Automation in Production Systems.

Summary

This script discusses the automation of manufacturing systems, categorizing them into automated manufacturing systems and computerized manufacturing support systems. It delves into three types of automation: fixed, programmable, and flexible, each suited to different production volumes and product varieties. The script also touches on computer-integrated manufacturing (CIM), highlighting its role in product design, planning, control, and information processing, aiming to streamline manufacturing operations.

Takeaways

• 🏭 Automated manufacturing systems operate within factories to perform tasks such as processing, assembly, inspection, and material handling with minimal human intervention.
• 🔗 The automation of manufacturing systems is closely tied to computerization, which supports both the factory floor operations and the broader enterprise management.
• 📊 Automated systems can be categorized into fixed automation, programmable automation, and flexible automation, each serving different production needs and volumes.
• 💼 Fixed automation is suitable for high-volume, consistent production due to its high initial investment and lack of flexibility.
• 🛠 Programmable automation allows for changes in the sequence of operations through programming, suitable for batch production with varying product configurations.
• 🔄 Flexible automation enables the production of a variety of parts or products with minimal changeover time, ideal for medium production rates and frequent design variations.
• 💡 Computerized manufacturing support systems aim to reduce manual and clerical work in product design, planning, control, and business functions.
• 🖥️ Computer-integrated manufacturing (CIM) represents the comprehensive integration of computer systems across all aspects of manufacturing, from design to production control.
• 🎛️ CAD (Computer-Aided Design) and CAM (Computer-Aided Manufacturing) are integral parts of CIM, supporting product design and manufacturing engineering functions.
• 📈 The implementation of CIM can lead to more efficient manufacturing processes by streamlining information flow and decision-making across the enterprise.

Q & A

What are the two categories of automation in a production system?

The two categories of automation in a production system are the automation of the manufacturing systems in the factory and the computerization of the manufacturing support systems.

What is the difference between automated and manual operations in a production system?

Automated operations in a production system perform tasks with a reduced level of human participation compared to the corresponding manual process. In highly automated systems, there can be virtually no human participation.

What are the examples of automated manufacturing systems?

Examples of automated manufacturing systems include automated machine tools, transfer lines, automated assembly systems, automatic material handling and storage systems, and automatic inspection systems for quality control.

How are automated manufacturing systems classified?

Automated manufacturing systems are classified into three basic types: fixed automation, programmable automation, and flexible automation.

What is fixed automation and what are its typical features?

Fixed automation is a system where the sequence of processing or assembly operations is fixed by the equipment configuration. Its typical features include high initial investment, high production rates, and low flexibility to accommodate product variety.

What is programmable automation and how does it differ from fixed automation?

Programmable automation allows the sequence of operations to be changed to accommodate different product configurations, controlled by a program. It differs from fixed automation by offering flexibility to deal with variations and changes in product configuration, and is suitable for batch production.

What is flexible automation and how does it extend programmable automation?

Flexible automation is capable of producing a variety of parts or products with virtually no time lost for changeovers. It extends programmable automation by allowing continuous production of variable mixtures of parts or products without significant changeover times.

What is the purpose of computerized manufacturing support systems?

The purpose of computerized manufacturing support systems is to reduce the amount of manual and clerical effort in product design, manufacturing planning and control, and the business functions of the firm.

What is computer-integrated manufacturing (CIM) and how does it relate to automation?

Computer-integrated manufacturing (CIM) refers to the pervasive use of computer systems to design products, plan production, control operations, and perform various information processing functions in a manufacturing firm. It involves integrating all these functions into one system that operates throughout the enterprise.

What are the four basic manufacturing support functions that computer integrated manufacturing supports?

The four basic manufacturing support functions supported by computer integrated manufacturing are business functions, product design, manufacturing planning, and manufacturing control.

Outlines

00:00

🤖 Automation in Manufacturing Systems

This paragraph discusses the automation of a firm's production system, which can be divided into two main categories: automation of manufacturing systems in the factory and computerization of manufacturing support systems. The automated manufacturing systems are further classified into three types: fixed automation, programmable automation, and flexible automation. Fixed automation involves a set sequence of operations with high initial investment and is suitable for high-volume production. Programmable automation allows for changes in the sequence of operations to accommodate different products, with flexibility for batch production. Flexible automation is designed for minimal downtime during changeovers and can produce a variety of parts without significant setup time. Examples of automated systems include machine tools, transfer lines, assembly systems, material handling, and inspection systems. The paragraph also touches on the economic justification for each type of automation based on production volume and product variety.

05:00

💻 Computerization of Manufacturing Support Systems

The second paragraph delves into computerized manufacturing support systems, which aim to reduce manual and clerical efforts in product design, manufacturing planning and control, and business functions. It highlights the role of computer technology in implementing automation within the factory and the concept of Computer Integrated Manufacturing (CIM), which integrates various functions such as product design, production planning, and control into a cohesive system. The paragraph mentions specific elements of CIM, including Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM), which support product design and manufacturing engineering functions, respectively. The integration of CAD and CAM into one system is also discussed. The paragraph concludes by emphasizing the importance of information processing in supporting the manufacturing support functions of business, product design, manufacturing planning, and control.

Keywords

💡Automation

Automation refers to the use of control systems and information technologies to reduce the need for human intervention in the production process. In the context of the video, automation is central to improving efficiency and reducing manual labor in manufacturing systems. The script discusses three types of automation: fixed, programmable, and flexible, each with different capabilities and applications in factory settings.

💡Manufacturing Systems

Manufacturing systems are the processes and machinery involved in the production of goods. The video script highlights how these systems can be automated to enhance productivity. Examples given include processing, assembly, inspection, and material handling, which are operations that can be performed with reduced human participation through automation.

💡Computerization

Computerization is the process of using computers to automate tasks that were previously done manually. In the video, computerization is discussed as a way to modernize manufacturing support systems, making them more efficient and reducing the clerical workload. It is closely linked to automation, as computer systems often drive the automated processes on the factory floor.

💡Fixed Automation

Fixed automation is a type of automation where the sequence of operations is set and does not change. The script explains that this type of automation is characterized by high initial investment and is suitable for high-volume, repetitive tasks where the product variety is limited. An example from the script is machining transfer lines, which perform a series of operations in a fixed sequence.

💡Programmable Automation

Programmable automation allows for the change of operation sequences to accommodate different product configurations. The video script mentions that this type of automation is controlled by programs that can be altered to produce new products. It is more flexible than fixed automation and is suitable for batch production where product variety is more significant.

💡Flexible Automation

Flexible automation is an advanced form of programmable automation that can produce a variety of parts or products with minimal changeover time. The script describes it as a system that can handle product design variations with ease, making it ideal for manufacturing environments that require frequent changes in product mix. Flexible manufacturing systems that perform machining processes are given as an example.

💡Computer-Integrated Manufacturing (CIM)

CIM is the comprehensive use of computer systems to design products, plan production, control operations, and perform information processing in a manufacturing firm. The video script emphasizes that true CIM involves integrating all these functions into one system that operates across the enterprise. It is a holistic approach to manufacturing that leverages computer technology to streamline and optimize all aspects of production.

💡Computer-Aided Design (CAD)

CAD is a technology that supports product design by using computer software to create detailed designs and models. The script mentions CAD as a component of CIM, highlighting its role in the product design function. It is an essential tool in modern manufacturing, allowing designers to create and modify designs digitally before physical production begins.

💡Computer-Aided Manufacturing (CAM)

CAM refers to the use of computer software and systems to aid in the manufacturing engineering processes such as process planning and numerical control part programming. The video script explains that some systems perform both CAD and CAM functions, indicating an integration that enhances the efficiency of the manufacturing process. CAM is crucial for translating design data into manufacturing instructions.

💡Manufacturing Support Systems

Manufacturing support systems are the auxiliary systems that assist in the manufacturing process, including product design, planning, and control. The video script discusses the automation of these systems to reduce manual and clerical effort, emphasizing the role of computer technology in streamlining these functions and making the manufacturing process more efficient.

Highlights

Components of the firm's production system are divided into automated and manual operations.

Automated elements can be categorized into automation of manufacturing systems and computerization of manufacturing support systems.

Automated manufacturing systems perform operations with reduced human participation.

Examples of automated manufacturing systems include machine tools, transfer lines, assembly systems, material handling, and inspection systems.

Automated manufacturing systems are classified into fixed, programmable, and flexible automation.

Fixed automation is characterized by a fixed sequence of operations and is suitable for high-volume production.

Programmable automation allows for changes in the sequence of operations to accommodate different products.

Flexible automation enables the production of various parts with minimal changeover time.

Computerized manufacturing support systems aim to reduce manual effort in product design, planning, and control.

Computer technology is integral to implementing both manufacturing and support systems automation.

Computer-integrated manufacturing (CIM) involves the comprehensive use of computer systems across all manufacturing functions.

CAD and CAM are specific elements of CIM, supporting product design and manufacturing engineering functions.

CIM integrates information processing activities to provide data and knowledge for successful product production.

Manufacturing support functions include business functions, product design, manufacturing planning, and control.

The economic justification for fixed automation is based on high initial costs spread over large production quantities.

Programmable automation is suitable for batch production with flexibility in product configuration changes.

Flexible automation systems can produce a variety of parts without significant downtime for changeovers.

The integration of CAD and CAM into one system streamlines the product design and manufacturing process.

Transcripts

some components of the firm's production

system are likely to be automated

whereas others will be operated manually

or clerical II the automated elements of

the production system can be separated

into two categories

number one automation of the

manufacturing systems in the factory and

number two computerization of the

manufacturing support systems in modern

production systems the two categories

are closely related because the

automated manufacturing systems on the

factory floor are themselves usually

implemented by computer systems that are

integrated with the manufacturing

support systems and management

information system operating at the

plant and enterprise levels the two

categories of

automation are shown in this figure at

first let's discuss in details about

automated manufacturing systems

automated manufacturing systems operate

in the factory on the physical product

they perform operations such as

processing assembly inspection and

material handling in many cases

accomplishing more than one of these

operations in the same system they are

called automated because they perform

their operations with a reduced level of

human participation compared with the

corresponding manual process in some

highly automated systems there is

virtually no human participation

examples of automated manufacturing

systems include automated machine tools

that process parts transfer lines that

perform a series of machining operations

automated assembly systems manufacturing

systems that use industrial robots to

perform processing or assembly

operations automatic material handling

and storage systems to integrate

manufacturing operations and automatic

inspection systems for quality control

automated manufacturing systems can be

classified into three basic types number

one fixed automation number two

programmable automation and number three

flexible automation they generally

operate as fully automated systems

although semi automated systems are

common in programmable automation fixed

automation

fixed automation is a system in which

the sequence of processing or assembly

operations is fixed by the equipment

configuration each operation in the

sequence is usually simple involving

perhaps a plain linear or rotational

motion or an uncomplicated combination

of the two such as feeding a rotating

spindle it is the integration and

coordination of many such operations in

one piece of equipment that makes the

system complex typical features of fixed

automation are high initial investment

for custom engineered equipment high

production rates and in flexibility of

the equipment to accommodate product

variety the economic justification for

fixed automation is found in products

that are made in very large quantities

and at high production rates the high

initial cost of the equipment can be

spread over a very large number of units

thus minimizing the unit cost relative

to alternative methods of production

examples of fixed automation include

machining transfer lines and automated

assembly machines programmable

automation in programmable automation

the production equipment is designed

with the capability to change the

sequence of operations to accommodate

different product configurations the

operation sequence is controlled by a

program which is a set of instructions

coded so that they can be read and

interpreted by the system new programs

can be prepared and entered into the

equipment to produce new products some

of the features that characterize

programmable automation include high

investment in general purpose equipment

lower production rates than fixed

automation flexibility to deal with

variations and changes in product

configuration and high suitability for

batch production programmable automated

systems are used in low and medium

volume production the parts or products

are typically made in batches to produce

each new batch of a different item the

system must be reprogrammed with the set

of machine instructions that correspond

to the new item the physical setup of

the machine must also be changed tools

must be loaded fixtures must be attached

to the machine table and any required

machine settings

must be entered this changeover takes

time consequently the typical cycle for

a given batch includes a period during

which the setup and reprogramming take

place followed by a period in which the

parts are produced examples of

programmable automation include

numerically controlled and see machine

tools industrial robots and programmable

logic controllers flexible automation

flexible automation is an extension of

programmable automation a flexible

automated system is capable of producing

a variety of parts or products with

virtually no time lost for changeovers

from one design to the next there is no

lost production time while reprogramming

the system and altering the physical set

up tooling fixtures machine settings

accordingly the system can produce

various mixes and schedules of parts or

products instead of requiring that they

be made in batches

what makes flexible automation possible

is that the differences between parts

processed by the system are not

significant so the amount of changeover

between designs is minimal features of

flexible automation include high

investment for a custom engineered

system continuous production of variable

mixtures of parts or products medium

production rates and flexibility to deal

with product design variations examples

of flexible automation are flexible

manufacturing systems that perform

machining processes we can see the three

types of automation relative to

production quantity and product variety

that we have just discussed till now we

were discussing the automated

manufacturing systems

now let's discuss about computerized

manufacturing support systems automation

of the manufacturing support systems is

aimed at reducing the amount of manual

and clerical effort in product design

manufacturing planning and control and

the business functions of the firm

nearly all modern manufacturing support

systems are implemented using computers

indeed

computer technology is used to implement

automation of the manufacturing systems

in the factory as well computer

integrated manufacturing CI M

denotes the pervasive use of computer

systems to design the products plan the

production control the operations and

perform the various information

processing functions needed in a

manufacturing firm true CI em involves

integrating all of these functions in

one system that operates throughout the

entreprise other terms are used to

identify specific elements of the CI m

system for example computer-aided design

in short CAD supports the product design

function computer-aided manufacturing in

short cam is used for functions related

to manufacturing engineering such as

process planning and numerical control

part programming some computer systems

perform both CAD and cam and so the term

CAD or cam is used to indicate the

integration of the two into one system

computer integrated manufacturing

involves the information processing

activities that provide the data and

knowledge required to successfully

produce the product these activities are

accomplished to implement the four basic

manufacturing support functions

identified earlier business functions

product design manufacturing planning

and manufacturing control