AIM summary

introduction

little or no human participation

Includes:

machanical systems
electrical systems
computer-based systems

Reasons:

increased productivity;high cost of labour;labour shortages;high cost of raw materials;improved product quality;reduced manufacturing lead time;reduction of in-process inventory;service sector;safety

Arguments:

subjugation of human being; reduction of labour force;reduce purchasing power

types:

fixed;programmable;flexible

methods of evaluating investment justifications

payback period

net annual cash flow = revenue-cost
IC = initial cost
n = payback period

for equal NACF:
n=IC/NACF;

[salvage value:残值]

present worth method[PW]

uniform series present worth factor
USPWF = [(1+i)^n-1]/[i(1+i)n]=(P/A,i%,n)
PW = -IC+NACF(USPWF)

uniform annual cost method[UAC]

capital recovery factor(CRF):
CRF = (A/P,i%,n)
UAC = -IC(CRF)+NACF

rate-of-return method

fixed automation

objectives

flow pattern: in line, rotary

in line : rectangle ; 90° turns
rotary : indexing machine ; around a circular table or dial
choice depends on the applications

w/p transport: continuous, intermittent, power and free

continuous transfer :

beverage bottling operations , packaging , manual assembly operations

intermittent transfer :

press working operations , progressive dies , mechanized assembly

asynchronous transfer :

each part moves independently

factors to consider for types of transport system

the type of operation to be performed

the number of stations on the line

the weight and size of the work piece

whether manual stations are included on the line

production requirements

balancing the various process ttime on the line

pallet fixtures :
cheese

parts feeding devices :

feeder units

hooper , parts feeder , selector and/or orientor , feedtracks , escapement and placement device

transport machanism: linear, rotary

linear:

walking beam system

power roller conveyor system

chain-drive conveyor system

rotary:

rack and pinion

ratchet and pawl

geneva mechanism

cam mechanism

buffer storage

sequence control: operational requirement

safety monitoring: safety requirement

quality monitoring: improving quality

control strategy:
instantaneous control ; memory control

automated materal handling

common types : conveyor , AGVS

types of conveyor :

roller conveyor , skate-wheel conveyor , belt conveyor , chain conveyor , slat conveyor , overhead trolley conveyor , in-floor towline conveyor , cart-on-track conveyor

analysis of conveyor system :

single direction , continuous loop , re-circulating conveyor

types of AGVS :

automated guided vechicle systems

driverless train , AGV pallet truck , AGV unit load carrier

materal handling:

criteria :
safely , efficiently , timely manner , accurately , without damage to the materials

Areas :
manufacturing, warehousing, distribution , retailing , inventory, postal services , airport baggage handling

materal handling analysis:

${\mathbb{R}}_f=assumingflowrate$
$L_d=lengthofdelivery$
$R_f\ast L_d=transportwork$

$totaltransportwork(TTW)=\sum (R_f\ast L_d)$

$T_h=handlingtimeforloading\&unloadingactivities$

$L_e=distanceofemptymove$

$V_c=velocityofcarrier$

$F_t=trafficfactor$

automated storage & retrieval system

performance criteria :

storage capacity , system throughput , utilization

common types of automated storage systems :

automated storage and retrieval systems(AS/RS)

machanized carousel systems

basic components of an AS/RS :

storage structure;
storage/retrieval machine;
storage modules;
pickup and deposit stations

other features in AS/RS :

aisle transfer cars;
full/empty bin detectors;
sizing stations;
load identification stations

flexible manufacturing system/cell

FMS: 6 or more machines

producitivity VS flexibility

hardware

visible and tangible

software

invisible and intangible

need for FMS :

maximize throughput

reduce labour

improve machine utilization

improve operation control

reduce inventory

priciple benefits

inventory reduction of 60% to 80%

direct labour savings of 30 to 50%

increased asset utilization approaching 80 to 90%

floor space reduction of 40 to 50%

automated factory

CNC machines
robots
automated inspection
computer process control
FMS
CIM

standardization

design standards
raw materials
tooling
process and methods

non-automated factories of the future

foreign factories
small businesses
emerging tevhnologies
companies that are going out of business

workers

reasons for automating

E-manufacturing

engineering : past

centralized locations
-design teams
-manufacturign plants

paper-based data sharing

long lead times

engineering : present

distributed locations

digital data sharing

collaboration via telephony and travel

E-design

E-training

benefits

shorten lead time

improve speed of response

optimize manufacturing processes

provide better-trained manpower

exploit IT to stay compeitive

harmoinzation and standardization of procedures

rapid and quality customer-oriented products/services