Automation in Computer-Integrated Manufacturing

1. Introduction to Computer-Integrated Manufacturing (Chapter 10) Dr. Sami El ferik

2. Automation • Definition 1: “automatically controlled operation of an apparatus, process, or system by mechanical or electronic devices that take the place of human organs of observation, effort and decision. • Definition2: “a process without direct human activity in the process”

3. Human beings role in automated systems • Designing the system • Monitoring of its operation • Maintaining the system • Presently, human involvement have been removed from many portions of the production system

4. Continuous flow processes • Example: oil refineries and chemical plants automation has reached a very high state of development. • Sensors measure critical process variables in real time and feed the measurement back to the control computer. • The computer exercises an on-line optimization to determine any needed adjustments in the controlled process components.

5. Human interaction in continuous flow processes. • The process is fully automated with human monitoring the process in a control room containing readouts of the process variables and parameter settings.

6. Mass Production of discrete items • Ex: Automobile components. • Usually called flow lines or transfer lines. • Many special machines arranged sequentially. Work parts are transferred automatically from one machines to another. The machine performs their operations automatically. • Ex: Robot welding, painting, parts handling and so on. • Automated flow lines are flexible Through the use of computer and flexible manufacturing system

8. Batch production and job shop production • Introduction of CNC (Computer numerical controlled) machine. • Use of flexible manufacturing concept. • Tools change automatically • Machine can do several dozen operation • 4 general type: • Flexible modules • Stand alone FMS • Classical FMS • Robotized FMS.

9. Robotics • A programmable, multifunction manipulator designed to move material, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks. • Type of robots. • Stationary robots • Mobile robots

10. Aspects of robots • Four basic components: • Manipulators • Actuator • Control unit • Variety of sensors: • Audio • Visual • Voice or speech recognition • Tactile • etc…

11. Use of robots: • Machine loading • Material transfer • Painting/coating • Welding • Assembly • Inspection • Packaging • Component insertion OPEL

12. CIM • CIM is the integration of • Computer in Product design • Computer in process design • Computer in Electronic design • Computer aided process planning • Numerical control • Group technology • Automated storage retrieval and handling • Computer aided testing and inspection • Computer aided factory management • Flexible manufacturing system CAD CAM

13. CAD: is hardware and software • Computer in Product design: (3 components) • Design development: Geometric shape • Design Analysis: weight volume, center of gravity, effect of temperature etc…) • Design simulation: system model, simulation and animation software • Design review and evaluation • Automated drafting • Design retrieval and modification.

14. CAD • Computer in the process design • Model that express the system behavior (dynamic) • Differential equation (physically based) • Statistically models • Time series models: output is function of the output previous values as well as the input present and previous values. • Parameters of the system are changed until the system gives the appropriate response.

15. CAM • Computer aided process planning • Numerical control • Group technology • Automated storage retrieval and handling • Computer aided testing and inspection • Computer aided factory management • Flexible manufacturing system

16. Computer aided factory management • Purpose: Coordinate review and control the activities of the entire plant. • Integration of all the information and concepts together to manage and control available sources

17. Think of the big picture of CIM • The role of technology in the implementation and operation of CIM. • Automation… key elements of CIM • The relationship between automation and the humans in the system • How CIM can make an operation more effective Continued….

18. Marketing/Sales Engineering R & D Quality Assurance Warehousing & Distribution Shipping and Receiving Finance & Accounting Information Systems Human Resources Customer Service Manufacturing Material Management Functional areas of the enterprise… How will CIM impact these areas?

19. Definitions of CIM • View 1: • technology, tool or method used to improve entirely the design and • manufacturing process and increase productivity • using computers to help people and machines to communicate

20. CIM cont. • View 2 • series of integrated activities and operations involving the design, materials selection, planning, production, quality assurance, management and marketing of discrete consumer and durable goods (Bunce, 1985) • deliberate integration of automated systems logical organization of individual engineering, production and marketing/support functions into a computer integrated system (Bunce, 1985)

21. CIM cont • architecture for integration of multiple technologies through computers, linking each individual island of automation to a closed loop business system (Foong, 1991) • integration of computer aided design, automatic material handling, robotics, • process technologies, manufacturing planning & control, computer aided test, computer aided manufacturing

22. CIM Wheel - 1985

23. 1993 SME Enterprise Wheel

25. CIM… More than just “automation” CIM Can be found at several levels: • Shop floor automation / work cell • “islands of automation” • Manufacturing Operations • “islands” are linked together • Information systems integration • Information shared across functional boundaries • Strategic or “Supply Chain” level • Integration extends up to customers and down to the suppliers Low High