Transcript Manual Assembly Lines

AUTOMATION IN MANUFACTURING
Foo Jin Hoe, PhD.
[email protected]
C23-408
+6(07)-5534703
Foo Jin Hoe, PhD.
Certificate in Laboratory Testing (ILPP) - 1995
Advanced Diploma in Manufacturing Eng.
(RMIT, Australia) - 1998
B.Eng (Hons.) in Manufacturing Eng. (Coventry University,
UK) - 2000
M.Sc (Merit.) in Eng Management & Manufacturing.
(Coventry University, UK) - 2002
PhD Nanocomposite Material (Shibaura Institute of
Technology, Japan) - 2013
“Automation can be defined as a
technology concerned with the
application of electronic, mechanical
and computer- based systems to
operate and control the production”.
Automation
“To perform a task ,without
human intervention to improve
the productivity and quality”.
CNC Machines, Automated guided
vehicles, robots etc……
Reasons for automation
1. To Increase labor productivity.
2. To reduce labor cost.
3. To mitigate the effects of labor shortages.
4. To reduce or eliminate routine manual and clerical tasks.
5. To improve worker safety.
6. To improve product quality
7. To reduce manufacturing lead time.
8. To accomplish processes that cannot be done manually.
Production Systems
- That are used to manufacture products and the parts assembled
into those products.
- Production system is the collection of people equipment and
procedures organized to accomplish the manufacturing
process of a company.
Production systems can be devided in two categories
Manufacturing support systems
Facilities :
Factory Equipment
Facilities
•The facilities of the production consist of the factory, the equipment in
the factory and the way the equipment is organized.
Hard product
-The variety between different product categories
Soft product
-The variety between different models within the same product categories
a)
b)
c)
d)
Fixed-position layout
Process layout
Cellular layout
Product layout
Various types of plant layout
Fixed-position layout : Workers and processing equipment are
brought to the product, rather than moving the product to the
equipment .This type of layout referred to as fixed-position layout.
Process layout: The individual parts that comprise these large
products are often made in factories that have a process layout.
 Cellular layout: The term cellular manufacturing often
associated with this type of production. 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.
 Product layout: The collection of stations is designed
specifically for the product to maximize efficiency.
Types of facilities and layouts used for different levels of
production quantity and product variety
Automation Principles and Strategies
 Automation is not always the right answer for a given
production situation. A certain caution and respect must be
observed in applying automation technologies.
 Three approaches for dealing with automation projects
1. USA Principle
2. Ten Strategies for Automation and Production Systems
3. Automation Migration Strategy
USA Principle
1. Understand the existing process
2. Simplify the process
3. Automate the process
USA approach is applicable to nearly any automation project
 Understand the existing process
The first step in the USA approach is to comprehend the current
process in all of its details.
* What are the inputs? What are the outputs ?
* What exactly happens to the work unit between input and
output?
* What is the function of process?
* How does it add value to the product?
* What are the upstream and downstream operations in the
product sequence, and can they be combined with the process
under consideration?.
 Simplify
the process
*Once the existing process is understood, then the search can
began for ways to simplify. This often involves a checklist of
questions about the existing process.
Unnecessary steps can be eliminated without detracting from the
function.
 Automate
the process
*Once the process has been reduced to its simplest form
then automation considered. The possible form of
automation include those listed in the ten strategies.
Ten Strategies for Automation and Production
Systems
 Automation seems a feasible solution to improving
productivity, quality, or other measure of performance then
the following ten strategies for these improvements
discussed.
1. Specialization of operations: The first strategy involves
the use of special-purpose equipment designed to perform
one operation with the greatest possible efficiency. This is
analogous to the concept of labor specialization. Which is
employed to improve labor productivity.
2. Combined operations: Production occurs as a sequence of
operations. Complex parts may require dozens, or even
hundreds, of processing steps. The strategy of combined
operations involves reducing the number of distinct
production machines or work stations.
3. Simultaneous operations: A logical extension of the combined
operations strategy is to simultaneously perform the operations
that are combined at one work-stations. In effect two or more
processing (assembly) operations are being performed
simultaneously on the same work part.
4. Integration of operations: Another strategy is to link several
work stations together into a single mechanism, using automated
work handling devices to transfer parts between stations.
5. Increased flexibility: This strategy attempts to achieve maximum
utilization of equipment for job shop and medium value situations
by using the same equipment for a variety of parts or products.
6. Improved material handling and storage: A great opportunity
for reducing non-productive time exists in the use of automated
material handling and storage systems.
7. On-line inspection: Inspection for quality of work is traditionally
performed after the process is completed. This means that any
poor-quality product has already been produced by the time it is
inspected.
8. Process control and optimization: Manual control to automated
control by optimization we can give the best parameters. Then
the individual process can be reduced.
9. Plant operation control: Those which are not related fabrication
process, each division specify automate. Business functions,
product design.
10. Computer- integrated manufacturing: Input from market
delivery to the final customer every operation is integrated to the
computer. Business functions, product design etc…..
Automation Migration strategy
Owing the competitive pressures in the marketplace,
often needs to introduce a new product in the shortest
possible time. A typical automated strategy is shown.
Phase 1: Manual production using single station manned
cells operating independently.
Phase 2: Automated production using single station
automated cells operating independently.
Phase 3: Automated integrated production using a multi
station automated system with serial operations and
automated transfer of work units between stations.
A typical automation migration strategy
Manual Assembly Lines
-Most manufactured consumer products are assembled. Each product
consists of multiple components joined together by various assembly
processes. These kinds of products usually made on a manual assembly
Line. Factors favoring the use of manual assembly lines include the
following.
 Demand for the product is high or medium .
 The products made on the line are identical or similar
 The total work required to assemble the product can be
divided into small work elements.
 It is technologically impossible or economically infeasible
to automate the assembly operations.
Configuration of a production line
A manual assembly line is a production line that consists of a
Sequence of workstations where the assembly tasks are performed
by human workers. Products are assembled as they move along the
line. At each station, a portion of the total work is performed on each
Unit.
Products usually made on Manual Assembly Lines
Audio equipment
Automobiles
Cameras
Cooking ranges
Dishwashers
Dryers
Electric motors
Lamps
Refrigerators
Luggage
Stoves
Microwave ovens
Telephones
Personal computers and
Toasters
peripherals
Toaster ovens
Power tools(saws, drills etc) Video cassette
Pumps
Washing machines
Manual Assembly Lines are so productive
compared with alternative methods.
 Specialization of labor: Called “Division of labor”, this
principle asserts that when a large job is divided into
small tasks and each task is assigned to one worker,
the worker becomes a specialist.
 Interchangeable parts: In which each component is
manufactured to sufficiently close tolerances that any
part of a certain type can be selected for assembly with
its mating component. Without interchangeable parts
assembly would require filing and fitting of mating
components.
 Work principle, in material handling, which provides
that each work unit flows smoothly through the
production line , traveling minimum distances
between stations.
 Line pacing: Workers on an assembly line are usually
required to complete their assigned tasks on each
product unit within a certain cycle time, which paces
the line to maintain a specified production rate.
Fundamentals of Manual Assembly Lines
A manual assembly line is a production line that consists of
Sequence of workstations where assembly tasks are performed
by human workers. Products are assembled as they move along the
line. At each station a portion of the total work is performed on each
unit. Base parts onto the beginning of the line at regular intervals. Each
base part travels through successive stations and workers and componen
through progressively build the product.
1. Assembly workstations
2. Work transport system
3. Line pacing
Assembly Workstations
A workstation on a manual assembly line is a designated location along
The workflow path at which one or more work elements are performed
By one or more workers. The work elements represent small portions of
the total work that must be accomplish to assemble the product.
Some Workstations are designed for workers to stand, while other allow th
workers to sit. When the workers stand, they can move about the station
Area to perform their assigned task. Example like cars, trucks……
The typical case is when the product is move by a conveyor at constant
Velocity through the station. The worker begins the assembly task near
the upstream side of the station an moves along with the work until the
task is completed, The walks back to the next work unit an repeats the
cycle. For smaller assembled products such as small appliances,
Electronic devices an subassemblies used on larger products. T he workers
To sit.
Typical Assembly Operations performed on a
Manual Assembly Lines
Application of adhesive
Arc welding
Brazing
Cotter pin applications
Expansion fitting applications
Insertion of components
Press fitting
Riveting
Shrink fitting applications
Soldering
Spot welding
Stapling
Stitching
Threaded fastener applications
For a manual assembly line, the manning level of work station i=1,2…n
And n= number of workstations on the line. The generic case is one
worker Mi=1.
In cases where the product is large such as car or a truck, multiple
workers are often assigned one station, so that Mi>1.
Multiple manning conserves valuable floor space in the factory and
reduces line length and throughput time because fewer work stations are
required. The average manning level of a manual assembly line is simply
the total number of workers on the line divided by the number of
stations. That is
M= w
n
Where M=average manning level of the line (workers/station)
W= number of workers on the line
n= number of workstations on the line
Manual assembly lines often include more workers than
those assigned to stations, so that M is not a simple average of
Mi values. These additional workers called utility workers, are
not assigned to specific workstations; instead they are
responsible for functions such as
1) Helping workers who fall behind, 2) relieving workers for
personal breaks, and 3) Maintenance and repair duties.
Including the worker count we have
M = wu+∑ wi (where i= 1 to n)
n
Where wu = number of utility workers assigned to the system
wi= number of workers assigned specifically to station i for i= 1,2,….n
Work Transport Systems
There are two basic ways to accomplish the movement of work
units along a manual assembly line
1) manually or
2) by a mechanized system.
Both methods provide the fixed routing (all work units proceed through
the same sequence of stations) that is characteristic of production lines.
Manual Methods of Work Transport: In manual work transport, the
units of product are passed from station-to-station by hand. Two
problems result from this mode of operation: Starving and blocking.
Starving is the situation in which the assembly operator has completed
the assigned task on the current work unit, but the next unit has not yet
arrived at the station. The worker is starved for the work.
When a station is blocked, it means that the operator has competed
the assigned task on the current work unit but cannot pass the unit
to the downstream station because that worker is not yet ready to
receive it. The operator is therefore blocked from working.
To mitigate the effects of these problems, storage buffers are
sometimes used between stations. In some cases, the work units
made at each station are collected in batches and then moved to the
next station. In other cases work units are moved individually along
a flat table or un powered conveyor.
Mechanized Work Transport
Powered conveyors and other types of mechanized material handling
equipment are widely used to move along units along a manual
assembly line. These systems can be designed to provide paced or
un paced operation of the line. Three major categories of work transport
System in production line.
a) Continuous transport
b) Synchronous transport
c) Asynchronous transport
Velocity-distance diagram and physical layout for three types of
Mechanized transport systems used in production lines
a) Continuous transport b) Synchronous transport c) asynchronous transpo
Introduction to Material Handling
Material handling is defined by the Material Handling
Industry of America as
“ the movement, storage,
protection and control of materials throughout the
manufacturing and distribution process including their
consumption and disposal”.

The handling of materials must be performed safely,
efficiently, at low cost, in a timely manner, accurately and
without damage to the materials.

( the right materials in the right quantities to the right
locations)
Material handling in the production system
 This cost of material handling is a significant portion of
total production cost, estimates averaging around 20 – 25
% of total manufacturing labor cost in the united states.
The proportion may varies , depending on the type of
production and degree of automation in the material
handling function.
 Some material handling devices are
- pallet shuttles in NC machining centers
- Conveyors in manual assembly lines
- transfer mechanisms in automated transfer lines
- parts feeding devices in automated assembly
Overview of Material Handling Equipment
 Material handling equipment is available commercially
1. Transport equipment
2. Storage systems
3. Unitizing equipment
4. Identification and tracking systems
Material Transport Equipment
 Material transport includes equipment that is used to move
materials inside a factory, ware house, or other facility. This
equipment can be divided into the following five categories
1. Industrial trucks: Industrial trucks divided into two types
powered and non-powered.
Non-powered trucks are platforms or containers with wheels
that are pushed or pulled by human workers to move the
materials.
Powered industrial trucks are steered by human workers.
They provide mechanized movement of materials.
2. Automated guided vehicles (AGVs): AGVs are battery –
powered, automatically steered vehicles that follow defined
pathways in the floor. AGVs are used to move unit loads
between load and unload stations in the facility. Routing
variations are possible ( Different loads move between different
stations)
3. Monorails and other rail guided vehicles: These are selfpropelled vehicles that ride on a fixed rail system . The vehicles
operate independently and are usually driven by electric
motors that pick up power from an electrified rail.
Routing variations are possible
4. Conveyors: Conveyors constitute a large family of material
Transport equipment that are designed to move materials over
fixed paths, generally in large volumes.
Powered conveyors roller, belt and tow-line and non-powered
by human workers
 5. Cranes and hoists: These are handling devices for
lifting , lowering, and transporting materials, often as
very heavy loads. Hoists accomplish vertical lifting.
Both manually operated and powered types are
available. Cranes provide horizontal travel and
generally include hoists.
a) Fork lift truck, industrial truck b) unit load automated guided vehicle
c) Monorail d) roller conveyor e) jib crane with hoist
Storage systems: It is generally desirable to reduce the storage of
materials in manufacturing, it seems unavoidable that raw
materials and work-in process will spend sometime being stored,
even if only temporarily. And finished products are likely to spend
sometime in a ware house or distribution center before being
delivered to the final customer.
Storage methods and equipment can be classified as follows
a) Bulk storage: It consists of simply storing materials in an open
floor area, generally in pallets or containers. It requires little or no
storage equipment
b) rack systems: These are structural frames designed to stack
unit loads vertically, thus increasing the vertical storage efficiency
compared to bulk storage
c) Shelving and bins: Steel shelving comes in standard widths,
depths, and heights to serve a variety of storage requirements.
Shelves can include bins, which are containers for loose items.
 d) Drawer storage: This storage medium is more costly than
shelves, but is more convenient. Finding items stored in shelves
can be difficult if the shelf level is too high or too low or too
deep. It is generally used for tools, hardware and other small
items.
 e) Automated storage systems: Automated and semi automated
systems are available to deposit and withdraw items into and
from the storage compartments.
There are two basic types: automated storage or retrieval systems:
consists of rack and shelf systems 2) Carousel systems that rotate
storage bins past a stationary load or unload station.
Unitizing equipment:
 It refers to 1) containers used to hold individual items
during handling 2) equipment used to load and
package the containers. Containers include pallets,
boxes, baskets, barrels, and drums.
 Identification and tracking systems: Material
handling must include a means of keeping track of the
materials being moved or stored. We assign label to
the item.
Examples of unit load containers for material handling
a) Wooden pallet b) pallet box and c) tote box
The 10 Principles in Material Handling
The 10 principles of material handling are explained below.
Implementing these principles will result in safer operating conditions
lower costs, and better utilization and performance of material handling
systems.
The unit load principles stands as one of the most important and widely
applied principle in material handling. In material handling, a unit load is
Simply the mass that is to be moved or otherwise handled at one time.
There are good reasons for using unit loads in material handling
1) Multiple items can be handled simultaneously
2) The required number of trips is reduced
3) Loading and unloading times are reduced
4) Product damage is decreased. These reasons result in lower cost
and higher operating efficiency.
Principle 1. PLANNING PRINCIPLE: All the material handling should
be the result of a deliberate plan where the needs, performance objectives
And functional specification of the proposed methods are completely
Defined at the outset.
Principle 2. STANDARDIZATION PRINCIPLE: Material handling
Methods, equipment, controls, and software should be standardized .It
means less variety and customization in the methods and equipment
employed.
Principle 3. WORK PRINCIPLE: Material handling work should be
minimized without sacrificing productivity or the level of service
required of the operation
Simplifying the processes by reducing, combining, shortening, or
eliminating unnecessary steps will reduce work.
Principle 4. ERGONOMIC PRINCIPLE: Human capabilities and
limitations must be recognized and respected in the design of material
handling tasks and equipment to ensure safe and effective operations.
Principle 5. UNIT LOAD PRINCIPLE: A unit load is one that can be
stored or moved as a single entity at one time, such as pallet, container
totes etc..
Less effort and work are required to collect and move many individual
items as a single load than to move many items one at a time.
Principle 6. SPACE UTILIZATION PRINCIPLE: Effective and efficien
use must be made of all available space
Space in material handling is three –dimensional and therefore is counte
Cubic space.
 Principle 7. SYSTEM PRINCIPLE: Material movement
and storage
activities should be fully integrated to form a co-ordinate ( receiving,
inspection, storage, production, assembly etc.)
 Principle 8. AUTOMATION PRINCIPLE: Material handling operations
should be mechanized and or automated to improve the operating
efficiency, increase responsiveness , decrease cost etc..
Principle 9. ENVIRONMENTAL PRINCIPLE: Environmental impact and
energy consumption should be considered as criteria.
Principle 10. LIFE CYCLE COST PRINCIPLE: Economic analysis should
account for the entire life cycle of all material handling equipment.
Applications of five categories of material handling equipment
Material Handling equipment
Features
Applications
Industrial trucks, manual
Low cost
Moving light loads
in a factory
Industrial trucks, powered
Medium cost
AGV’S
High cost,
Movement of pallet
loads
Movement of pallet
loads
Moving single produc
assemblies
Monorails and other rail
Guided vehicles
High cost,
Flexible routing
Conveyors, powered
Variety of equipment Moving product
along assembly li
Industrial trucks:
Opening Windchill PDMLink
Browser based and web
style navigation
Windchill PDMLink Home page
Personalized Product
Workspace with information on
assigned user activities
Subscription provides
notifications of actions
that modify parts and
documents
Creation of Organization
Creation of Organization Administrator
Creation of Users
Creation of Groups
Adding Users to Group
Creation of Libraries & Products
* Creation of Libraries
Creation of Roles for Libraries & Products
Customization of PDM software
• Creation of Attributes
• Creation of Document Type.
• Creation Life Cycle.
• Creation Of Workflow.
• Creating Access Permissions.
• Creation of Folders.
Creation of Attributes
An attribute represents a characteristic of an
object, such as a part. Examples of attributes
are part number, page count, length, and fax
number.
Creation of Attributes
* Creation of Attribute Organizer
Creation of Attributes
* Creation of Attribute
Creation of Document Types
The Type Manager allows us to create new
subtypes of parts, documents, change
objects (all of which are modeled, or hard
types) and types created using the Type
Manager (soft types).
Creation of Document Types
Creation of Document Types
* Adding Attributes Type
Creation of Document Types
DWG
Fixture
My Test
Document
Design Document
Reference
Document
Creation of Workflows
Workflow is an E-mail System Which can
used to transfer the data through out the
enterprise securely.
Creation of Workflows
Creation of Workflows
Creation of Workflows
Creation of Workflows
* Fixture Drawing Workflow
Creation of Lifecycles
Life cycle is an automated, graphical model,
which employs phases and gates to manage
business objects as they progress from
conceptualization through obsolescence.
Creation of Lifecycles
* Process DWG Lifecycle
Creation of Lifecycles
* Fixture Drawing Lifecycle
* Assigning Life Cycle to a Type
Creation of Access Controls
 Policy Administrator
Policy Administrator is used to manage
administrative domains and the access
control, indexing, and notification policies for
those domains.
Creation of Access Controls
Uploading Pro-E drawing directly in
Windchill PDMLink
Creating a Document under Library tab:
Creating a Document under Library tab
Creation of Reports
A Report is the output of a predefined
search and is used for generating
statistics and metrics against business
information.
Creation of Reports