Automation

1. Automation Chapter 1 Introduction Dr. Osama Al-Habahbah

2. 1.0 Introduction The economic realities of the modern world that affect manufacturing enterprises are: • Globalization. • International outsourcing . • Local outsourcing . • Contract manufacturing . • Tend toward the service sector in developed economies. • Quality expectations. • Operational efficiency.

3. Globalization. More countries are be coming industrialized, such as China and India, due to their high population and low labor cost . International outsourcing . More parts and products are outsourced to companies outside the USA . Local outsourcing . Within the same country . Due to specialty of the suppliers, cheaper rate in smaller companies, lack of in hoes manufacturing capability

4. Contract manufacturing . The customer designs product while the supplier makes the product . Tend toward the service sector in developed economies. Erosion of direct in manufacturing . Quality expectations. perfect quality is expected Operational efficiency. used to offset the high labor cost

5. Some modern manufacturing technology that help to compete :

6. Automation Reduces labor cost, decreases production cycle time, and improves quality. • Material handling technology Include transportation, storage, tracking . • Manufacturing system Production line, manufacturing cells. • Flexible manufacturing Helps to compete in the low-volume/hig-mix product categories .

7. Quality programs Such as statistical quality control and six sigma. • Computer Integrated Manufacturing (CIM) Includes (CAD) : Computer Aided Design,(CAM): Computer Aided Manufacturing, and integrating computer networks . • Lean production Accomplish more with less resources  increases productivity

8. 1.1 production system • It is a collection of people, equipment, and procedures to perform the manufacturing operation they are two categories Manual support system Facilities The set of procedures used by the company to manage production ,such as product design. Factory Equipment Layout

9. Using unpowered hand too; Using power equipment • Automated facility branches out-to: • Semi-automated machines and fully automated machines

10. Communicating with customer Either provided by customer or in house if it’s proprietary Scheduling, Capacity, planning and process planning Shop floor control Product progress Balancing too little and too much inventory Inventory control Quality control Product quality meets standard

11. 1.2 Automation in production system • 1.2.1 Automated Manufacturing System Examples include :Automated machine tool that process parts , Automated assembly , industrial robots , Automatic material handling storage , Automatic quality control (inspection).

12. Minimalchange High initial investment , high production rate, inflexibility High initial investment , high production rate, inflexibility High investment , low production rate, flexibility

13. 1.2.2 Computerized Manufacturing Support System Computer Integrated Manufacturing (CIM) : Such as CAD / CAM

14. 1.2.3 Reason for Automating • Increase labor productivity . • Reduce labor cost . • Mitigate the effect of labor shortages • Reduce manufacturing lead time • Accomplish processes that can’t be done manual . • To avoid the high cost of not automating (competition) • Eliminate routine tasks • Improves safety • Improves quality

15. 1.3 Manual labor in production systems It is still needed . • 1.3.1 Manual labor in factory operations It can be preferred to automation in some cases :

16. 1.3.1 Manual labor in factory operations 1- Task is technologically or economically too difficult to automate . < E.g: hand-eye coordination >. 2- Short product life cycle <Automation takes time>. 3- Customized product . 4- Ups and downs in demand . 5- To reduce risk of products failure < In the market>. 6- Lack of capital to invest in automation.

17. 1.3.2 Labor in manufacturing support system • Equipment maintenance • Programming and computer operation • Engineering project work • Plant management.

18. 1.4 Automation Principle And Strategies • 1.4.1 The USA Principle Stand for Automate the process. Simplify the process. Understand the exiting process.

19. 1.4.2 Ten strategies for Automation and process improvement 1- Specialization of operations: Use of special-purpose equipment for greatest efficiency. 2- Combined operations: Perform more than one operation at a given machine. 3-Simultaneous operations: To reduce processing time. 4- Integration of operations: Linking work-stations together → increasing output 5- Increased flexibility: Maximum utilization of equipment → Use the same equipment for a variety of products.

20. 1.4.2 Ten strategies for Automation and process improvement 6- Improved material handling and storage: reduce work in process and shorter manufacturing lead times. 7-On-line inspection: (of quality) reduce scrap and improves quality. 8- Process control and optimization: process time decrease ,quality increase. 9- Plant operations control (of the factory) 10-Computer-integrated manufacturing CIM: ( Design → Operations → Business ) Computer Network

21. 1.4.3 Automation Migration Strategy Manual production. • Automated production → single-station system. • Automated integrated production • → multi-station system.

22. 1.4.3 Automation Migration Strategy Advantages of this strategy: • Shout product introduction time. • Gradual automation. • Lower risk at the start.