Automation in Manufacturing

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M.S.RAMAIAH INSTITUTE OF TECHNOLOGY DEPARTMENT OF MECHANICAL ENGINEERING BANGALORE AUTOMATION IN MANUFACTURING SEMINAR ON: Assembly process, assembly systems Shahin Shafiee USN : 1MS08MCM12 3 rd Sem , M.Tech , CIM 2009

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Contents Introduction Fundamentals of manual assembly lines Assembly workstations Work transport systems Line Pacing Coping with product variety Fundamentals of automated assembly systems System configuration Parts delivery at workstations Applications

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Introduction Each product consists of multiple components joined together by various assembly processes 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 Several reasons why manual assembly lines are so productive: Specialization of labor Interchangeable parts Work flow principle Line pacing

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Fundamentals of manual assembly lines A manual assembly line is a production line that consists of a sequence of workstations where assembly tasks are performed by human workers, as depicted in Figure 1 A mechanized material transport system is typically used to move the base parts along the line as they are gradually transformed into final products The production rate of an assembly line is determined by its slowest station

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Fundamentals of manual assembly lines Assembly workstations A workstation: a designated location along the work flow path at which one or more work elements are performed by one or mare workers Workstation includes the tools (hand tools or powered tools) required to perform the task assigned to the station Some workstations are designed for workers to stand, while others allow the workers to sit Standing worker station: common for assembly of large products such as cars, trucks, and major appliances Sitting worker station: for smaller assembled products such as small appliances, electronic devices, and subassemblies used on larger products; more comfortable and less fatiguing for the workers and more conducive to precision and accuracy in the assembly task The manning level of workstation

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Fundamentals of manual assembly lines Work transport systems Two basic ways: manually ,mechanized Manual transport: Two problems starving and blocking; to mitigate, storage buffers are sometimes used between stations Troubles: work-in-process, unpaced workers, production rates tend to be lower Mechanized Work Transport: Three major categories: (a) continuous transport, (b) synchronous transport, and (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 transport

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Fundamentals of manual assembly lines Line Pacing The pacing of the workers: one of the reasons why a manual assembly line is successful Pacing: a discipline for the assembly line workers that guarantee a certain production rate Three alternative levels of pacing: (1) rigid pacing, (2) pacing with margin, (3) no pacing

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Fundamentals of manual assembly lines Coping with product variety Manual assembly lines can be designed to deal with differences in assembled products Three types of assembly line: (1) single model, (2) batch model, and (3) mixed model A single mode/line produces only one product in large quantities Batch model and mixed model lines are designed to produce two or more models

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Fundamentals of automated assembly systems Automated assembly system consists of: One or more workstations at which the assembly steps are accomplished Pints feeding devices that deliver the individual components to the workstations A work handling system for the assembled entity Control functions required in automated assembly machines: Sequence control Safety monitoring Quality control

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Fundamentals of automated assembly systems System configuration Principal configurations: In-line assembly machine Dial-type assembly machine Carousel assembly system Single-station assembly machine

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Fundamentals of automated assembly systems Parts delivery at workstations A workstation accomplishes one or both of the following tasks: A part is delivered to the assembly work head and added to the existing base part in front of the work head A fastening or joining operation is performed at the station to permanently attach parts to the existing base part The parts delivery system typically consists of the following hardware: Hopper Parts feeder Selector and/or orientor Feed track Escapement and placement device

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Fundamentals of automated assembly systems Parts delivery at workstations Vibratory bowl feeder (a) Selector and (b) orientor devices used with part feeders in automated assembly systems

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Fundamentals of automated assembly systems Parts delivery at workstations Various escapement and placement devices used in automated assembly systems: (a) horizontal device and (b) vertical device for placement of parts onto dial indexing table; (c) escape­ment of rivet-shaped parts actuated by work carriers, (d) and (e) two types of pick-and-place mechanisms

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Fundamentals of automated assembly systems Parts delivery at workstations Hardware elements of the parts delivery system at an assembly workstation

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Fundamentals of automated assembly systems Applications Typical Products Made by Automated Assembly Typical Assembly Processes Used in Automated Assembly Systems

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Thank You