Introduction

▪ Production Systems
▪ Automation in Production Systems
▪ Manual Labor in Production Systems
▪ Automation Principles and Strategies

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing

Manufacturing ➔ manus (hand) + factus (make)

➔ made by hand

Ever-changing Scenarios

Small shops ➔ Factories

Handicraft techniques ➔ Machines
Workers see the entire product ➔ Specialization

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The Realities of Modern Manufacturing

▪ Globalization
▪ International outsourcing
▪ Local outsourcing
▪ Contract manufacturing
▪ Trend toward the service sector
▪ Quality expectations
▪ Need for operational efficiency

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Modern Manufacturing Approaches and
Technologies
▪ Automation - automated equipment instead of labor
(reduces labor cost, decreases production cycle times,
increases product quality and consistency)

▪ Material handling technologies - manufacturing usually

involves a sequence of activities; material handling
provides transportation, storage and tracking of
materials through the plant

▪ Manufacturing systems - integration and coordination

of multiple automated or manual workstations through
material handling technologies

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Modern Manufacturing Approaches and
Technologies

▪ Flexible manufacturing - to compete in the low-

volume/high-mix product categories

▪ Quality programs - to achieve the high quality expected

by today's customers

▪ Computer Integrated Manufacturing (CIM) - to integrate

design, production, and logistics

▪ Lean production - more work with fewer resources

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Production System Defined
“A collection of people, equipment, and procedures
organized to accomplish the manufacturing operations of
a company”

Two categories:
▪ Facilities – the factory and equipment in the facility and
the way the facility is organized (plant layout)

▪ Manufacturing support systems – the set of procedures

used by a company to manage production and to solve
technical and logistics problems in ordering materials,
moving work through the factory, and ensuring that
products meet quality standards
Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The Production System

White collar

Blue collar

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Facilities
Facilities include the factory, production machines and
tooling, material handling equipment, inspection
equipment, and computer systems that control the
manufacturing operations

▪ Plant layout – the way the equipment is physically

arranged in the factory

▪ Manufacturing systems – logical groupings of

equipment and workers in the factory
▪ Production line
▪ Stand-alone workstation and worker
Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Systems

1. Manual work systems - a worker performing one or

more tasks without the aid of powered tools, but
sometimes using hand tools

2. Worker-machine systems - a worker operating

powered equipment

3. Automated systems - a process performed by a

machine without direct participation of a human

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manual Work System

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Worker-Machine System

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated System

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated System

▪ A semi-automated machine performs a portion of the work

cycle under some form of program control, and a human
worker tends to the machine for the remainder of the
cycle, by unloading and loading it, or performing some
other task each cycle.

▪ A fully automated machine has the capacity to operate for

extended periods of time with no human attention.

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Support Systems

“People and procedures by which a company manages

its production Operations”

▪ Design the process and equipment

▪ Plan and control the production orders

▪ Satisfy product quality requirements

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Information Processing Cycle in Manufacturing Support
Systems

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Support Systems
Business functions – principal means of communicating with
customer
Sales and marketing, sales forecasting, order entry, cost
accounting, customer billing

The production order will be in one of the following

forms:
1. an order to manufacture an item to the
customer’s specifications
2. a customer order to buy manufacturer’s product
3. an internal company order based on a forecast
of future demand
Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Support Systems

• Product design - research and development,

design engineering, prototype shop

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Support Systems

Manufacturing planning – the information and

documentation that constitute the product design
flows into the manufacturing planning function

• Process planning
• Master Production Schedule (MPS)
• Materials Requirement Planning (MRP)
• Capacity planning is concerned with manpower
and machine resources of the firm

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manufacturing Support Systems
Manufacturing control – concerned with managing and
controlling the physical operations in the factory to
implement the manufacturing plans

• Shop floor control deals with the problem of controlling the

progress of the product as it is being processed, assembled,
moved, and inspected in the factory

• Inventory control

• Quality control

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation in Production Systems

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
▪ Computer-Integrated Manufacturing (CIM)

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Computer Integrated Manufacturing

Opportunities for automation and computerization in a

production system

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated Manufacturing Systems

▪ Processing
▪ Assembly
▪ Inspection
▪ Material handling

They are called automated because they perform their

operations with a reduced level of human
participation compared with the corresponding
process (sometimes virtually no human participation)

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated Manufacturing Systems: Examples

▪ Automated machine tools

▪ Transfer lines
▪ Automated assembly systems
▪ Industrial robots that perform processing or
assembly operations
▪ Automated material handling and storage systems to
integrate manufacturing operations
▪ Automatic inspection systems for quality control

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automated Manufacturing Systems

▪ Fixed automation

▪ Programmable automation

▪ Flexible automation

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Fixed Automation

“A manufacturing system in which the sequence of

processing (or assembly) operations is fixed by the
equipment configuration”

▪ Suited to high production quantities

▪ High initial investment for custom-engineered
equipment
▪ High production rates
▪ Relatively inflexible in accommodating product variety

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Fixed Automation

The economic justification for fixed automation is

found in products that are produced in very large
quantities

Examples
▪ Transfer lines
▪ Automated assembly lines

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Programmable Automation
“A manufacturing system designed with the capability
to change the sequence of operations to
accommodate different product configurations”

Typical features:
▪ High investment in general purpose equipment
▪ Lower production rates than fixed automation
▪ Flexibility to deal with variations and changes in
product configuration
▪ Most suitable for batch production
▪ Physical setup and part program must be changed
between jobs (batches)

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Programmable Automation

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

equipment to produce new products.

▪ Numerically controlled (NC) machine tools

▪ Industrial robots
▪ Programmable logic controllers

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Flexible Automation

“An extension of programmable automation in which the

system is capable of changing over from one job to the
next with no lost time between jobs”

Typical features:
▪ High investment for custom-engineered system
▪ Continuous production of variable mixes of products
▪ Medium production rates
▪ Flexibility to deal with soft product variety

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Product Variety and Production Quantity for Three
Automation Types

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Computerized Manufacturing Support Systems
Objectives of automating the manufacturing support systems:

▪ To reduce the amount of manual and clerical effort in

product design, manufacturing planning and control,
and the business functions

▪ Integrates computer-aided design (CAD) and computer-

aided manufacturing (CAM) in CAD/CAM

▪ CIM includes CAD/CAM and the business functions of

the firm

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Reasons for Automation

▪ To increase labor productivity

▪ greater output per hour of labor
▪ To reduce labor cost
▪ To mitigate the effects of labor shortages
▪ To reduce or remove routine manual and clerical tasks
▪ To improve worker safety
▪ To improve product quality
▪ To reduce manufacturing lead time
▪ To accomplish what cannot be done manually
▪ To avoid the high cost of not automating

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manual Labor in Production Systems

Is there a place for manual labor in the modern

production system?
▪ Answer: YES

▪ Two aspects:
▪ Manual labor in factory operations
▪ Labor in manufacturing support systems

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Manual Labor in Factory Operations
The long-term trend is toward greater use of automated
systems to substitute for manual labor

▪ When is manual labor justified?

▪ Some countries have very low labor rates and
automation cannot be justified
▪ Task is too technologically difficult to automate
▪ Short product life cycle
▪ Customized product requires human flexibility
▪ To cope with ups and downs in demand
▪ To reduce risk of product failure

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Labor in Manufacturing Support Systems

▪ Product designers who bring creativity to the design task

▪ Manufacturing engineers who
▪ Design the production equipment and tooling, and
▪ Plan the production methods and routings
▪ Equipment maintenance
▪ Programming and computer operation
▪ Engineering project work
▪ Plant management

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation Principles and Strategies

Automation is not always the right answer for a given

production situation.

▪ The USA Principle

▪ Ten Strategies for Automation and Process
Improvement
▪ Automation Migration Strategy

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
U.S.A Principle
▪ Understand the existing process
▪ Input/output analysis/what happens in between etc
▪ Value chain analysis
▪ Charting techniques and mathematical modeling
▪ Simplify the process
▪ Reduce unnecessary steps and moves
▪ Automate the process
▪ Ten strategies for automation and production
systems
▪ Automation migration strategy

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Operation Chart

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Flow Process Chart

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 Ten Strategies for Automation and Process
Improvement

If automation seems a feasible solution, then the following ten strategies

provide a road map.

1. Specialization of operations: The use of special-purpose

equipment designed to perform one operation with the greatest
possible efficiency.

2. Combined operations: Involves reducing the number of distinct

production machines or workstations through which the part must be
routed. Saves setup, material handling effort, waiting time, lead time.

3. Simultaneous operations: Reduces total processing time.

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Ten Strategies for Automation and Process
Improvement
4. Integration of operations: Linking several workstations together
into a single integrated mechanism, using automated work
handling devices to transfer parts between stations.

5. Increased flexibility: Attempts to achieve maximum utilization of

equipment for job-shop and medium-volume situations by using
the same equipment for a variety of parts or products (reduce
setup and programming time).

6. Improved material handling and storage: Reduces WIP and

shortens manufacturing lead time.

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Ten Strategies for Automation and Process
Improvement

7. On-line inspection: Permits corrections to the process as the

product is being made (reduces scrap, improves quality)

8. Process control and optimization: Control at process/machine

level

9. Plant operations control: Control at plant level

10. Computer-integrated manufacturing: Integration of factory

operations with design and the business functions.

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation Migration Strategy For Introduction of
New Products
A formalized plan for evolving the manufacturing systems used to
produce new products as demand grows.
1. Phase 1 – Manual production
▪ Single-station manned cells working independently
▪ Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
▪ Single-station automated cells operating independently
▪ As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
▪ Multi-station system with serial operations and automated
transfer of work units between stations

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Automation
Migration
Strategy

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Summary

Automation, Production Systems and Computer-integrated Manufacturing, M. P. Groover, PHI; ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.