Thursday, September 7, 2023

Automated Manufacturing - Automated Production Operations in Manufacturing Processes

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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 projects are to be identified and developed by industrial engineers.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.

https://nraoiekc.blogspot.com/2021/04/jidoka-automation-and-mechanization.html

Automation of Operations in Flow Process Chart

Automated Manufacturing - Production Operations in Manufacturing Processes

Automated Inspection - Bibliography

Automated Material Handling - Transport - Bibliography

Automated Storage and Warehousing - Storage Operation Improvement in Engineering Processes

Automation for Preventing Temporary Delays - Lean WIP Processes - Systems

Automation for Productivity and Cost Reduction - Productivity Automation Engineering. - Lesson 112 of Industrial Engineering ONLINE Course

The article included in the collection: Productivity Automation Engineering - Redesigning products or processes by incorporating automation to improve productivity.

Manufacturing Automation - Magazine

https://www.automationmag.com/

https://www.automationmag.com/digital-edition/

March - April 2022

October 2021

Basic Principles

5 Principles of Flexible Assembly Line Design

By following these principles of flexible assembly line design, manufacturers can pursue lean manufacturing in their current operation while also building capabilities to maintain or add lean improvements in the future.

Mark Sobkow, Jul 9th, 2018

https://www.automationworld.com/home/blog/13318850/5-principles-of-flexible-assembly-line-design

Issues in Designing and Building Automated Assembly Systems

September 10, 2018

John Sprovieri

There are many ways to automate an assembly process: standalone cells combining manual and automated processes; synchronous systems based on rotary or linear indexers; and asynchronous systems based on pallet-transfer conveyors. Which way to go depends on such factors as production volume; cycle time; delivery timeline; budget; floor space; and product life cycle.

‘Lights-out’ automation, is a whole different solution. If some operators are employed for processes that would be difficult or expensive to automate more cost effective solution can be designed.

Important questions: How many parts are there in the product? What do they look like? How many steps are needed to assemble them? Fast cycle times favor indexing assembly systems over power-and-free systems. Small products are ideal for rotary indexing dials. Larger ones are best assembled on linear systems. A product with relatively few parts can be economically assembled on a rotary indexer, while a large number of parts would point to a linear system. Cycle time is a key factor. The approaches are different depending on whether the customer needs to produce a product every two seconds or 35 seconds. An important consideration is whether the system will need to assemble a family of products. Most customers need to produce variations of the same product. The need to assemble variants typically favors a power-and-free system. If an assembly doesn’t need a particular part, it can simply bypass that station.

Available floor space is another issue of consideration. An indexing dial can output a lot of product in a small footprint. A power-and-free system might be more flexible, but it also takes up a lot of space. Based on the cycle time needed to produce the total volume of parts they need per year. decisions related to robots and operators are made. The data used is how many a given robot can produce say in terms of welds or how many parts an operator can load.

Power-and-free systems are more expensive than indexing systems. Manually loading parts at a station will be less expensive than a robot and a bowl feeder. “If the customer will be making the product for several years, he may be able to justify the added investment with a longer pay-back period.

Price, performance and delivery often present competing challenges. Indeed, it’s not uncommon for integrators to present two approaches to the same RFQ. Providing a little extra space on a rotary indexing dial to accommodate variants is less expensive than having to redesign the entire system later.

Decisions Regarding Processes - Basic Assembly Processes

Once the basic approach has been decided, engineers must decide which processes to include and which to omit. Time can be a determining factor. “If an assembly is to be made every three seconds, there is insufficient time for an operator to complete a task. Some processes are not amenable to automation. For example, people are better at handling fragile or flexible parts.

Parts feeding often tops the list for process development. “The goal is to guarantee 100-percent reliable feeding,” he says. Some assembly processes, such as screwdriving, are easily automated. Others require some engineering.

A pick-and-place operation can be done by linear actuators, a Cartesian robot, a SCARA or a six-axis arm. Which to choose depends on the work envelope and how many axes of motion the customer needs now—and in the future.

Even after the automated assembly system has been built, engineers often need to make certain changes to debug the processes.

Assembly systems now come with sensors and test equipment. A basic pick-and-place operation will have several sensors: one to signal that a part is ready to be picked, another to signal that it has been picked up, and a third to ensure that the part has been placed correctly.

Establishing the Sequence of Assembly

A product’s assembly plan affects both line design and process efficiency. While the order of operations may seem obvious, a product with multiple parts and subassemblies could be produced in a variety of layouts and assembly sequences.

For example, Genesis Automation worked with an assembly system that included a labeling operation in an automated assembly system. Initially, it is believed the labeling operation should be at the end of the line, after the product had been fully assembled. As it turned out, it was easier to print and apply the label midway through the process to allow more accurate positioning of the label.

Data collection and traceability requirements can also influence the order of operations. The design of a system can depend on whether the customer simply wants a lot number for a batch of 10,000 assemblies or if he wants serial numbers on each subassembly or final assembly.

On an automotive welding line, the sequence of operations depends on what secondary operations need to be done, such as punching, grinding or dispensing. In some cases, the sequence of operations may need to be altered to allow the parts to cool off. “Welding puts a tremendous amount of heat into the part, and that can cause distortion. You may need to vary the sequence of welds to minimize that distortion. Process sequencing decisions are part of the IE method - ECRS.

https://www.assemblymag.com/articles/94475-designing-and-building-automated-assembly-systems

Smartphone Assembly Automation

Real-World Example from Electronics Production - Festo solutions

https://www.festo.com/us/en/e/solutions/industries/electronics-industry/assembly-and-test/smartphone-assembly-id_253053/

Title of Thesis : IMPLEMENTATION OF AUTOMATED ASSEMBLY

Kang H. Kong : Master of Science in

Manufacturing Engineering, 1991.

Thesis directed by : Professor Steve Kotefski

http://archives.njit.edu/vol01/etd/1990s/1991/njit-etd1991-025/njit-etd1991-025.pdf

Title of Thesis:

Design For Assembly: Re-design of An Electrical Switch For The Ease of Automatic Assembly

Name of Candidate: Achyuta Reddy Pannala

Master of Science in Manufacturing Engineering, 1991

http://archives.njit.edu/vol01/etd/1990s/1991/njit-etd1991-021/njit-etd1991-021.pdf

Recent

SAP - Industry4.Now

https://www.sap.com/dmc/exp/2020-10-industry4now-experience/d2o/design/requirements/02

Watch interactive presentation above.

The Industry 4.0 strategy we published in 2020 has reached a wide audience, with more than 40,000 downloads to date. Meanwhile, the passage of time has made it clear that the digital transformation of manufacturing companies is no longer optional. Reflecting how the world is changing, I am proud to share the updated whitepaper, The Digital Transformation of Manufacturing Companies: SAP’s Strategy for Industry 4.0.

https://news.sap.com/2021/11/industry-40-updated-whitepaper/

Books on Automation

2nd Edition, 2005

Assembly Automation and Product Design

By Geoffrey Boothroyd

https://www.routledge.com/Assembly-Automation-and-Product-Design/Boothroyd/p/book/9781574446432

Assembly Automation and Product Design

Geoffrey Boothroyd

CRC Press, 30-Aug-1991 - Technology & Engineering - 432 pages

https://books.google.co.in/books/about/Assembly_Automation_and_Product_Design.html?id=XFtgaNFzMHQC

Assembly Automation, Second Edition

A Management Handbook

Frank J. Riley

Pages 320 Pages, Hardcover

Published Date: June, 2005

https://books.google.co.in/books?id=ECK5ElwQGi4C&printsec=frontcover&source=gbs_atb#v=onepage&q&f=false

https://books.google.co.in/books?id=ECK5ElwQGi4C

https://books.industrialpress.com/assembly-automation-second-edition.html

1st Edition

Assembly Processes

Finishing, Packaging, and Automation

Edited By Richard Crowson

https://www.routledge.com/Assembly-Processes-Finishing-Packaging-and-Automation/Crowson/p/book/9780849355653

The Electronics Assembly Handbook

Frank Riley, Electronic Packaging and Production

Springer Science & Business Media, 29-Jun-2013 - Technology & Engineering - 603 pages

The assembly of electronic circuit boards has emerged as one of the most significant growth areas for robotics and automated assembly. This comprehensive volume, which is an edited collection of material mostly published in "Assembly Engineering" and "Electronic Packaging and Production", will provide an essential reference for engineers working in this field, including material on Multi Layer Boards, Chip-on-board and numerous case studies. Frank J. Riley is senior vice-president of the Bodine Corporation and a world authority on assembly automation.

https://books.google.co.in/books/about/The_Electronics_Assembly_Handbook.html?id=mFjuCAAAQBAJ

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Articles and Papers

Automation of 5 Axis Machines

https://go.ellisontechnologies.com/automation

Automated Manufacturing - Automated Production Operations in Manufacturing Processes News Year-Wise

2023

Samsung's Automated Semiconductor Packaging Lines

According to the results of Samsung’s conversion of its packaging production lines to an unmanned process, manufacturing manpower has been reduced by 85%, the occurrence rate of equipment failures has been reduced by 90%, and the overall equipment efficiency has increased by approximately 2 times or more.

https://www.equipment-news.com/samsung-automates-semiconductor-packaging/

https://www.digitimes.com/news/a20230901PD204/samsung-ic-manufacturing-packaging-automation.html

The fully automated FOSB packing/unpacking solution for the Semiconductor industry

Success story | Zurich, Switzerland | 2022-10-13

Easy Field Corporation (EFC) is a leading system integrator for the electronics and semiconductor industry. In order to maintain stable and rapid production needs and avoid wafer pollution or electrostatic damage, ABB Robotics and EFC together create a high-efficiency automatic unpacking solution.

https://new.abb.com/news/detail/95783/cstmr-the-fully-automated-fosb-packingunpacking-solution-for-the-semiconductor-industry

https://www.einnosys.com/semiconductor-factory-automation-the-future-of-manufacturing-production/

New guide to automate existing machine tools, Author: Cutting Tool Engineering

February 07, 2022

https://www.ctemag.com/news/industry-news/new-guide-automate-existing-machine-tools

Making the Decision to Automate CNC Machining

Dec. 2, 2021

For machine shops wanting to boost productivity, improve part quality, or increase shop flexibility, automation can be a powerful tool. While deciding on which automation use-case will provide the greatest benefit. Shop owners need to work to identify several key performance indicators (KPIs) or metrics that can be associated with the automation goals. Gathering and analyzing a combination of several metrics — like scrap rates, the average number of tool assemblies, parts out the door per month, and cycle time —likely will be necessary to provide insight into how well automation is performing in a shop.

Before automating machining or finishing processes, manufacturers should determine if their facilities are ready for automation and if automation would provide a good return on investment.

Alternatives: To automate a CNC lathe a shop may use a gantry robot to perform loading and unloading of the chuck. Another shop may adopt a flexible machine-tending robot arm that can manage both raw materials and finished parts. A variety of automated finishing processes and related workflows, like vibratory finishing, centrifugal disc finishing, and magnetic separation, are available.

https://www.americanmachinist.com/automation-and-robotics/article/21182722/what-cnc-machine-automation-can-do-for-machine-shops-machine-shop-tips

Sustainably produced and highly individual: BMW M4 small series takes shape using new paint process. BMW Group Plant Dingolfing pilots new paint process.

October 1, 2021

https://www.automotiveworld.com/news-releases/sustainably-produced-and-highly-individual-bmw-m4-small-series-takes-shape-using-new-paint-process/

Dürr building smart and resource-efficient paint shop at San Luis Potosí in Mexico for BMW Group; Industry 4.0

12 April 2018

Dürr is building a paint shop in Mexico for the BMW Group (BMW 3 Series Sedan) that meets the requirements for connected Industry 4.0 production.

Dürr is supplying the complete paint shop: from pretreatment (PT) and electrocoating (EC) processes all the way through to the spray booths with application technology and the ovens. The waste water treatment plant, the deionization system of the water (DI plant), and the shop ventilation are also included in the scope of services. The respective processes are designed around the consistent integration of smart solutions.

In the first stage, the paint shop is designed for a capacity of 35 vehicles per hour, with the option to increase the throughput to twice this capacity later. The PT/EC area is designed to accommodate 60 vehicles per hour from the outset. BMW will use its tried-and-tested, fully automatic Integrated Paint Process (IPP) in this plant, which eliminates the primer and a drying phase.

https://www.greencarcongress.com/2018/04/20180412-d%C3%BCrr.html

CoroPlus® Connected for Automation in Machining

Establishes connectivity between your machine tool and cutting tools, enabling machining automation.

CoroPlus® Connected enables automation through data-driven decisions and initiates actions to ensure component quality and improve efficiency, with the ambition to eliminate machine downtime.

Technology:CoroPlus® Connected uses standardized hardware and PLC interface for secure and high-speed machine connectivity.

The user interface is integrated in the CNC controller or on a nearby connected device, depending on user needs. The machine control access enables rapid commands and process adjustments.

A dedicated antenna ensures a stable and secure wireless communication with digital cutting tools.

CoroPlus® Connected enables additional features of the digital tooling solution Silent Tools™ Plus:

Overload protection

Vibration protection

Temperature protection

https://www.sandvik.coromant.com/en-gb/products/coroplus-connected/pages/default.aspx

The dawn of automation secures SWEP’s heat transfer advancement

September 09, 2021

https://www.swep.net/company/news-and-media/news/2021/09/the-dawn-of-automation-secures-sweps-heat-transfer-advancement/

Automation for Everyone

February 18, 2021

By Geoff Giordano, Contributing Editor, SME Media

Automation was once only for big factories, but now small job shops can benefit as well

https://www.sme.org/technologies/articles/2021/march/automation-for-everyone/

Practical Approaches to Automation

Automation isn't just useful for large volumes of the same part. Today, it is increasingly being used in machine shops for high-mix, low-volume jobs.

10/23/2020

https://www.mmsonline.com/articles/practical-approaches-to-automation

Automation In Machine Tool Manufacturing

By: Masaya Takeda, General Manager CNC Systems, Mitsubishi Electric India Pvt. Ltd. | Monday, 28 September 2020

https://www.theindustryoutlook.com/manufacturing/industry-experts/automation-in-machine-tool-manufacturing-nwid-711.html

Assembly system configuration through Industry 4.0 principles: the expected change in the actual paradigms

YuvalCohen* MaurizioFaccio** Francesco Gabriele Galizia** CristinaMora*** FrancescoPilati***

IFAC-PapersOnLine

Volume 50, Issue 1, July 2017, Pages 14958-14963

https://www.sciencedirect.com/science/article/pii/S2405896317334754

Design for automation in manufacturing systems and processes

2016 MIT MBA Thesis

Ezolino, Juan Stefano

https://dspace.mit.edu/handle/1721.1/104311

Automation in Mechanical Systems

Modules / Lectures

Introduction

Automated systems

Hydraulic and pneumatic controls

Electropenumatics

Programmable logic controllers

https://nptel.ac.in/courses/112/102/112102011/

Lean Automation

February 1, 2009

By Patrick Waurzyniak

Contributing Editor,

SME Media

Combining lean manufacturing tools with the right automation systems can boost productivity

https://www.sme.org/technologies/articles/2009/lean-automation/

Automation Systems and Components - Suppliers

Distitec

https://www.distitec.com/en/sectors-and-machinery/machine-tools-automation-and-measuring-instruments

HWACHEON CNC Machine Tools - Made by Hwacheon. Made in Korea

Automated Machining Line with High Flexibility in CNC Machining

May 20, 2021

https://hwacheonasia.com/automation-line-with-high-flexibility-in-cnc-machining/

Hyundai WIA Assembly automation line

Hyundai WIA provides automation lines to assemble key components of finished car, engine and transmission.

https://machine.hyundai-wia.com/eu/fa/assembly.asp

Rockwell Automation

Design flexible manufacturing and assembly machines with the right balance of machine performance, safety, and cost.

Flexibility and Speed

Increase Flexibility, Decrease Machine Time and Cost

Manufacturing and assembly machines support a wide range of applications. Manufacturing machines such as forming, stamping and curing are used to transform materials to create finished goods. Assembly machines assemble parts into final products or subcomponents.

No matter the machine type, flexibility and speed are critical. Your customers also want process repeatability with minimized scrap. Your challenge is to balance machine performance, safety and cost.

Our range of manufacturing and assembly automation and control systems give you the design flexibility to easily modify machine functionality. This allows you to quickly respond to evolving customer and market demands.

Customer Case Studies are also available

https://www.rockwellautomation.com/en-gb/capabilities/machine-equipment-builders/manufacturing-and-assembly-automation.html

RNA Automation

Bespoke Assembly Machines

RNA design and manufacture Bespoke Automated Assembly Machines and Special Purpose Machines including rotary indexing tables, robotic systems, vision inspection systems, walking beam, feeding and handling systems and special purpose, automated test solutions across a wide range of industry sectors.

Bespoke Assembly Solutions

RNA designs and develops bespoke assembly automation across a range of industries including automotive, pharmaceutical, medical device, food & beverage, consumer goods, electronics and other manufacturing industries.

From simple, standalone poka yoke mechanical devices to fully automated assembly line, we have the knowledge and experience to provide cutting edge industrial automation solutions to improve OEE, efficiency and productivity.

Our Knowledge & Experience

Bespoke Assembly Machines

Flexible automatic assembly machine

Automation systems

Semi or fully automated production line

Semi or fully automated assembly line

Sorting and assembly turnkey solutions

System integration and development

https://www.rnaautomation.com/products/automation-solutions/

Automatic Screw Driving and Feeder Systems

Single Spindle

Screw Driving Component

Screw Assembly Machine

Multiple Spindles

Screw Driving Component

Multi-Spindle-Screw-Driving-Slide

Vacuum Based

Screw Driving Slide

Vacuum Based Screw Driving Slider

Collaborative Robot

Screw Driving Slide

https://www.assemblyauto.com/

Delta Electronics India

https://deltaelectronicsindia.com/industrial-automation/

(Saw the bill board in Mumbai airport)

Delta offers automation products and solutions with high performance and reliability, including drives, motion control systems, industrial control and communication, power quality improvement, human machine interfaces, sensors, meters, and robot solutions. We also provide information monitoring and management systems such as SCADA and Industrial EMS for complete, smart manufacturing solutions.

Drive & Power Quality

AC Motor Drives

High Power Motor Drives

Power Quality