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No Slide TitleThe University of Texas at Arlington Automation & Robotics Research Institute
Reconfigurable Automation
Raul Fernandez
Program Manager
The University of Texas at Arlington
Page *, * DMCFlexCell99.ppt
The University of Texas at Arlington Automation & Robotics Research Institute
Presentation Outline
The need for Strategic Cash Flow Justification strategies
The structure of modular reconfigurable automation systems
A case study presenting the deployment of modular automation in a DoD high mix/low volume production environment
Today’s Manufacturing Environment
Emphasis on Cost with No Compromises on Quality and Performance
Tactical Justification of Manufacturing Technology
Conventional
Manufacturing
Methods
Automated
Manufacturing
Methods
Traditional Economic Trade Studies based on lowest cost alternatives bound by minimum performance requirements
Problems With Avoiding Automation
Implement Manual Assembly Systems
Low capital / high flexibility yet productivity, precision, and quality issues
Outsource Assembly & Test Operations
Quality, delivery exposure
Conventional Automation Systems
Very Cost-Driven
Life of system is tied directly to life of product
Limited opportunity for system re-use
A Traditional “Flexible” Assembly Machine
Has a robot (versus “hard” mechanical actuation)
No separate process modules
Dedicated parts feeding, tooling
Conventional Automation Systems
Inhibit manufacturing agility
Unable to adapt to changes in product mix and volume
Product life cycles are becoming shorter than the time required to bid, design, install & debug traditional automated assembly systems
Cost of re-implementing traditional automation is prohibitive
In conflict with current manufacturing needs:
Reconfigurable Automation Systems
Product
Base
Process
Modular Capacity to Match Volatile Demand
Production Volume of 1st Model
: Required Production Volume
: System Production Capacity
: Required Production Volume
: System Production Capacity
Layered System Architecture
PRODUCT LAYER - specific product hardware and information which identifies the processes and production sequences required to produce specific products
PROCESS LAYER - the base platform and the process building blocks provided determine the functional capability of the system.
BASE LAYER - provides generic production resources and application development toolsets
A three-layered approach
Reconfigurable Automation Technology
Can Be Reconfigured Into a Large Number of Base Configurations
Supports the Development of a Large Number of Base Cell Configurations
Base Layer Hardware
Flexible Automation Technology
Cell Configuration Software
Device Control Software
Flexible Cell Configuration -
Process Layer Components
Process Specific Tooling
Layered Software Architecture
Flexible Automation Technology
Product Specific Tooling
Product Layer Configuration
New Technology Implementation
Development & maintenance of a library of generic intelligent automated process technologies
Design for Flexible Automation
Affordable Multi-Missile Manufacturing
Aerospace Applications
Lockheed Martin Proprietary Information
Flex Cell Process Simulation
Product
Process
Base
Two documents were generated that capture our NGF effort, The NGF vision outlines the technologies, requirements and philosophy required in our factory,
The second document, a 3rd quarter payable milestone, identifies the requirements to capture the NGF in a simulation, The simulation is identified as a tool to evaluate the potential impact of the NGF factory on current and future products, to conduct what-ifs and to evaluate the influence of new emerging technologies that are being considered for implementation in the factory,
Automated Process Prototyping - ACS Assembly
ACM Insertion End Effectors
Probe
Product
Process
Two documents were generated that capture our NGF effort, The NGF vision outlines the technologies, requirements and philosophy required in our factory,
The second document, a 3rd quarter payable milestone, identifies the requirements to capture the NGF in a simulation, The simulation is identified as a tool to evaluate the potential impact of the NGF factory on current and future products, to conduct what-ifs and to evaluate the influence of new emerging technologies that are being considered for implementation in the factory,
Honeywell - light duty aerospace
High-mix / low volume production environment
Multiple cell redeployment scenarios justified
Use of Automation for Labor Reduction is Enabled by Flex Cell Approach
Reduced Dependence on Product-Specific Systems and Facilities
Reduced Implementation/Deployment Time
Small Reconfigurable Cell Configuration
Potential Applications
Systems processing assemblies fitting within a 30 liter, <5 kg envelope
Consumer electronics, medical products, small electromechanical assemblies for automotive, aerospace, and defense industries
Medium Reconfigurable Cell Configuration
Systems processing assemblies fitting within a one cubic meter, <20 kg envelope
Automotive engine and transmission assembly, appliance assembly, and missile section assembly
Large Reconfigurable Cell Configuration
Systems processing assemblies greater than a one cubic meter and 20 kg, envisioned to exceed the reach and payload of all but the largest industrial robots
Airframe assembly, heavy automotive assembly, and large reach palletizing applications
Reconfigurable Automation Enables Scalable Systems
Low volume / high work content at production introduction
Higher production volumes are supported by adding cells and distributing work content
Benefits of Reconfigurable Manufacturing Systems
System can be reconfigured to meet the needs of high-mix low-volume manufacturing
Base layer, which has highest capital investment, is reusable but costs 10% to 25% more
The required process building blocks can be quickly added to the base platform system
Process layer has plug-in reusable modules which can be changed over from one process to the next within minutes instead of hours or days
Product layer has minimal investment and is capable of responding to instant changes in product demands
In Conclusion
. . . Creating Reconfigurable
Automation Systems . . .
:
System Production Capacity
. . . That support multiple product life cycles in a rapidly changing global market place
Production Volume of 1
:

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