Manufacturing Automation

MAE 464-564

Course requirements

• Lecture classes– Mid term and final exam

• Laboratory exercise– Robotics – PLC Two projects– CNC Programing

• One research oriented paper for Grad. students

Announcements

• Interactive class - Unique opportunities

• Discussions - One topic every two weeks– Respond to it actively

• Resources and sites– Research projects and Other organizations

• http://wings.buffalo.edu/academic/department/eng/mae/460-564/

Manufacturing

Changing raw material finish product

Flow of material, energy, information

Proceses that added value

Conceptual design into a real product

What is manufacturing?

• Conversion of raw material to end product

• Adding value

• Improvisation, innovation, solving problem,

• Process of Man, material and machine o get a product

• Time to market

• Processes

• Supply chain

• Need or want

• Customer sastisfaction

What is Manufacturing

Manufacturing

A series of interrelated activities and operations involving design, material selection, planning, production, quality assurance, management, and marketing of discrete consumer and durable goods.

Manufacturing is a Systematic process of converting raw materials to its value added form

• Robots • Production line• Least human intervention• Conveyors• AGVs, MH • Timely process• Control of processes – • Repetitive processes• Computers – Quality, motions, engineering, • Feedback and adaptive systems imrove• Cell, FMS, DNC, lines, • Efficiency, optimization, cost, effectiveness• Customization vs mass production.

Types of manufacturing

• Process (continuous) type– steel, glass, chemical, semi-conductors– High degree of automation

• Part discrete type– individual parts are made– Quite often complex assembly is required– Mechanical, electromechanical and electronic

Software or systems?

Manufacturing Automation

• Organized and Systematic method of increasing the productivity and reducing the product development cycle.

History of Automation

• When did automation start ?– CAM based machines were used in 1930 and 40s– Multiple head turning and milling– Flow line assembly with several repetitive

machines– Electronic controller– PLCs and computer– CNC machines, CAD, FMA cellular systems.

Competitive Advantage

Proper Strategy Formulation

Understand customer desires

Internal rapid response mechanisms

Faster and cost effective products

Manufacturing Perspective

1970’s - Cost focused1980’s - Quality first1990’s - Delivery performance, customization,

and environmental issues2000’s - Information and Knowledge integration

Design for Manufacturing

(Verb) The process of creating a specification for construction of a part which involves synthesis, analysis, and optimization.

(Noun) The resulting specification and includes geometry, topology, tolerances, material, and other parameters necessary for manufacturing the part.

Highly Agile Product Automation

Missing Link

Design AutomationCAD

Manufacturing AutomationCAM

Design for:ManufacturingAssemblyAutomationInspection

Manufacturing Processes:to allow easy design

Made to order?

CustomerSpecs.

Planning

Design

Manufacturing

SoftwareInformationAutomation

HardwareAutomation

Enterprise Level Automation

HardwareAutomation•PLCs•Robots•CNC•AGVs

SoftAutomation•GT-based•CAPP•Features•FMS

Informationbased Automation•Web•Message•PMI•ERP

Types of Automation

• Fixed and Hard Automation– CAM, levers

– Where is it used ?

– High volume, High reliability, High production rates, High initial investment

• Flexible Automation– Programmable automation, Low production rates,

medium quantity and varied production batches.

Philosophies of automation

• Concept A– Machines which are completely automated

should be used in production

• Concept B– Machines with limited automation, intelligence

and capabilities aided by human intelligence• Use machines for what it does the best

• Use human to ease the complexities