Mechanics Supervision

Level-IV

Learning Guide
Module Title: - Supervising and Guiding Computer-
Integrated Manufacturing (CIM) Production
Operations
Unit code:- IND MCS4 06 0217
LO1:- Interpret the design brief or scope of production including CIM system
LO2:- Prepare production process including possible CIM system
LO3:- Perform supervision of conventional and /or CIM supported production
LO4:- Assure quality production process

Prepared By: Boka Terefe

Module Description:- This module covers the competency required of supervising and guiding
production operations including control of machine and processes and the capture of
manufacturing data through conventional or CIM processes
LO1: Interpret the design brief or scope of production including CIM system
Definition of CIM

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Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to
control entire production process. This integration allows individual processes to exchange
information with each other and initiate actions.
Computer-integrated manufacturing (CIM) makes the use of computer-controlled machineries and
automation systems in manufacturing products. CIM combines various technologies like CAD and
CAM to provide an error-free manufacturing process that reduces manual labor and automates
repetitive tasks.
The term "computer-integrated manufacturing" is both a method of manufacturing and the name of
a computer-automated system in which individual engineering, production, marketing, and support
functions of a manufacturing enterprise are organized.
In a CIM system functional areas such as design, analysis, planning, purchasing, cost accounting,
inventory control, and distribution are linked through the computer with factory floor functions such
as materials handling and management, providing direct control and monitoring of all the
operations.
CIM is defined as a computer system in which the peripherals are robots, machine tools and
other processing equipment.

Advantages of CIM
 Error Reduction :- Elimination of human error in many assignment and reporting functions on
factory floor operations drastically reduces the error rate.

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 Speed:- CIM environments reduce the time it takes to perform manufacturing fabrication and
assembly, allowing quicker flow of product to customers and increased capacity.
 Flexibility:- With CIM companies quickly react to market conditions and then return to
previous settings when market conditions change.
 Integration:- CIM offers a degree of integration that enables the flexibility, speed and error
reduction required to compete and lead markets. Integrating factory floor operations with
enterprise software enables employees to do higher value functions for their companies.
Benefit from CIM
Integration of technologies brings following benefits:
1. Creation of a truly interactive system that enables manufacturing functions to communicate
easily with other relevant functional units
2. Accurate data transferability among manufacturing plant or subcontracting facilities at implant
or diverse locations
3. Faster responses to data-changes for manufacturing flexibility
4. Increased flexibility towards introduction of new products
5. Improved accuracy and quality in the manufacturing process (continued)
6. Improved quality of the products.
7. Control of data-flow among various units and maintenance of user-library for system-wide
data.
8. Reduction of lead times which generates a competitive advantage.
9. Streamlined manufacturing flow from order to delivery.
10. Easier training and re-training facilities.

1.1. Required features and extent of integration of the CIM system

Nature and Role of the Elements of CIM System
Nine major elements of a CIM system
are in Figure 2 they are,
 Marketing
 Product Design
 Planning
 Purchase
 Manufacturing Engineering
 Factory Automation
Hardware
 Warehousing
 Logistics and Supply Chain
Management
 Finance
 Information Management

1. Marketing: The need for a product

is identified by the marketing
division. The specifications of the product, the projection of manufacturing quantities and the

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 strategy for marketing the product are also decided by the marketing department. Marketing
also works out the manufacturing costs to assess the economic viability of the product.
2. Product Design: The design department of the company establishes the initial database for
production of a proposed product. In a CIM system this is accomplished through activities
such as geometric modeling and computer aided design while considering the product
requirements and concepts generated by the creativity of the design engineer. Configuration
management is an important activity in many designs. Complex designs are usually carried
out by several teams working simultaneously, located often in different parts of the world. The
design process is constrained by the costs that will be incurred in actual production and by the
capabilities of the available production equipment and processes. The design process creates
the database required to manufacture the part.
3. Planning: The planning department takes the database established by the design department
and enriches it with production data and information to produce a plan for the production of
the product. Planning involves several subsystems dealing with materials, facility, process,
tools, manpower, capacity, scheduling, outsourcing, assembly, inspection, logistics etc. In a
CIM system, this planning process should be constrained by the production costs and by the
production equipment and process capability, in order to generate an optimized plan.
4. Purchase: The purchase departments is responsible for placing the purchase orders and
follow up, ensure quality in the production process of the vendor, receive the items, arrange
for inspection and supply the items to the stores or arrange timely delivery depending on the
production schedule for eventual supply to manufacture and assembly.
5. Manufacturing Engineering: Manufacturing Engineering is the activity of carrying out the
production of the product, involving further enrichment of the database with performance data
and information about the production equipment and processes. In CIM, this requires
activities like CNC programming, simulation and computer aided scheduling of the production
activity. This should include online dynamic scheduling and control based on the real time
performance of the equipment and processes to assure continuous production activity. Often,
the need to meet fluctuating market demand requires the manufacturing system flexible and
agile.
6. Factory Automation Hardware: Factory automation equipment further enriches the
database with equipment and process data, resident either in the operator or the equipment to
carry out the production process. In CIM system this consists of computer controlled process
machinery such as CNC machine tools, flexible manufacturing systems (FMS), Computer
controlled robots, material handling systems, computer controlled assembly systems, flexibly
automated inspection systems and so on.
7. Warehousing: Warehousing is the function involving storage and retrieval of raw materials,
components, finished goods as well as shipment of items. In today's complex outsourcing
scenario and the need for just-in-time supply of components and subsystems, logistics and
supply chain management assume great importance.
8. Finance: Finance deals with the resources pertaining to money. Planning of investment,
working capital, and cash flow control, realization of receipts, accounting and allocation of
funds are the major tasks of the finance departments.

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 9. Information Management: Information Management is perhaps one of the crucial tasks in
CIM. This involves master production scheduling, database management, communication,
manufacturing systems integration and management information systems.
1.2. Technical, commercial and environmental parameters
Manufacturing is the process of converting raw materials, components or parts into finished
goods that meet a customer's expectations or specifications.
Manufacturing is a value-adding process allowing businesses to sell finished products at a
premium over the value of the raw materials used.
It is a series of interrelated activities and operations involving design, material selection, planning,
production, quality assurance, management, and marketing of discrete consumer and durable
goods.
Use of Computers
 A computer is a machine that can be instructed to carry out sequences of arithmetic or
logical operations automatically via computer programming.
 Modern computers have the ability to follow generalized sets of operations, called
programs.
These programs enable computers to perform an extremely wide range of tasks
Computer Assistance

Communication System in Manufacturing

The physical integration of industrial controllers with Computer Aided Design (CAD) systems and
manufacturing management systems has become one of the most important issues in the field of

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Computer Integrated Manufacture (CIM). Communications links between these intelligent,
computer based systems are a vital part of all modern, manufacturing organizations endeavoring
to integrate management systems and production systems into a more efficient, responsive and
cohesive unit.
Communications within a manufacturing organization can take on many forms. At a basic level it
is often necessary to reliably transfer data or programs, developed on a Computer, to a Computer
Numerical Control (CNC) machine tool, robot or Programmable Logic Controller (PLC). At a
higher level it may be necessary to integrate CAD workstations, industrial controllers (CNCs &
PLCs) and manufacturing management computer systems through a Local Area Network (LAN).
However, in order to establish links and networks that can function with industrial equipment, there
needs to be an understanding of the basic mechanisms and problems of data communications
and the special needs of the manufacturing environment.

1.3. Consulting production process in compliance with engineering

standards
Engineering Standards
Computer-Aided Design (CAD) is the use of computer systems (or workstations) to aid in the
creation, modification, analysis, or optimization of a design.
CAD software is used to increase the productivity of the designer, improve the quality of design,
improve communications through documentation, and to create a database for manufacturing.
CAD output is often in the form of electronic files for print, machining, or other manufacturing
operations. The term CADD (for Computer Aided Design and Drafting) is also used.

Its use in designing electronic systems is known as electronic design automation, or EDA. In
mechanical design it is known as mechanical design automation (MDA) or computer-aided
drafting (CAD), which includes the process of creating a technical drawing with the use of
computer software.
CAD software for mechanical design uses either vector-based graphics to depict the objects of
traditional drafting, or may also produce raster graphics showing the overall appearance of
designed objects. However, it involves more than just shapes. As in the manual drafting of
technical and engineering drawings, the output of CAD must convey information, such as
materials, processes, dimensions, and tolerances, according to application-specific conventions.
CAD may be used to design curves and figures in two-dimensional (2D) space; or curves,
surfaces, and solids in three-dimensional (3D) space.

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CAD is an important industrial art extensively used in many applications, including automotive,
shipbuilding, and aerospace industries, industrial and architectural design, prosthetics, and many
more. CAD is also widely used to produce computer animation for special effects in movies,
advertising and technical manuals, often called DCC digital content creation. The modern
ubiquity and power of computers means that even perfume bottles and shampoo dispensers are
designed using techniques unheard of by engineers of the 1960s. Because of its enormous
economic importance, CAD has been a major driving force for research in computational
geometry, computer graphics (both hardware and software), and discrete differential geometry.
CAD software enables engineers and architects to design, inspect and manage engineering
projects within an integrated graphical user interface (GUI) on a personal computer system. Most
applications support solid modeling with boundary representation (B-Rep) and NURBS geometry,
and enable the same to be published in a variety of formats. A geometric modeling kernel is a
software component that provides solid modeling and surface modeling features to CAD
applications.
Based on market statistics, commercial software from Autodesk, Dassault Systems, Siemens
PLM Software and PTC dominate the CAD industry. The following is a list of major CAD
applications, grouped by usage statistics.
Commercial

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 Autodesk AutoCAD  Siemens Solid Edge  SpaceClaim
 Autodesk Inventor  PTC Pro/ENGINEER  PunchCAD
 Bricsys BricsCAD (now renamed Creo)  Rhinoceros 3D
 Dassault CATIA  TurboCAD  VariCAD
 Dassault SolidWorks  IronCAD  VectorWorks
 Kubotek KeyCreator  MEDUSA  Cobalt
 Siemens NX  ProgeCAD  RoutCad RoutCad

DETAILED DRAWING
An engineering drawing, a type of technical drawing, is used to fully and clearly define
requirements for engineered items.
Engineering drawing (the activity) produces engineering drawings (the documents).
More than just the drawing of pictures, it is also a language—a graphical language that
communicates ideas and information from one mind to another. Most especially, it
communicates all needed information from the engineer who designed a part to the
workers who will make it.
An engineering drawing is a legal document (that is, a legal instrument), because it
communicates all the needed information about "what is wanted" to the people who will
expend resources turning the idea into a reality. It is thus a part of a contract; the
purchase order and the drawing together, as well as any ancillary documents
(engineering change orders [ECOs], called-out specs), constitute the contract.

1.4. Manual or Possible CIM project

Your project brief should only include your project objectives, timeline and schedule,
target audience, and project scope.
Your project plan should include seven elements:
 Project goals.
 Success metrics.
 Stakeholders and roles.
 Budget.
 Milestones and deliverables.
 Timeline and schedule.
 Project communication plan.
1.4. OHS, regulatory requirements
OHS, regulatory, sustainability and environmental issues includes:

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  OHS Acts and regulations
 Relevant standards
 Industry codes of practice
 Risk assessments
 Registration requirements
 Safe work practices
 Minimising ecological and environmental footprint of process, plant and
product
 Maximising economic benefit of process plant and product to the
organisation and the community
 Minimising the negative OHS impact on employees, community and
customer
 State and territory regulatory requirements

Parameters of the brief or contract might be includes:

 Design cost and system capital cost
 Maintainability and product life cycle cost
 Durability, function, performance and aesthetics
 Energy and environmental sustainability and social issues
 Equipment availability and worksite restrictions
 Other special features and limits in the design brief
Conventional manufacturing:
Limited use of ICT’s and the conventional part May include, but not limited to:
 Analysis
 Planning
 Purchasing
 Materials handling and management
 Providing direct control
 Supervision of operations

LO2: Prepare production process including possible CIM system

Production Process
Production function is that part of an organization, which is concerned with the
transformation of a range of inputs into the required outputs (products) having the
requisite quality level. Production is defined as “the step-by-step conversion of one form
of material into another form through chemical or mechanical process to create or
enhance the utility of the product to the user.” Thus production is a value addition
process. At each stage of processing, there will be value addition.

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Conventional Production System
The production system of an organization is that part, which produces products of an
organization.
It is that activity whereby resources, flowing within a defined system, are combined and
transformed in a controlled manner to add value in accordance with the policies
communicated by management.
Classification of Production System
Production systems can be classified as Job Shop, Batch, Mass and Continuous
Production systems.

JOB SHOP PRODUCTION

Job shop production are characterized by manufacturing of one or few quantity of
products designed and produced as per the specification of customers within prefixed
time and cost. The distinguishing feature of this is low volume and high variety of
products. A job shop comprises of general purpose machines arranged into different
departments. Each job demands unique technological requirements, demands
processing on machines in a certain sequence.
Characteristics
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The Job-shop production system is followed when there is:
1. High variety of products and low volume.
2. Use of general purpose machines and facilities.
3. Highly skilled operators who can take up each job as a challenge because of
uniqueness.
4. Large inventory of materials, tools, parts.
5. Detailed planning is essential for sequencing the requirements of each product,
capacities for each work Centre and order priorities.
BATCH PRODUCTION
Batch production is defined “as a form of manufacturing in which the job passes through
the functional departments in lots or batches and each lot may have a different routing.”
It is characterized by the manufacture of limited number of products produced at regular
intervals and stocked awaiting sales.
Characteristics
Batch production system is used under the following circumstances:
1. When there is shorter production runs.
2. When plant and machinery are flexible.
3. When plant and machinery set up is used for the production of item in a batch and
change of set up is required for processing the next batch.
4. When manufacturing lead time and cost are lower as compared to job order
production.
MASS PRODUCTION
Manufacture of discrete parts or assemblies using a continuous process are called
mass production.
This production system is justified by very large volume of production. The machines
are arranged in a line or product layout. Product and process standardization exists and
all outputs follow the same path.
Characteristics
Mass production is used under the following circumstances:
1. Standardization of product and process sequence.
2. Dedicated special purpose machines having higher production capacities and output
rates.
3. Large volume of products.
4. Shorter cycle time of production.
5. Lower in process inventory.
6. Perfectly balanced production lines.
7. Flow of materials, components and parts is continuous and without any back tracking.
8. Production planning and control is easy.
9. Material handling can be completely automatic.
CONTINUOUS PRODUCTION
Production facilities are arranged as per the sequence of production operations from the
first operations to the finished product. The items are made to flow through the

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sequence of operations through material handling devices such as conveyors, transfer
devices, etc.
Characteristics
Continuous production is used under the following circumstances:
1. Dedicated plant and equipment with zero flexibility.
2. Material handling is fully automated.
3. Process follows a predetermined sequence of operations.
4. Component materials cannot be readily identified with final product.
5. Planning and scheduling is a routine action.
Manufacturing Systems
Manufacturing systems is a collection of integrated equipment and human resources,
whose function is to perform one or more processing and/or assembly operations on a
starting raw material, part, or set of parts.
•It is a logical grouping of equipment and workers in the factory.
•Components of a Manufacturing System are:-
1. Production machines
2. Material handling system
3. Computer system to coordinate and/or control the preceding components
4. Human workers to operate and manage the system

Categories of Manufacturing Systems

It is classified in three categories in terms of the human participation in the processes
performed by the manufacturing system:
 Manual work system - a worker performing one or more tasks without the aid of
powered tools, but sometimes using hand tools
 Worker-machine system - a worker operating powered equipment

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  Automated system - a process performed by a machine without direct
participation of a human

Manufacturing Support Systems

Manufacturing support involves a sequence of activities that consists of four functions:
 Business functions - sales and marketing, order entry, cost accounting, customer
billing
 Product design - research and development, design engineering, prototype shop
 Manufacturing planning - process planning, production planning, MRP, capacity
planning
 Manufacturing control - shop floor control, inventory control, quality control

Automation in Production Systems

Automation is technology associated with the applications of Mechanical, electrical and
computer based systems to operate and control production
Two categories of automation in the production system:
1. Automation of manufacturing systems in the factory
2. Computerization of the manufacturing support systems
The two categories overlap because manufacturing support systems are connected to
the factory manufacturing systems.

Automated Manufacturing Systems

Examples:
 Automated machine tools
 Transfer lines
 Automated assembly systems
 Industrial robots that perform processing or assembly operations
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  Automated material handling and storage systems to integrate manufacturing
operations
 Automatic inspection systems for quality control
Automation Defined
Automation is a technology concerned with the application of mechanical,
electronic, and computer-based systems to operate and control production.
This technology includes:
 Automatic machine tools to process parts
 Automatic assembly machines
 Industrial robots
 Automatic material handling and storage systems
 Automatic inspection systems for quality control
 Feedback control and computer process control
 Computer systems for planning, data collection, and decision making
to support manufacturing activities
TYPES OF AUTOMATION
Automated production systems are classified into three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation
Fixed automation
Fixed automation is a system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration. The
operations in the sequence are usually simple. It is the integration and
coordination of many such operations into one piece of equipment that
makes the system complex. The typical features of fixed automation are:
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product changes
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 the system can read and interpret them. New programs can be prepared and
entered into the equipment lo produce new products. Some of the features that
characterize programmable automation include:
 High investment in general-purpose equipment
 Low production rates relative to fixed automation
 Flexibility to deal with changes in product configuration
 Most suitable for batch production
Automated production systems that are programmable are used in low and medium
volume production. The parts or products are typically made in batches.
Flexible automation
Flexible automation is an extension of programmable automation. The
concept of flexible automation has developed only over the last 15 to 20
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years, and the principles are still evolving. A flexible automated system is
one that is capable of producing a variety of products (or parts) with virtually
no time lost for changeovers from one product to the next. There is no
production time lost while reprogramming the system and altering the
physical setup (tooling, fixtures and machine settings). Consequently, the
system can produce various combinations and schedules of products,
instead of requiring that they be made in separate batches.
The essential features that distinguish flexible automation from
programmable automation are (1) the capacity to change part programs with
no lost production time, and (2) the capability to change over the physical
setup, again with no lost production time.
Flexible Manufacturing Systems (FMS)
An FMS is a “reprogrammable” manufacturing system capable of producing a variety of
products automatically. Conventional manufacturing systems have been marked by
one of two distinct features:
 The capability of producing a variety of different product types, but at a high cost
(e.g., job shops).
 The capability of producing large volumes of a product at a lower cost, but very
inflexible in terms of the product types which can be produced (e.g., transfer
lines).An FMS is designed to provide both of these features.

FMS Applications
 Metal-cutting machining
 Metal forming
 Assembly
 Joining-welding (arc , spot)
 Surface treatment
 Inspection
 Testing
FMS Advantages
 To reduce set up and queue times
 Improve efficiency
 Reduce time for product
completion
 Utilize human workers better
 Improve product routing
 Produce a variety of Items under
one roof
 Improve product quality
 Serve a variety of vendors
simultaneously
 Produce more product more
quickly

Cellular Manufacturing
Process
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Concept of performing all of the necessary operations to make a component are
includes subassembly, or finished product in a work cell.
Basic assumption is that product or part families exist and that the combined volume of
products in the family justifies dedicating machines and workers to focused work-cells.
Basic building blocks of cells
 Workstations
 Machines
 Workers
 Tools, gages, and fixtures
 Materials storage
 Materials handling between work stations

Work Cell Applications

 Work cells are more applicable for products (subassemblies) that are not
extremely complex. Skills and abilities of the workers must fit the range of tasks
required.
 Large work cells have a negative impact on teamwork.
 A workgroup of between 5 and 7 people is optimal- cells with 10 or more work
stations are less common.
 If the products are very complex, a multi-station assembly line is typically used,
with work cells potentially acting as feeder cells.

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 Types of FMS
Kinds of operations -Processing vs. assembly
Type of processing
Number of machines (workstations):
Single machine cell (n= 1)
Flexible manufacturing cell (n= 2 or 3)
Flexible manufacturing system (n= 4 or more)

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 Five Types of FMS Layouts
The layout of the FMS is established by the material handling system
Five basic types of FMS layouts
 In-line
 Loop
 Ladder
 Open field
 Robot-centered cell

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CAD - computer aided design:- The use of computer methods to develop the geometric
model of the product in three-dimensional form, such that the geometric and
manufacturing requirements can be examined.
CADD - computer aided design and drafting:- Combining the CAD function with drafting
to generate the production drawings of the part for the purpose of downstream
processing.
CAE - computer aided engineering:- The use of computer methods to support basic
error checking, analysis, optimization, manufacturability, etc., of a product design.
CAM - computer aided manufacturing. Generally refers to the computer software used
to develop the Computer Numerical Control part programs for machining and other
processing applications.
CAPP - computer aided process planning. The use of computer to generate the process
plans for the complete manufacture of products and parts.
CAP - computer aided planning. The use of computer for many of the planning functions
such as material requirement planning, computer aided scheduling, etc.
CAQ – Computer Aided Quality assurance. The use of computers and computer
controlled equipment for assessing the inspection methods and developing the quality
control and assurance functions.
CAT – Computer aided testing refers to the software tools that can take a system
through its various phases of operations and examine the response against the
expected results.

LO3: Perform supervision of conventional and for CIM supported

production
CIM manufacturing:
Using ICTs ’to control the entire production process. It May include, but not limited to:
1. Computer-aided Design/Computer-aided Manufacturing
(CAD/CAM)
Computer-aided manufacturing (CAM) is the use of computer-based software tools
that assist engineers and machinists in manufacturing or prototyping product
components. CAM is a programming tool that allows you to manufacture physical
models using computer-aided design (CAD) programs. CAM creates real life versions of
components designed within a software package. CAM was first used in 1971 for car
body design and tooling.
 The effective use of computer technology in manufacturing planning and control
 Most closely associated with functions in manufacturing engineering, such as
process planning and NC part programming. CAM has been considered as an
NC programming tool wherein 3D models of components generated in CAD
software are used to generate CNC code to drive numerical controlled machine
tools.
 CAM functions have expanded to integrate CAM more fully with CAD/CAM/CAE
PLM solutions. CAM leverages the value of the most skilled manufacturing
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 professionals through advanced productivity tools, while building the skills of new
professionals through visualization, simulation and optimization tools.
CAM applications can be divided into two broad categories:
1. Manufacturing planning
2. Manufacturing control
CAM Applications in Manufacturing Planning
 Computer-aided process planning (CAPP)
 Computer-assisted NC part programming
 CAD/CAM assisted NC part programming
 Computerized machinability data systems
 Computerized work standards
 Cost estimating
 Production and inventory planning
 Computer-aided assembly line balancing

CAM Applications in Manufacturing Control

 Process monitoring and control
 Quality control
 Shop floor control
 Inventory control
 Just-in-time production systems

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 2. Computer Numerical Control (CNC) machine tools
CNC:- Computer numerical control (CNC) uses computer-controlled machines to
perform a series of operations over and over.
• Drilling, milling, and lathes are often controlled by CNC programming.
• CNC machines are reprogrammed to make different parts.
Advantages of CNC
 Increased Flexibility
 Greater Accuracy
 More Versatility

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 3. Automated Guided Vehicles (AGV)
AGV defined as an automatic guided vehicle system (AGVS) consists of one or more
computer-controlled, wheel-based load carriers (normally battery powered) that runs on
the plant or warehouse floor (or if outdoors on a paved area) without the need for an
onboard operator or driver. An automated guided vehicle or automatic guided vehicle
(AGV) is a mobile robot that follows markers or wires in the floor, or uses vision or
lasers. They are most often used in industrial applications to move materials around a
manufacturing facility or a warehouse.
The term "automated guided vehicle" (AGV) is a general one that encompasses all
transport systems capable of functioning without driver operation. The term "driverless"
is often used in the context of automatic guided vehicles to describe industrial trucks,
used primarily in manufacturing and distribution settings, that would conventionally have
been driver-operated.
A materials handling system that uses automated vehicles such as carts, pallets or trays
which are programmed to move between different manufacturing and warehouse
stations without a driver. These systems are used to increase efficiency, decrease
damage to goods and reduce overhead by limiting the number of employees required to
complete the job.
AGVs are sophisticated machines that represent a complete material handling solution and are
installed in numerous industries and a wide range of applications. AGVs can increase efficiency
and productivity as well as reduce product damage and labor costs.

Why are AGVs used?

 Replace manually operated material handling vehicles such as a lift truck
 Good response to labor shortages
 Allow employees to be reassigned to areas where they can add value to the
product
 Provide safe, efficient, cost-effective movement of materials
What types of AGVs are available?
 Masted vehicles – forked, clamp, single-double
 Unit Load – lift deck, conveyor
 Tow or Tuggers
 Carts
 Custom
What types of applications use AGVs?
Manufacturing
 Raw material handling
 Work-in-process movement
 Parts/Tooling delivery
 Finished goods movement
 Removal of waste to recycling
Warehousing/Distribution

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  Product storage and retrieval (block stack, in racking, etc.)
 Pallet handling
 Automatic truck/Trailer loading
 Material movement to support picking of mixed pallets

What are the parts of an AGV system? These are the most common pieces of an
AGV system:
 Vehicle
 Host software
 Wireless communication
 User interface
 Battery/Charger

PERFORMANCE ANALYSIS
Automated guided vehicle systems consist of the computer, software and technology that are the
―brains‖ behind the AGV. Without computer software systems and communications networks,
only the simplest AGV functions can be performed
The analysis of AGV systems is used to determine
 the number of AGV‘s required
 cycle times
 handling system efficiency
It is assumed that the vehicle operates at a constant speed of V.
The acceleration, deceleration and other effects that influence the speed are ignored.
The time for a typical delivery cycle in the operation of the vehicle includes
 loading at the pick up station
 unloading at the drop off stations
 travel time to the drop off station
 empty travel time of the vehicle between deliveries

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The analysis of AS/RS is used in order to determine the transaction cycle time.
The transaction cycle involves retrieval of load out of storage or delivery of a load in to
the storage or both of the activities in a single cycle.
The two types of transaction cycles are:
1. Single command cycle: It involves either retrieving a load from the storage or
entering a load into the storage but not both in a single cycle.
2. 2. Dual command cycle: It involves both entering a load into storage and retrieval
of the load from storage in the same cycle. It represents the most efficient way to
operate the AS/RS since two loads are handled in a single transaction.

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Quantitative Analysis

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Let us consider a retrieval cycle and the storage transaction is performed under the same assumption of
random storage would be equivalent to a retrieval transaction.
• The average distance that the carousel has to travel to move randomly located bin to the unload
station at the end of the carousel depends on whether the carousel revolves in only one or both
directions.
• For the single direction, the average travel distance is given by

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 3. Industrial Robotics and automated conveyance
Typical knowledgebase for the design and operation of robotics systems
 Dynamic system modeling and analysis
 Feedback control
 Sensors and signal conditioning
 Actuators (muscles) and power electronics
 Hardware/computer interfacing
 Computer programming
Mobile Robots
Mobile robots have wheels, legs, or other means to navigate around the
workspace under control. Mobile robots are applied as hospital helpmates,
vacuum cleaners, lawn mowers, among other possibilities. These robots
require good sensors to see the workspace, avoid collisions, and get the job
done.

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 Fixed v/s Mobile
Robotic manipulators used in manufacturing are examples of fixed robots. They can not
move their base away from the work being done.
Sensors
Human senses: sight, sound, touch, taste, and smell provide us vital information to
function and survive.
 Robot sensors: measure robot configuration/condition and its environment and
send such information to robot controller as electronic signals (e.g., arm position,
presence of toxic gas)
 Robots often need information that is beyond 5 human senses (e.g., ability to:
see in the dark, detect tiny amounts of invisible radiation, measure movement
that is too small or fast for the human eye to see)
Actuators/Muscles
Common robotic actuators utilize combinations of different electro-mechanical devices
 Synchronous motor
 Stepper motor
 AC servo motor
 Brushless DC servo motor
 Brushed DC servo motor
Controller
 Provide necessary intelligence to control the manipulator/mobile robot
 Process the sensory information and compute the control commands for the
actuators to carry out specified tasks
Storage Hardware
Storage devices: e.g., memory to store the control program and the state of the robot
system obtained from the sensors

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Industrial Applications of Robots
 Material handling
 Material transfer
 Machine loading and/or unloading
 Spot welding
 Continuous arc welding
 Spray coating
 Assembly
 Inspection

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Categories of Material Handling Equipment
 Material transport equipment - to move materials inside a factory, warehouse, or other
facility;
 Storage - to store materials and provide access to those materials when required;
 Unitizing equipment - refers to (1) containers to hold materials, and (2) equipment used
to load and package the containers;
 Identification and tracking systems - to identify and keep track of the materials being
moved and stored.
In other word there are four main categories of material handling equipment include: storage,
engineered systems, industrial trucks and bulk material handling.

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Other types of engineered systems include:
 Conveyor systems
 Robotic delivery systems
 Automatic guided vehicles (AGV)

Industrial Trucks:- Industrial trucks refer to the different kinds of transportation items and
vehicles used to move materials and products in materials handling. It include small hand-
operated trucks, pallet-jacks, and various kinds of forklifts.
There are many types of
industrial trucks:
• Hand trucks
• Pallet jacks
• Pallet trucks
• Walkie Truck
• Platform trucks
• Order picker
• Side loader
• Many types of AGV

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The Range and Scope of Computers within Manufacturing
Within any modern manufacturing organization, computers may be used at a number of
different levels, including:
 Management / Financial Information Systems
 Production and Inventory Control / MRP / MRPII
 Software Simulation • Computer Aided Process Planning
 Computer Aided Design and Drafting
 Control of Automated Mechanisms (Programmable Logic)
 Data-acquisition
 Machine Control Systems (Computer Numerical Control)
 Robot Control • Continuous Chemical Process Control
 Production Line Control (In-line Transfer Machines)
 Flexible Manufacturing System Control.
Programmable Logic Controllers
(PLCs) are perhaps the most prolific of all modern industrial control systems. They are
used for a wide range of applications and are very diverse in their capabilities.
Multiple Axis Motion Controllers (CNC and Robotics)
Many machines and devices within manufacturing consist of little more than a number
of servo-motor driven axes, which are used to either position an end-effector (tool) or a
work-piece so that the work-piece can be either moved, machined or processed. The
most common examples of this are Computer Numerical Control (CNC) machine tools
and robots.
Linking Computer Aided Design to Manufacture
Complex CNC machine programs are seldom developed on the machines themselves.
They are either developed off-line on a PC based, ASCII word processor or on some
form of Computer Aided Design system. In either event it is necessary to down-load the
CNC programs, developed on a remote (host) computer system to the CNC machine.

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 Communication - Protocol
Internal data communication within a single computer system is very well coordinated
and synchronized. Devices are specially selected and integrated into a system to
perform in a unified and ordered manner. Regardless of the autonomy of any one
device or chip, within a computer system, a Central Processing Unit (microprocessor or
processor board) is responsible for supervising the activities of all other devices.

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 Parallel Data Transmission and Communications Ports
Data within a computer system is transferred in a "bit-parallel" manner. This means that
all the binary digits (which together represent a basic unit of computer information) are
essentially transmitted at the same time and received at the same time. If the basic
internal unit of computer information is say, an 8-bit byte, then at least 8 conductors are
required to link the two devices for "bit-parallel" operation.

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 LO4: Assure quality production process
Definition of Key Terms
Term Meaning
Quality Conformance to requirements
Quality ‘A part of quality management focused on fulfilling quality requirements’
Control A corrective tool focused on the quality of output.
(QC) Example: Validation/product testing, inspection, peer reviews.
Quality A part of quality management focused on providing confidence that
Assurance quality requirements will be fulfilled’
(QA) A managerial tool focused on the process of quality
Example: Verification activities, process checklists, project audits and
methodology and standards development.
Quality Management activities and functions involved in determination of quality
Manageme policy and its implementation through means such as quality planning,
nt quality assurance and quality control)
Quality A system comprised of quality planning and quality improvement
Manageme activities, the establishment of a set of quality policies and objectives that
nt System will act as guidelines within an organization, and QA and QC.
Process Any activity or set of activities that uses resources to transform inputs
into outputs
Procedure An outline of how to perform a process e.g. ‘Purchasing’
Work Description of how to perform a task which is a more detailed portion of
Instruction the procedure e.g. ‘Completing a Purchase Order’
4.1. ISO 9001
It is a quality management model that can be adopted by any kind of organization. The
system is focused towards the meeting of customer requirements and enhancing of
customer satisfaction. The ISO 9001 management system standard makes these
successful practices available for all organizations large and small.
The ISO 9001 Standard is a powerful business improvement tool, providing the
framework and guidance you need to help you consistently meet your customer’s
expectations and regulatory requirements.
ISO 9001 is an International Standard that is used worldwide by over one million
organizations. It assists businesses of all sizes by providing best practice requirements
for an effective Quality Management System (QMS). A quality management system
enables a business to run more efficiently and profitably.
The current version of the ISO 9001 standard is 9001:2015.

The standard is used by organizations to demonstrate their ability to consistently

provide products and services that meet customer and regulatory requirements and to
demonstrate continuous improvement.

Keywords:
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1. Quality
2. Management system
3. Customer requirements
4. Customer satisfaction
4.2. ISO 14001
The ISO 14001 Standard will help you quantify, monitor and control the ongoing
environmental impact of your operations. By managing the use of natural resources,
energy and waste you can improve your corporate image and credibility, helping you to
win new customers as well as identify opportunities for cost savings.
Occupational Health & Safety
Gaining the ISO 45001 certification allows you to demonstrate that your business
operates a best-practice Occupational Health and Safety Management System –
reducing the likelihood of accidents and breaches of legislation, as well as improving
your organization’s overall performance.
ISO 14001 is a globally recognized standard for an environmental management system
(EMS). This standard defines the requirements for controlling and improving the
organization’s environmental impact. The standard was first implemented by the
organizations in 1996. The ISO 14001 standard recommends controls for those
processes that have an environmental impact. E.g. Use of environment resources,
environmental waste management & energy consumption.
Purpose of ISO 14001
The main purpose of ISO 14001 is to define the requirements for the EMS and provides
guidance for its implementation. The standard gives a structured activity for making
environmental improvements in the organization.
The ISO 14001 environmental management systems standard contains the
following key elements:
 Environmental policy;
 Planning;
 Implementation and Operation;
 Checking and Corrective Action.
 Management review.

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