American Society fur Quality Control (ASQC) defines quality as "the totality of
features and characteristics of a product or service that bear on its ability to satisfy given need’’.
TRADITIONAL AND MODERN QUALITY CONTROL.
Traditional Quality Control
Traditional QC focused on inspection. In many factories, the only department responsible for QC was the
inspection department. Much attention was given to sampling and statistical methods. In SQC, inferences are
made about the quality of a population of manufactured items (e.g.. components, subassemblies, products.] based
on a sample taken from the population. The sample consists of one or more of the items drawn at random from
the population. Each item in the sample is inspected for certain quality characteristics of interest. For example. a
cylindrical part maybe inspected for diameter following the turning operation that generated it.
The Modern View of Quality Control
(using SPC tools)
SPC methods are applicable in both manufacturing and nonmanufacturing situations, but most of the
applications are in manufacturing. The overall objectives of SPC are to (1) improve the quality of the
process output, (2) reduce process variability and achieve process stability, and (3) solve processing
problems. some principal methods or tools used in SPC are listed below
1. control charts
2. histograms
3. Pareto charts
4, check Sheet,
5. scatter diagrams

.
Conti…
A control chart is a graphical technique in which
statistics computed from measured values of a certain
process characteristic are plotted over time to
determine if the process remains in statistical control.

The histogram is a basic graphical tool in statistics.

After the control chart, it is probably the most
important member of the SPC tool kit. A histogram is
a statistical graph consisting of bars representing
different values or ranges of values, in which the
length of each bar is proportional to the frequency or
relative frequency of the value or range.
Conti…
A Pareto chart is a special form of histogram, in which
attribute data are arranged according to some criterion such as
cost or value. When appropriately used, it provides a
graphical display of the tendency for a small proportion of a
given population to be more valuable than the much larger
majority.

The check sheet (not to be confused with "check list") is a

data gathering tool generally used in the preliminary stages of
the study of a quality problem.
The operator running the process (e.g., the machine operator)
is often given the responsibility for recording the data on the
check sheet, and the data are often recorded in the form of
simple check marks.
Conti…
A scatter diagram is simply an .x-y
plot of the data taken of the two
variables in question. The data are
plotted as pairs; for each xj value,
there is a corresponding yi value. The
shape of the data points considered in
aggregate often reveals a pattern or
relationship between the two
variables.
Inspection Principles and Practices
In quality control. inspection is the means by which poor quality is detected and good quality is assured.
Inspection is traditionally accomplished using labor-intensive methods that are time-consuming and costly.
Inspection Procedure
1. Presentation:-The item is presented for examination.
2. Examination:-The item is examined for nonconforming feature(s). In inspection
for variables, examination consists of measuring a dimension or other attribute of
the part or product. In inspection for attributes, this involves gaging one or more dimensions or searching
the item for flaws.
3. Decision:-Based on the examination. a decision is made whether the item satisfies
the defined quality standards. The simplest case involves a binary decision, in which
the item is deemed either acceptable or unacceptable. In more complicated cases,
the decision may involve grading the item into one of more than two possible quality categories. such as
grade A, grade B. and unacceptable.
4. Action-The decision should result in some action, such as accepting or rejecting the
item, or sorting the item into the most appropriate quality grade, It may also be desirable to lake action to
correct the manufacturing process to minimize the occurrence of future defects.
Conti…
Inspection Accuracy
Errors sometimes occur in the inspection procedure during the examination and decision
steps. Items of good quality are incorrectly classified as not conforming to specifications,
and nonconforming items are mistakenly classified as conforming. These two kinds of mistakes are called
Type I and Type II errors. A Type I error occurs when an item of good
quality is incorrectly classified as being defective. It is a "false alarm." A Type II error is
when an item of poor quality is erroneously classified as being good. It is a "miss.“