Automation considerations for a manufacturing system

This thesis examines the present manufacturing system of Apollo Valve Company, a solenoid control valves manufacturing. After analyzing the present system, the automation considerations and proposed new system were recommended. Chapter 1 presenti the background material of automation and manufacturing system. The development of the automated factory is also included. The plant layout, organization, and departments functions of the present system are briefly described in the Chapter 2. Analysis of the present manufacturing system by the production volume, by plant layout, and by the manufacturing operations, is discussed in Chapter 3. Proposed automation considerations and improvements, such as group technology (GT), computer-aided process planning (CAPP), computer-aided manufacturing (CAM), automatic assembly and testing, packing, and flexible manufacturing system (FMS), are presented in the Chapter 4. The last chapter, the conclusions are discussed and the new manufacturing system is recommended

Resource selection and route generation in discrete manufacturing environment

When put to various sources, the question of which sequence of operations and machines is best for producing a particular component will often receive a wide range of answers. When the factors of optimum cutting conditions, minimum time, minimum cost, and uniform equipment utilisation are added to the equation, the range of answers becomes even more extensive. Many of these answers will be 'correct', however only one can be the best or optimum solution. When a process planner chooses a route and the accompanying machining conditions for a job, he will often rely on his experience to make the choice. Clearly, a manual generation of routes does not take all the important considerations into account. The planner may not be aware of all the factors and routes available to him. A large workshop might have hundreds of possible routes, even if he did know it all', he will never be able to go through all the routes and calculate accurately which is the most suitable for each process - to do this, something faster is required. This thesis describes the design and implementation of an Intelligent Route Generator. The aim is to provide the planner with accurate calculations of all possible production routes m a factory. This will lead up to the selection of an optimum solution according to minimum cost and time. The ultimate goal will be the generation of fast decisions based on expert information. Background knowledge of machining processes and machine tools was initially required, followed by an identification of the role of the knowledge base and the database within the system. An expert system builder. Crystal, and a database software package, DBase III Plus, were chosen for the project. Recommendations for possible expansion of and improvements to the expert system have been suggested for future development

"The Shift from Belt Conveyor Line to Work-cell Based Assembly Systems to Cope with Increasing Demand Variation and Fluctuation in The Japanese Electronics Industries"

As consumption patterns become increasingly sophisticated and manufacturers strive to improve their competitiveness, not only offering higher quality at competitive costs, but also by providing broader mix of products, and keeping it attractive by launching successively new products, the turbulence in the markets has intensified. This has impelled leading manufacturers to search the development of alternative production systems supposed to enable them operate more responsively. This paper discusses the trend of abandoning the strategy of relying on factory automation technologies and conveyor-based assembly lines, and shifting towards more human-centered production systems based on autonomous work-cells, observed in some industries in Japan (e.g. consumer electronics, computers, printers) since mid-1990s. The purpose of this study is to investigate this trend which is seemingly uneconomic to manufacturers established in a country where labor costs are among the highest in the world, so as to contribute in the elucidation of its background and rationality. This work starts with a theoretical review linking the need to cope with nowadays' market turbulence with the issue of nurturing more agile organizations. Then, a general view of the diffusion trend of work-cell based assembly systems in Japanese electronics industries is presented, and some empirical facts gathered in field studies conducted in Japan are discussed. It is worthy mentioning that the abandonment of short cycle-time tasks performed along conveyor lines and the organization of workforce around work-cells do not imply a rejection of the lean production paradigm and its distinctive process improvement approach. High man-hour productivity is realized as a key goal to justify the implementation of work-cells usually devised to run in longer cycle-time, and the moves towards this direction has been strikingly influenced by the kaizen philosophy and techniques that underline typical initiatives of lean production system implementation. Finally, it speculates that even though the subject trend is finding wide diffusion in the considered industries, it should not be regarded as a panacea. In industries such as manufacturing of autoparts, despite the notable product diversification observed in the automobile market, its circumstances have still allowed the firms to rely on capital-intensive process, and this has sustained the development of advanced manufacturing technologies that enable the agile implementation and re-configuration of highly automated assembly lines.

Set up time Reduction and Quality Improvement on the Shop floor using different lean and quality tools

The purpose of this thesis document is to describe a method developed for reducing setup time in machining processes and simultaneously improve the quality of production after setup. Bosch Rexroth at Fountain Inn is a semi-automated plant and is still in its initial stages of standardizing the setup process. Setup time at different machining centers includes: machining time, inspection time, loading and unloading times and deburring. The focus of the described method is in reducing setup times related to inspection time and loading and unloading times. To achieve success in these problems the following new tools were developed: first piece inspection charts, design inspection fixture and design of new handling tools. This work involved interaction with operators, collection of data, and analyzing and developing new plans based on the analysis. Tools like Failure Modes Effects Analysis (FMEA), 5S and Single-Minute Exchange of Die (SMED) techniques helped in making and implementing these changes on the production line. Implementation of first piece inspection charts and inspection reduced inspection time by almost 50%. Design of handling tools helped in reducing stress on the operator and also in reducing loading and unloading time by 40%. Also quality was improved through a related project. This subproject\u27s aim is to reduce shaft alignment problems as reported by the customer. To achieve this goal I designed a fully automatic shaft alignment tool, which helps operator in installing the shaft into the pump without any difficulty. This shaft alignment tool is installed on the line and eliminated the shaft alignment problems completely. Also the quality improvement techniques and set up time reduction techniques used at BOSCH are discussed in this documen

New manufacturing technologies

"To appear in: Strategic manufacturing : dynamic new directions for the 1990's"--p. 1.Includes bibliographical references.by Charles H. Fine

Tools for the design of flexible manufacturind systems

Flexibility in manufacturing systems can broaden the horizons for a company. But the means for achieving it are far more critical. This trend is created by the increase in competitiveness, growth of technology along with demand variations, more customization, and short product life cycles. But Flexible Manufacturing Systems to most of the manufacturers sounds like a synonym for automation. A real Flexible Manufacturing System is designed when every unit of the company is synchronized in such a way to respond in a harmony to any changes that come against it. Fine-tuning of each and every part of the company is essential to make the company profitably sustainable to any internal or external changes. This research aims at realizing real flexibility in the company. It aims at bringing out the bottlenecks, the issues that a company owns and tries to solve them in a feasible way so as to make the company more and more self-reliant, countering all the external and internal changes that occur during its time. A process of conducting Flexibility audit is described in thesis, which is a powerful tool when, used methodically with the FM design process (Figure 3.1), The data gathered from audit is analyzed to identify factors contributing to inflexibility and to resolve them in a feasible innovative way. This philosophy when applied continuously over a period of time can build immunity against the change shock or the adjustment time

An investigation into manufacturing execution systems

Hardware and software developments of this decade have exposed an hiatus between business/management applications and process control in heavy industry in the implementation of computer technology. This document examines the development of discrete manufacturing and of relevant implementations of computing. It seeks to examine and to clarify the issues involved in a perceived current drive to bridge this gap, to integrate all the systems in a manufacturing enterprise in a Manufacturing Execution System (MES) in order to address two hypotheses: I) That overseas trends towards the development of manufacturing execution systems have application in the Australian industrial context. 2) That significant gains in production efficiency and quality may be achieved by the application of an MES. It became apparent early in this study that any understanding the function of an MES requires an understanding of the context in which it works. Following the Introduction, therefore, Section Two contains a brief overview of the history and development of modem industry with particular attention to the subject of inventory and inventory management. Since the 1970s, three main streams of change in manufacturing management methodology developed. These are dealt with in some detail in Section Three. Section Four outlines a variety of areas of increasing computerisation on the shop floor while Section Five addresses the integration of the whole system, management and shop floor, seeking to demonstrate the complexity of the subject and to discover current trends and developments. Section Five includes a survey of some of the software and hardware options currently available and Section Six summarises the work and presents some observations and conclusions. Three appendices provide more detailed information on MES software availability, pricing and market penetratio

Trends and topics in IJPR from 1961 to 2017:a statistical history

This paper studies the history of the International Journal of Production Research (IJPR) by analysing the topics that have received the most attention in each of the journal’s publication years. Text mining exposed for scrutiny the most frequently mentioned and cited terms contained in the titles, abstracts and keywords of IJPR papers. Analyses suggest that the triad of scheduling/optimisation/simulation and supply-chain-related topics have been IJPR’s mainstays, but valuable opportunities remain for relevant topics that have not yet been concurrently and frequently studied. Results also show that terms related to sustainability and risk management topics have gained recent relevance. In addition, IJPR appears to complement its modelling technique focus with empirical methodological approaches to provide a well-balanced perspective, since the ‘case study’ term is common. Finally, a linear relationship is found between the number of papers that have covered certain topics and the number of citations those topics have received, highlighting which topics had fewer or more citations than expected, given the number of papers that covered those topics. IJPR stands as one of the most prestigious and established journals in its field and the results from this study indicate the evolving interests of the field for over half a century

Scheduling With Alternatives Machine Using Fuzzy Inference System And Genetic Algorithm.

As the manufacturing activities in today's industries are getting more and more complex, it is required for the manufacturing company to have a good shop floor production scheduling to plan and schedule their production orders. Industri pengeluarcim kini telah berkembang pesat dan aktiviti pengeluarannya semakin kompleks, dengan itu syarikat pengeluar memerlukan jadual lantai pengeluaran (shop floor) yang terbaik untuk merancang permintaan pengeluaran (product)