Manufacturing And Automation exam 1

Automation is important because it adds value to the economy and we can produce products faster.

Why Automation is important?

Facilities and Manufacturing support systems

What are the two major categories that a Production System consists of?

Business functions, Product Design, Manufacturing planning, and Manufacturing Control

What are the four distinct activities of Manufacturing Support Systems?

Master Scheduling, Capacity planning, Process planning, and Material requirements planning

What are the four different activities that are included in the Manufacturing Planning?

Shop floor control, Inventory control, and quality control

What are the different types of Manufacturing Controls?

Manual Work Systems, Worker-Machine Systems, and Automated Systems

What are the three types of Manufacturing Systems?

Fixed Automation- The sequence of processing (or assembly) operations is fixed by the equipment configuration

Programable automation- It is designed with the capability to change the sequence of operations to accommodate different product configurations.

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

Compare three types of Automation in Manufacturing Systems.

Dangerous work environment, working continuously without stooping, Repetitive tasks,

What are the few reasons for Automation?

•Understand the existing process
•Simplify the process
•Automate the process

What does the USA Principle of Automation stand for?

1.Specialization of operations
2.Combined operations
3.Simultaneous operations
4.Integration of operations
5.Increased flexibility
6.Improved material handling and storage
7.On-line inspection
8.Process control and optimization
9.Plant operations control
10.Computer-integrated manufacturing

What are ten strategies for automation?

Phase 1 - Manual production

Single-station manned cells working independently
•Quick to set up
•Low-cost tooling
Production capacity can be reduced or grown

Phase 2 - Automated production

Single-station automated cell operating independently
As demand grows and automation can be justified.

Phase 3 - Automated integrated production

Multi-station system with serial operations and automated transfer of work units between station
Able to meet the high demand with reduced cost

Primary- Mining, Farming, logging

secondary- car manufacturers, any manufacturing and production of goods

tertiary- education, medical providers, personal trainers, Haircuts

What are some examples of Primary, Secondary and Tertiary (Service) Industries?

Processing and assembly operations, Material handling, Inspection and testing, and Coordination and control

What are the different aspects of manufacturing operations?

Material transport- Vehicles, e.g., forklift trucks, AGVs, monorails, Conveyors, Hoists and cranes

Storage systems- Manual, Automated

What are different types of material handling and storage systems used in manufacturing?

Types of products made, Production quantity, Product variety

What are the different factors that influence the layout of a production facility?

Fixed Position Layout- Low quantity, High variety

Process Layout- could work for all quantity and variety

Cellular Layout- Medium quantity, Medium variety

Product Layout- High quantity, Low variety

What are the different types of plant layout? How are related to product variety and quantity?

Fixed Position Layout- Job shop

Process Layout- Job shop, batch production, quantity production

Cellular Layout- cellular manufacturing

Product Layout- flowline production

How are different types of plant layout and types of production facilities related?

as quantity goes up variety goes down

How are production quantity and production variety related?

Programable automation- High variety, low quantity

Flexible automation-Medium variety, Medium quantity

Fixed automation- Low variety, High quantity

How different types of automation are related to the production quantity and product variety?

Machine Qualities

• Perform repetitive tasks consistently
• Store large amount of data
• Retrieve data from memory reliably
• Perform multiple tasks simultaneously
• Apply high forces and power
• Perform simple computations quickly
• Make routine decisions quickly

Human Qualities

• Sense unexpected stimuli
• Develop new solutions to problems
• Cope with abstract problems
• Adapt to change
• Ability to empathize
• Generalize from observations
• Learn from experience
• Make decisions based on incomplete data

Task is technologically too difficult to automate
• Short product life cycle
• Customized product that requires human flexibility
• To cope with ups and downs in demand
• To reduce risk of new product failure
• Lack of Capital
• Equipment maintenance
• Programming and computer operation
• Engineering project work
• Plant Management

When is manual labor preferred?

-Number of shifts per day
-Number of hours per shift
-Employment levels

What the "operating conditions" refer to when calculating Plant Capacity?

Over the short term- Increase/decrease number workers, Increase/decrease shifts per week, Increase/decrease hours per shift (e.g., overtime)

intermediate and long terms- Increase number of machines n, Increase production rate Rp by methods improvements and/or processing technology

How the plant capacity can be adjusted over short and long term?

Fixed costs, Variable costs

What are two major categories of Manufacturing Costs?

fixed- cost of energy and facilities

Variable- Labor, materials

What are examples of fixed and variable costs?

The product quantity that makes the total cost the same

What is the breakeven point when comparing Manual and Automated Production costs?

1. Materials - costs of raw materials
2. Tooling - cost of cutting tools, dies, mold etc.
3. Fixed costs - cost of energy, facilities, etc.
4. Equipment - cost of machinery, building, land etc.
5. Direct labor - wages and benefits paid to workers
6. Overhead - Also known as Indirect or Nonproductive labor cost. All expenses associated with running the manufacturing firm:

What are the typical break-up of selling price of a product?

Factory- plant supervision, Equipment, power, tools

Cooperate- engineering, Taxes, insurance, Legal, Finance

What are two different types of overhead costs? What are some of the examples?

integrates the software and hardware in manufacturing from initial product concept through its production and distribution in the marketplace.

Elements- Adaptive Control
• Automated Material Handling
• Automated Assembly Systems
• Computer-Aided Process Planning
• Computer Numerical Control
• Group Technology & Cellular Manufacturing
• Industrial Robots
• Flexible Manufacturing
• Lean & Just-in-time Production
• Artificial Intelligence and Machine Learning

What is Computer integrated Manufacturing (CIM) and its various elements?

Power, control system, program of instructions

What are the basic elements of an automated system?

Electricity -
• it is widely available at moderate cost
• can be readily converted to alternative forms, e.g. mechanical, thermal, etc.
• can be stored in long-life batteries

What is the principle power source for automation and why?

Solar
• Wind
• Hydroelectric
• Biomass
• Geothermal

What are different types of renewable power sources?

Solar Photovoltic (PV) Cells, Concentrating Solar Power

What are two main types of Solar energy production methods?

Process parameter (input to a Process): Temperature dial setting of a furnace

Process variable (output of a Process): Actual temperature of the furnace

What are process parameters and process variables?

Safety monitoring, Maintenance and repair diagnostics, Error detection and recovery

What are different types of advanced automation functions?

To protect workers and equipment

What are the reasons for safety monitoring when using automation?

• Complete stoppage of the system
• Sound an alarm
• Reduce operating speed of process

What are the possible responses to hazards for automation?

Take corrective action to recover from the safety violation

How to address safety violation?

Status monitoring, Failure diagnostics, Recommendation of repair procedure

What is the role of the Maintenance and Repair Diagnostics functions in automated Production systems?

Detection-
Use the system's available sensors to determine when a deviation or malfunction has occurred
• Correctly interpret the sensor signal
• Classify the error

Recovery-
Make adjustments at end of work cycle
• Make adjustments during current work cycle
• Stop the process to invoke corrective action • Stop the process and call for help

What are the few possible strategies for error detection and recovery?

5. Enterprise level - corporate information system
4. Plant level - factory or production systems level
3. Cell or system level - manufacturing cell or system
2. Machine level - CNC machine tools and similar production equipment, industrial robots, material handling equipment
1. Device level - actuators, sensors, and other hardware components to form individual control loops for the next level

What are the different levels of automation that can be incorporated in a company?

Continuous control - variables and parameters are continuous and analog.

Discrete control - Process parameters and variables are discrete.

What are the different types of control systems in automation?

Logic control - controls the execution of event driven changes.

Sequence control - controls the execution of time-driven changes.

What are logic control and sequence control?

Polling (data sampling), Interlocks, Interrupt system, Exception handling

What are four types of capabilities of computer control System?

An automatically controlled, reprogrammable, multipurpose manipulator programmable in three or more axes, which may be either fixed in place or mobile for use in industrial automation applications

What is an Industrial Robot?

China

Which country has most industrial robots?

Able to work in hazardous work environments
High endurance and speed
Consistency and accuracy of the robots are not attainable by humans They can be reprogrammed
Robots at different locations can be controlled through Computer Network

What are some of the advantages for using industrial robots?

Joints and links

What is a Robot arm or Manipulator made of?

linear- 2 types

Rotational- 3 types

How many types of Joints can a manipulator have?

Articulated Robot, Polar Configuration, SCARA Robot, Cartesian Coordinate Robot, Delta Robot

What are a few examples of different types of Industrial robots?

• Uses the joint symbols (L, O, R, T, V) to designate joint types used to construct robot manipulator.
• Separates body-and-arm assembly from wrist assembly using a colon (:)

How does the joint notation system work?

The end effecters attach to it and it can move in all directions during operation.

What is the function of wrist assembly?

- Roll (rotation about robot's arm axis)
- Pitch (up and down rotation)
- Yaw (right and left rotation)

What are the typical configuration of a three axis wrist assembly

grippers, tools

What are the two types of end effectors?

Mechanical, Vacuum, Magnetized, Adhesive devices, etc.

What are different types of grippers?

Welding gun, spray painting gun, rotating spindle for drilling, and grinding, automatics screwdriver, heating torch, etc.

What are the different types of tools an end effectors can use?

Electric, Hydraulic, Pneumatic

What are the different types of Joint Drive System that are used in industrial robots?

Internal, External

What are the two categories of sensors that are used in industrial robots?

Simple sensors can tell weather something is there or not

Complex sensors can tell properties of the object such as hardness and shape.

What are the difference between simple and complex external sensors?

Defined as the three-dimensional space within which the robot can manipulate the end of its wrist. It is also known as work envelope

What is work volume?

Number and types of joints
Ranges of joints
Physical sizes of links

How can you determine the work volume?

Limited sequence control, Playback with point-to-point (PTP) control, Playback with continuous path (CP) control, Intelligent control

What are the different types of robot control systems?

Powered leadthrough, Manual leadthrough

Teach pendent is used to control the motion of the robots

What are the two types of Robot Programming? What is a teach pendent?

Control Resolution, Accuracy, and Repeatability

What are the three measurement metrics for precision of a robot?