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How does ISAT331 fit in the curriculum?

How does ISAT331 fit in the curriculum?. ISAT 331 Automation in Manufacturing. 211,330. 211, 330. ISAT 211 & 330. Factory Operations 211. 211, 330. 211, 330. 331. 331. ISAT 331. 331. 331. References.

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How does ISAT331 fit in the curriculum?

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  1. How does ISAT331 fit in the curriculum? ISAT 331 Automation in Manufacturing

  2. 211,330 211, 330 ISAT 211 & 330 Factory Operations 211 211, 330 211, 330

  3. 331 331 ISAT 331 331 331

  4. References • Groover, M.P, Automation, Production Systems, and Computer Integrated Manufacturing, Prentice-Hall 2001 • Bedworth, D.D.,Henderson, M.R., and Wolfe P.M., Computer-Integrated Design and Manufacturing, McGraw-Hill, 1991. • Chang,T., Wysk,R..A, Wang, H. Computer Aided Manufacturing, Prentice Hall, 2nd Ed, 1991

  5. Module 1 Introduction 1/10/05 • Production Systems Facilities • Automation in Production Systems • Manual Labor in Production Systems • Automation Principles and Strategies • CAD, CAM and CIM

  6. ISAT330 Production System Terminologies Manufacturing Support Activities ISAT331 Computerization Manufacturing System CIM Automation

  7. Computers in Manufacturing • Automate physical system and information system in manufacturing • Automation is more related to automating the factory operations • Computerization is more related to automating information cycle • CIM is more related to automating of both factory operations and information cycle

  8. Hard MH automated Changeover (set up)Time Product Variety Soft 100 10,000 1 M Low High Production Quantity Product Variety vs Production Quantity Job Shop Mid Variety Mid Production (Most Difficult) Mass Production

  9. Fig 1.3

  10. Hard Product Variety Soft 100 10,000 1 M Low High Production Quantity Types of Production Plant (facilities) and Layout • Fixed Position (Large) • Process Job Shop • Process (Batch) • Cellular (GT families) • FMS (GT families- automated MH) Mid Variety Mid Production (Apply GT) Flexibility • Product (Flow line) • Process (Quantity) Efficiency Mass Production

  11. Characteristics of Production Plants • Job Shop has processes that cope with low volume and high number of products • - Uses Process or Fixed position layout • - Make to order. - Production Rate = Demand Rate • Batch, cellular, and FMS Production has processes that cope with medium volume and medium variety in products • Cellular deals with harder variety products than FMS • FMS is highly automated (MH) when compared to cellular • - Repeated set up-a major disadvantage. • - Production rate > Demand rate. • - Make to Stock.

  12. Characteristics of Production Plants • Mass Production has processes that cope with high volume and limited number of products • - Process or cellular layout is used for quantity production (single station ‘equipment’) • - Product layout ’Flow Line’ when multiple stations are required (single- or mixed model lines) • - Demand Rate ~ Production Rate

  13. Automation of Production Plant • Definition of Automation • Why to Automate? • Arguments for Automation • Arguments against Automation • Examples • Types of Automated Manufacturing Systems • Categorized based on sequence of operations • Justified based on production volume and variety of products • Fixed Automation • Programmable Automation • Flexible Automation

  14. Hard Product Variety Soft 100 10,000 1 M Low High Production Quantity Manual vs Automation

  15. Hard Product Variety Automation Manual Soft 100 10,000 1 M Low High Production Quantity Fig 1.1 Automation/Production Volume/Product Variety Programmable Automation Job Shop Flexible Automation Change Over (Set-up) Time Mid Variety Mid Production (Most Difficult) Fixed Automation Mass Production

  16. Programmable Automation • MOST FLEXIBLE • Sequence of operations can be changed (variety of products that are made by similar processes) • High investment (general purpose equipment) • Low – Medium production rate (relatively longer time lost for changeoversofprogramming and set-up) • Automation of operations (processes or workstations) • is emphasized (not MH)

  17. Fixed Automation • MOST EFFICIENT • Sequence of operation is fixed (fixed configurations) • Many simple ( reliability) operations (complex system) • Initial investment is high (custom-engineered equipment) • Production rates are high (mass production-Examples) • Automated Operations (processes or workstations) • and Material handling

  18. Flexible Automation • Extension of Programmable Automation with • Lower time lost on changeovers (continuous production of a group of parts – GT family- that accommodate part variations within the family) • Mid volume/variety range • Higher investment (custom-engineered devices (e.g fixtures and Jigs) for changeover)

  19. Automation Strategies & Migration • Automation is not the answer (Robotics application?) • Main principle Understand (charting?), Simplify, and Automate • Strategies? • Automation Migration Strategy

  20. Fig 1.9

  21. Manufacturing Support Activities Back to our Conceptual Model Manufacturing System

  22. Factory Operations • (Fig 2.2) • Processing ‘advance to completion’ (Basic, Secondary, Property Enhancement, Finishing) • Assembly • Material handling&Storage • Inspection (specifications)and Testing (function) • Control on shop floor (process control, quality control)

  23. SAP system?

  24. Manufacturing Support Activities • (Fig 2.4) • Business functions (type of orders?) • Product Design (source of specifications?) • Manufacturing Planning (process planning and route sheet?) • Manufacturing Control (management) ‘implement plans’(type of controls?), performance of processes “ # rejects, machine rate, etc”, performance of plant “operating cost, meeting schedule”, etc)

  25. Manual Labor in Production System • Factory Operations • Supporting Activities

  26. Fig 24.7 Scope of CAD, CAM and CIM

  27. Fig 24.8

  28. Definitions • CAD is any design activity that involves the effective use of computer technology to create,modify, or document an engineering design (part or system) • CAM is the effective use of computer technology in the planning, management, and control of the manufacturing function • CAD/CAM integration of the design and manufacturing activities. That is to automate the transition from design to manufacturing (e.g NC and process plan and Rapid Prototyping)

  29. Home Work#1 Due Wednesday 1/18/2006 • Explain and contrast the characteristics of the basic production systems • Explain and contrast the characteristics of the basic automated production systems • Discuss TWO situations in which humans are preferred over automation in Factory Operations (blue collar tasks) • Discuss TWO situations in which humans are preferred over automation in Manufacturing Support Systems (white collar tasks) • Explain THREE strategies for automating production systems

  30. Unused Slides

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