19-205-0605 CAD/CAM

Manufacturing systems

Dr. Harikrishnan S
Assistant Professor
Division of Mechanical Engineering
Text Book

Consider this PPT as starting point, always refer standard text books!
Industry 4.0!
Manufacturing Systems

• Man, machine and process working together to transform raw materials

to finished goods
• Basic functions of manufacturing systems:
• Product and process design
• Planning and control
• Manufacturing process
• Now efforts are made to integrate above three functions
• Factors considered while designing manufacturing systems
• Cost
• Quality
• Flexibility
• Deliverability
Manufacturing System
Manufacturing System
Manufacturing systems: Competitiveness
From Design to Product process
Types of Manufacturing Systems

• According to the physical arrangement, there are four kinds of classical

manufacturing systems and two modern manufacturing systems that is
rapidly gaining acceptance in industries
Classical systems
1. Job shop
2. Flow shop
3. Project shop
4. Continuous process

Modern manufacturing systems

1. Linked cell system (Cellular manufacturing system)
2. Flexible manufacturing system (FMS)
CLASSICAL SYSTEMS
1. JOB SHOPS

• In a Job shop, varieties of products are manufactured in small lot sizes to a

specific customer order.
• Workers must have relatively high skill levels to perform a range of
different work arrangements
• ‘ROUTE SHEETS’ /Functional or Process layout:- Each different part
requiring its own sequence of operations can be routed through the
various departments in the proper order.
1. JOB SHOPS..
2. FLOW SHOPS

• “product oriented layout” composed mainly of flow lines

• The plant may be designed to produce the particular product or family,
using “Special purpose machines” rather than general purpose equipment.
• The workstations are arranged in line according to the processing
sequence needed
2. FLOW SHOPS..
3. PROJECT SHOP

• A product must remain in a fixed position or location because of its size

and weight.
• The materials, machines and people in fabrication are brought to site. The
layout is also called as fixed position layout.
3. PROJECT SHOP..
Example: Ship building
4. CONTINUOUS PROCESS

• The product seems to flow physically.

• This system is sometimes called as flow production
• It is the most efficient but least flexible kind of manufacturing system. It
usually has the leanest and simplest production system because this
manufacturing system is the easiest to control because it has the least
work- in progress(WIP)
Material Handling Systems
• Material Handling: Movement, storage, protection and control of materials
throughout the manufacturing and distribution process
• It must be performed safely, efficiently, at low cost, in a timely manner,
accurately, without damage
• Cost of material transport:- approx. 20-25% of total manufacturing labor
• Material Handling
1. Material transport system
2. Material storage systems
3. Automatic identification and tracking systems
Material Handling
• Materials are moved, stored, and tracked
• For larger systems:- Logistics
• Logistics
• External:- Activities occur outside the factory
• Internal:- Inside the factory
• Traditional Modes
• Rail
• Road
• Air
• Ship
• Pipeline
Material Handling Equipment

• Four categories

1. Material transport equipment

2. Storage systems
3. Unitizing equipment
4. Identification and tracking systems
1. Material Transport Equipment

• Transporting materials to factory/ware houses

1. Industrial Trucks
2. Automated Guided Vehicles
3. Rail-guided vehicles
4. Conveyors
5. Hoists and Cranes
Material Transport Equipment

1. Industrial Trucks
• Manual
• Powered
Material Transport Equipment

2. Automated Guided Vehicles

• Independently operated self propelled
vehicles guided along defined pathways
1. Driverless trains
2. Pallet trucks
Material Transport Equipment

3. Monorails and Rail guided vehicles

• Motorized vehicles that are guided by fixed rail systems
Material Transport Equipment

4. Conveyors
• A mechanical apparatus for
moving items or bulk
materials usually inside a
facility
• Usually used when material
must be moved relatively
large quantities between
locations
Material Transport Equipment

5. Cranes and Hoists

• Crane:- Horizontal movements
• Hoists:- Vertical movements
• Hoist is a component of crane which lift the load
2. Storage Systems

• Raw materials / work-in-process

1. Conventional storage system
2. Automated storage system
Conventional Storage Methods

• Choice of method and equipment depends largely on the material to be

stored
Bulk Storage Rack Storage Shelves and Bins

Drawer storage
Automated Storage Systems
Automated Storage Systems

• Mechanized and automated storage systems, eliminate human

intervention
• Two types
1. Fixed Aisle
2. Carousel storage systems

Fixed Aisle system Carousal storage system

3. Unitizing Equipments

• Containers used hold individual items during handling

• Equipment used to load package the container
 4. Identification and Tracking Systems

• Keeping track of materials being moved/stored

• Usually done by affixing labels to each item
Automatic Identification and Data
Capture
• Refers technology that provide direct entry of data into a computer or other
microprocessor controlled system without using a keyboard
• No human involvement in data capture and entry
• Widely used in material handling and manufacturing applications
• Shipping, receiving storage, sortation, order packing etc.
• Drawbacks of manual entry are,
• Error
• Time factor
• Labor cost
Overview of AIDC

• Principal components are,

• Data encoder:- code, that are translated into a machine readable code
• Machine reader/scanner:- Device that reads the encoded data,
converting them to alternative form usually an electrical analog signal
• Data decoder:- Component transforms electrical signal into digital data
and finally back to alphanumeric characters
Identification technologies

• Optical
• Electromagnetic
• Magnetic
• Smart card
• Touch techniques such are touch screens/button memory
• Biometric
Identification technologies
Applications

• Shipping
• Order picking
• Finished goods storage
• Manufacturing processing
• Work-in-process storage
• Assembly
• Sortation
Automation
 Automation

Automation can be defined as the technology by which a process or procedure is

accomplished without human assistance.
Automation

• Technology concerned with the application of mechanical, electronics, and

computer based system to operate and control production in order to improve
productions
• It includes
• Automated machine tools
• Automated assembly machines
• Industrial robots
• Automated material handling and storage systems
• Automated inspection for quality control
• Feedback control and computer process control
• Computer integrated system for planning, data collection and decision making
Applications

• Processing
• Assembly
• Material handling and storage
• Inspection and testing
• Control
Examples
Reasons for automation

• Increased productivity due to competition

• High cost of labor
• Labor shortage
• Safety
• Improved product quality
• Reduced manufacturing lead time
Levels of automation
1. Device level:- It includes the
actuators, sensors, and other
hardware components that comprise
the machine level. Ex:- Feedback
control loop for one axis of a CNC
machine or one joint of an industrial
robot.
2. Machine level:- Hardware at the device
level is assembled into individual
machines. Ex:- CNC machine tools and
similar production equipment, industrial
robots, powered conveyors, and
automated guided vehicles
Levels of automation…
3. Cell/System level:- A manufacturing cell or system is a group of
machines or workstations connected and supported by a material
handling system, computer, and other equipment appropriate to the
manufacturing process.
4. Plant level:- It receives instructions from the corporate information
system and translates them into operational plans for production.
Likely functions include order processing, process planning, inventory
control, purchasing, material requirements planning, shop floor
control, and quality control.
5. Enterprise level:- It is concerned with all of the functions necessary
to manage the company: marketing and sales, accounting, design,
research, aggregate planning, and master production scheduling.
Product Design
Product design

• Product design is a critical function in the

production system
• Product design is that a very significant portion
of the cost of the product is determined by its
design
Product Design and CAD
Example:- Design of a side stand
Improper designs! examples
Computer Aided Design

• Any design activity that involves the effective use of computer systems to
create, modify, analyze, optimize, and document an engineering design
• Steps:
• Geometric modeling:- Using modeling softwares
• Engineering analysis:- Using softwares (Computer Aided Engineering)
• Design evaluation and review:- include plant layout design as well
• Prototyping:- it can be Rapid prototyping/Virtual prototyping
Example: Engineering analysis

Computer based analysis of a crash test for newly designed bumper

Computer Aided Manufacturing

• Use of computer technology in manufacturing control and planning

• Two broader categories
• Manufacturing planning:- computer is used indirectly to support the
production function, but there is no direct connection between the
computer and the process. Examples: CAPP, NC Part programming, cost
estimations, production and inventory planning
• Manufacturing control:- computer systems to control and manage the
physical operations in the factory. Examples: Process monitoring, quality
control, shop floor control, inventory control etc.
Computer Integrated Manufacturing
Computer Integrated Manufacturing
• Includes all of the engineering functions of CAD/CAM, but it also includes
the firm’s business functions that are related to manufacturing.
• CIM system applies computer and communications technology to all the
operational functions and information-processing functions in
manufacturing from order receipt through design and production to product
shipment.
• CIM concept is that all of the firm’s operations related to production are
incorporated in an integrated computer system to assist, augment, and
automate the operations.
• In this integrated computer system, the output of one activity serves as the
input to the next activity, through the chain of events that starts with the
sales order and culminates with shipment of the product.
Flexible Manufacturing System

• Cellular manufacturing:- Each cell is

designed to produce a limited variety
of part configurations; that is, the cell
specializes in the production of a
given set of similar parts or products,
according to the principles of group
technology
Group Technology
Group technology is a manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of their similarities in design
and production
Group Technology
Flexible Manufacturing System
• Type of machine cell to implement cellular manufacturing
• Most automated and technologically sophisticated of the group-technology
(GT) cells
• FMS:- Highly automated GT machine cell, consisting of one or more
processing stations (usually CNC machine tools), interconnected by an
automated material handling and storage system and controlled by a
distributed computer system
• Reason the FMS is called flexible is that it is capable of processing a
variety of different part styles simultaneously at the various workstations,
and the mix of part styles and quantities of production can be adjusted in
response to changing demand patterns
FMS

• Components
• Workstations:- Processing/Assembly equipment
• Material handling and storage systems:-
• Computer control systems:- distributed computer control that is
interfaced to the workstations, material handling system, and other
hardware components
 FMS Layouts

In-line layout

Loop layout
Artificial Intelligence in Manufacturing

• AI in manufacturing involves using technology to automate complex tasks

and unearthing previously unknown patterns in manufacturing processes
or workflows
• Applications of AI in manufacturing
• Product development
• AI based robots
• Process automation
• AI and Internet of Things
• Warehouse management
• Visual inspection and quality control
• Demand forecasting
• Failure prediction and maintenance planning
Expert systems

• Branch of AI
• Performs tasks normally done by human experts that possess a particular
knowledge
• Perform intellectually demanding tasks rather than mechanical tasks
• Components
• Data base
• Knowledge base:- rule based
• Interface engine
Example:
Optimizing the motorcycle's swingarm using generative design

Lightning Motors - Lighter and faster motorcycles (autodesk.com)

Examples

• BMW Group uses automated image recognition for quality checks,

inspections, and to eliminate pseudo-defects (deviations from target
despite no actual faults).
• Porsche use autonomous guided vehicles (AGVs) to automate significant
portions of automotive manufacturing
Thank You