Industrial Engineering - Role of Engineering, Mechanization and Automation
In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.
Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.
Automation of Operations in Flow Process Chart
Understand and Improve Principles of Industrial Engineering
Understand
Understand the engineering and technology - products related and processes related and the product design and process design of your organization.
Industrial engineers have to monitor developments in engineering and technology on a continuous basis.
Improve
Improve the product and process based on the understanding of current technologies and opportunities for application in the process under investigation for productivity improvement.
You will see the same thing expressed as USA in system design context in the article.
Industrial Engineering & ISE - Engineering & Technology, Process, and People
Prof. Mikell Groover, Professor of Industrial Engineering, Lehigh University
Prof. Mikell Groover, Professor of Industrial Engineering, Lehigh University made a significant contribution to transform industrial engineering into industrial engineering 4.0. He wrote a series of books on modern developments in manufacturing and provided the direction to industrial engineering to evolve towards its practice in the connected and highly automated manufacturing systems of the Industry 4.0 Era.
Let us start with introduction to automation in manufacturing systems. The content is developed using the first chapter of Groover's book on automation and CIM.
The production system is the collection of equipment, procedures and people, organized to accomplish the manufacturing operations of a company or firm. Production systems have to following components.
Manufacturing System
Manufacturing Facilities.
Power Supply Facilities
Utilities Supply Facilities
Information Technology Facilities
Trained Man Power
Manufacturing Support System
Product design, Process Plan
Production Quantity Plan
In manufacturing operations, portions of the production system were automated and computerized long back and the process is being modernized with each new development in technology.
Production System Resources and Facilities
The facilities in the production system are the factory, production machines and tooling, material handling equipment, inspection equipment, and the computer systems that control the manufacturing operations. Facilities also include the plant layout, which is the way the equipment is physically arranged in the factory. The equipment is usually organized into logical groupings, and we refer to these equipment arrangements and the workers who operate them as the manufacturing systems in the factory. Manufacturing systems can be individual work cells, consisting of a single production machine and worker assigned to that machine. We more commonly think of manufacturing systems as groups of machines and workers, for example, a production line. The manufacturing systems come in direct physical contact with the parts and/or assemblies being made. They "touch" the product.
Manufacturing Support Systems
To create and operate the production facilities, a company must organize itself to design the processes and equipment. plan and control the production orders, and satisfy product quality requirement. These functions are accomplished by manufacturing support systems. Most of these support systems do not directly contact the product, but they plan and control its progress through the factory,
Manufacturing support involves a cycle of information-processing activities. The activities can be grouped into (1) strategy related to product and process (2) product design, (3) manufacturing planning. and (4) manufacturing control and (5) business functions.
Product Design.
Product design may be provided by the customer in some orders. The manufacturer's product design department will not be involved, if the product is to be produced to customer specifications. But in many organizations, the manufacturer's product design department is asked to do the design work for the product.
Manufacturing Planning.
Manufacturing planning has multiple tasks.
The information and documentation that constitute the product design flows into the manufacturing planning function.
Process planning consists of determining the sequence of individual processing and assembly operations needed to produce the part. The manufacturing engineering and industrial engineering departments are responsible for planning the processes and related technical derails,
Based on the process plans, equipment requirements are to be determined and they have to be procured and are to be arranged in a layout. After process plan, there is facilities planning.
Industrial engineering: Industrial engineering is continuous improvement in process plans as well as product designs to increase productivity and reduce cost using latest development technology, its applications and various problems and opportunities identified during shop operations through reports, complaints and data, and specific studies undertaken by industrial engineers. Process improvement studies, method studies, motion studies, and time studies are some of the popular methods of industrial engineering. Motion study and time study were combined into work study. In the recent literature machine effort and human effort were identified as important in production systems and machine work study and human work study were proposed as two important components of the popular idea of work study.
Principles of Industrial Engineering - Taylor - Narayana Rao
24 May 2017
IISE Annual Conference Presentation
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https://www.youtube.com/watch?v=pU8CdWfZZdU
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Manufacturing planning also includes logistics issues, commonly known as production planning. It is better termed production quantity planning. It starts with aggregate planning of production and is translated into the master production schedule. The master production schedule is a listing of the products to be made, when to be delivered. and in what quantities. Months are traditionally used to in the master schedule. Based on this schedule, the individual components and subassemblies that make up each product must be planned. Raw materials must be purchased and purchased parts must be ordered from suppliers.
Based on production quantity plans, a function called capacity planning recalculates the requirement of machine manpower resources of the firm and arranges for acquisition. There will be consultation with process planning department and industrial engineering department to determine the best machines as available at that point in time.
Manufacturing Control. Manufacturing control is concerned with managing and controlling the physical operations in the factory to implement the manufacturing plans. Included in the manufacturing control function are shopfloor control inventory control and quality control,
Shop floor control deals with the problem of monitoring the progress of the product as it is being processed, assembled, moved and inspected in the factory. Shop floor control is concerned with inventory in the sense that the materials being processed in the factory are work-in-process inventory. Thus. shop floor control and inventory control overlap to some extent. Inventory control may point out to certain actions. The mission of quality control is to ensure that the quality of the product and its components meet the standards specified by the product designer. To accomplish its mission, quality control depends on inspection activities performed in the factory at various times during the manufacture of the product. Also, raw materials and component parts from outside sources are inspected when they arc received. and final inspection and testing of the finished product is performed to ensure functional quality and appearance,
Business Functions. The business functions procure orders. Communicating with the customers is their responsibility. The order to produce a product typically originates from the customer and proceeds into the company through the sales and marketing department of the firm.
AUTOMATION IN PRODUCTION SYSTEMS
Automation in Production Systems
Automation can be defined as a technology concerned with the application of mechanical, electronic, and computer-based systems to operate and control production.
The automation is separated into two categories: (1) automation of the manufacturing systems in the factory and (2) computerization of the manufacturing support systems.
Automation in manufacturing existed even before computers were invented. But in modern production systems, computers are used in automation of production equipment also. The most popular example is CNC machine tool. The automated manufacturing systems operating on the factory floor are now monitored using the computer systems and connected to the computerized manufacturing support systems and management information system operating at the plant and enterprise levels. The term computer-integrated manufacturing is used to indicate this extensive use of computers in production systems.
Automated Manufacturing Systems
Automated manufacturing systems operate in the factory on the physical product. They perform operations such as processing, assembly, inspection, or material handling, in some cases accomplishing more than one of these operations in the same system. They are called automated because they perform their operations with a reduced level of direct human participation compared with the corresponding manual process. But setting up the automated systems is done by human effort only. Various modifications to the automated systems are done by men only. |The maintenance of the system is done by men only.
Examples of automated manufacturing systems include:
• automated machine tools
• transfer lines that perform a series of machining operations
• automated assembly systems
• industrial robots that perform processing or assembly operations
• automatic material handling and storage systems to integrate manufacturing operations
• automatic inspection systems for quality control
Automated manufacturing systems can be classified into three basic types
(1) fixed automation. (2) programmable automation, and (3) flexible automation.
Fixed Automation. Fixed automation is a system in which the sequence of processing (or assembly) operations is fixed for one or very limited variety of parts.
Programmable Automation. In programmable automation. the production equipment is designed with the capability to work on a larger variety of predetermined set of components. The operation sequence is controlled by a program, a set of instructions coded so that they can be read and interpreted by the system.
Flexible Automation. Flexible automation is designed to increase flexibility so that even new components can be produced with minimum additional costs. In case of flexible automation, at the time of design of the equipment and system, certain features that support flexibility of incorporated. It can be related to work holding, tools that can be used, size of parts that can be worked on etc.
Computerized Manufacturing Support Systems
Computerization of the manufacturing support systems is aimed al reducing the amount of manual and clerical effort in product design, manufacturing planning and control, and the business functions of the firm. Initially simple arithmetic numbers and text were processed using data processing machines. But the technology progressed and now computer aided design is being done. Computer technology is used to implement automation of the manufacturing systems in the factory as well. The term computer integrated manufacturing (CIM) denotes the pervasive use of computer systems to design the products, plan the production, control the operations, and perform the various business-related functions needed in a manufacturing firm. True CIM involves integrating all of these functions in one system so that there is no duplication of data entry or additional non-value adding data modification and the entire organization operates on the integrated data base and programs.
Reasons for Automating and Benefits of Automating
To increase labor productivity. Labor productivity is essential for increasing standard of living of people. When the self employed person can produce more by maintaining number of automatic machines, his income will rise and standard of living will rise. Same phenomenon applies to factories. If factories increase automation and create jobs that manage multiple machines, income of operators will increase, Automating a manufacturing operation usually in labor productivity This means greater output per hour. World over per capita increase in GDP took place due to more mechanization and automation.
To improve product quality. Automation reduces product defects also.
To reduce manufacturing lead lime. Automation helps to reduces the lead time.
Automation Principles
USA Principle
The USA Principle is the industrial engineering approach used for automation.
.USA stands for
1. Understand the existing process
2. Simplify the process - Improve the process with current facilities by eliminating waste activities.
3. Automate the process.
Understand the Existing Process. This is the first step of any IE study.
Simplify the Process. This is a step of ECSR steps of industrial engineering.
Automate the Process. Once the current process has been improved eliminating the waste activities, automation can be studied. It is important to remember the principle of reengineering. It is very important for the new technology implementer to thoroughly understand the new technology and use its full power in converting the input into the operation or process into output. The current process is not a constraint for the new automatic production process design.
Ten Strategies for Automation of Production Systems
Groover in 1980 suggested the following ten.
1. Specialization: Design special-purpose equipment to perform one operation with the greatest possible efficiency.
2. Combined operations. Complex parts production require tens or even hundreds, of processing steps. The strategy of combined operations involves reducing the number of distinct production machines or work stations by performing more than one operation at a given machine. An economic evaluation has to be done for combining specialized machines.
3. Simultaneous operations. A logical extension of the combined operations strategy is to simultaneously perform the operations that are combined at one workstation.
4. Integration of operations. Another strategy is to link several workstations together into a single integrated mechanism, using automated work handling devices to transfer parts between stations. Scheduling becomes simplified.
5. Increased flexibility. Design for flexibility
6. Improved material handling and storage. Automated material handling and storage systems give reduced work-in-process and shorter manufacturing lead times.
7. On-line inspection. Incorporating inspection into the manufacturing process permits corrections to the process as the product is being made and also reduces errors.
8, Process control and optimization. This includes a wide range of control schemes intended to operate the individual processes and associated equipment more efficiently from more central locations.
9. Plant operations control. There is control of the individual manufacturing processes. But we required also control at the plant level. It attempts to manage and coordinate the aggregate operations in the plant more efficiently. Its implementation usually involves a high level of computer networking within the factory.
10. Computer-integrated manufacturing (CIM). Integration of factory operations with engineering design and the business functions of the firm, CIM involves extensive use of computer applications, computer data bases, and computer networking throughout the enterprise
Automation Migration Strategy or Implementation Sequence
The easiest and least investment way to introduce a new product is to design a manual production method, using a sequence of workstations operating independently. If the product turns out to be successful and high future demand is anticipated, then it makes sense for the company to automate production. The improvements are often carried out in phases. A typical automation implementation strategy takes place in the following phases.
Phase 1: Manual production using single-station manned cells operating independently.
Phase 2· Automated production using single-station automated cells operating independently as appropriate.
Phase 3: Automated integrated production using a multistation automated system
Automated and Integrated Flexible Manufacturing System
Developing Automated and Integrated Flexible Manufacturing System
Wei Deng Solvang, Hao Yu, Gabor Sziebig
Department of Industrial Engineering, Narvik University College, Narvik, Norway.
CogInfoCom 2014 • 5th IEEE International Conference on Cognitive Infocommunications • November 5-7, 2014, Vietri sul Mare, Italy, pp. 437-442
Ralph Barnes, Motion and Time Study, 7ed. 1980, Chapter 18
BLACK, J. T.. The Design of the Factory with a Future, McGraw-Hill, Inc., New York, 1991
GROOVER. M. P., Fundamentals of Modem Manufacturing: Materials, Processes, and Systems, Prentice Hall, Upper Saddle River. New Jersey, 1996 (now published by John Wiley & Sons, Inc., New York)
HARRINGTON, J., Computer Integrated Manufacturing, Industrial Press, Inc., New York, 1973.
KAPP, K.M., "The USA Principle", APlCS - The Performance Advantage, June 1997,pp 62-66
Manufacturing Automation Management
A Productivity Handbook
By Roger W. Bolz · 2012
Preview
https://www.google.co.in/books/edition/Manufacturing_Automation_Management/oRaoBgAAQBAJ
Updated on 14.6.2023, 19.12.2020
First published on 17.10.2020
Computer Integrated Manufacturing to Smart Factory - IIOT Integrated Manufacturing - Supply Chain System
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