IEPM Automation

8/2/2019 IEPM Automation

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Coined at Ford Motor Company in 1945 to describe

a logical development in technical progress whereautomatic handling between machines is combined withcontinuous processing at machines

It is the technology concerned with the application of

complex mechanical, electronic and computer basedsystems in the operation and control of production.

Examples are -

Automatic Materials Handling System

Feedback Control Systems

Computer Process Control Systems


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1. To increase labor productivity

2. To reduce labor cost

3. To mitigate the effects of labor shortages

4. To reduce or remove routine manual and clerical tasks5. To improve worker safety

6. To improve product quality

7. To reduce manufacturing lead time

8. To accomplish what cannot be done manually

9. To avoid the high cost of not automating


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Functional Group Technology

Processing, Fabrication

and Assembly

Numerically Controlled (N/C) MachinesCNC

DNC

Robotics

Flexible manufacturing systems (FMS)

Automated Material

Handling

Automated storage and Retrieval system(AS/RS)

Automated Guided Vehicle (AGV)

Design and Engineering

Computer-Aided Design/Manufacturing

(CAD/CAM)

Computer Integrated Manufacturing (CIM)

Inspection and

CommunicationsAutomatic Identification Systems (AIS)


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Numerical control (NC) refers tothe automation of machine tools

that are operated by abstractly

programmed commands encoded

on a storage medium, as opposed

to manually controlled via handwheels or levers, or mechanically

automated via cams alone.

Form of flexible (programmable)

automation in which the process

is controlled by numbers, letters,and symbols.


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The EIA definition ofcomputer numericalcontrol (CNC). A numerical control system

wherein a dedicated, storedprogram computer is used toperform some or all of thebasic numerical controlfunctions in accordance withcontrol programs stored in the

read-write memory of thecomputer.


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The first benefit offered by all forms of CNC machine tools is improved

automation The second major benefit of CNC technology is consistent and accurate

workpieces

A third benefit offered by most forms of CNC machine tools is flexibility-just a change of variable is required.


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In DNC, several NC machinesare directly controlled by acomputer, eliminatingsubstantial hardware from theindividual controller of eachmachine tool.

If the computer is connected to

a number of machines it candistribute programs to differentmachines as required. Usually,the manufacturer of the controlprovides suitable DNCsoftware.

The part-program isdownloaded to the machinesdirectly (thus omitting the tapereader) from the computermemory.


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It consists of a variety of computer-controlled methods for automaticallyplacing and retrieving loads from specific storage locations

It is used in manufacturing, distribution, retail, wholesale and institutions

It is typically used in applications where:

there is a very high volume of loads being moved into and out of storage

storage density is important because ofspace constraints

accuracy is critical because of potential expensive damages to the load

The traditional vending machine is the most common and familiar AS/RSsystem


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AS/RS

Fixed AisleSingle masted

Double masted

Man-aboardCarousels/VerticalLift Modules (VLMs)


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Increased inventory control and tracking

Savings in inventory storage costs

Improved warehouse space utilization, both vertically and

horizontally

Creates greater storage density

Reduced labor costs

Increasing workplace safety

Removing personnel from difficult working conditionsEg : Cold food storage environments


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It is a mobile robot that follows markers or wires in the

floor, or uses vision or lasers

They are most often used in industrial applications to move

materials around a manufacturing facility or a warehouse

They increase efficiency and reduce costs by helping to

automate a manufacturing facility or warehouse

In an automated process, AGVs are programmed to

communicate (via an offboard server) with other robots to

ensure the product is moved smoothly through the warehouse,whether it is being stored for future use or sent directly to

shipping areas


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It is the manufacturing approach of using computers tocontrol the entire production process

This integration allows individual processes to exchange

information with each other and initiate actions

Through the integration of computers, manufacturing canbe faster and less error-prone

CIM implies that there are at least two computersexchanging information, e.g. the controller of an arm robotand a micro-controller of a CNC machine


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As with all systems, CIM too has its challenges to be solved

Integration of components from different suppliers:

When different machines, such as CNC, conveyors and robots, are using

different communications protocols

Data integrity:

The higher the degree of automation, the more critical is the integrity of the

data used to control the machines

Process control: Computers may be used to assistthe human operators of the manufacturing

facility, but there must always be a competent engineer on hand to handle

circumstances which could not be foreseen by the designers of the control

software


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Use of computer systems to assist in

the creation, modification, analysis,

and optimization of a design

Typical tools: Tolerance analysis

Mass property calculations

Finite-element modeling and visualization

Defines the geometry of the design


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Use of computer systems to plan,

manage, and control

manufacturing operations

Direct or indirect computerinterface with the plants

production resources

Numerical control of machine

tools

Programming of robots


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Major component is hardwareand software allowing shapemanipulation

Hardware includes graphicdevices and their peripherals forinput and output operations

Software includes packages thatmanipulate or analyze shapesaccording to user interaction


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Sense and input data into computers

Use bar codes, radio frequencies, magnetic stripes, optical

character recognition, machine vision

Data read from products, documents, parts, and containers

Used in warehouses, factory floors, retailing, wholesaling


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Better Inventory Management

Increased Throughput and Productivity

Shorter Order Cycles

Faster Shipping Reduced Labor cost

Increased Revenue


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Robotics:Robotics is the science and technology of

Robots, their design, manufacture, and

application.

An Industrial robot is a general-purpose,programmable machine possessing certain

anthropomorphic characteristics.

A robot can be programmed to perform of a

sequence of repetitive tasks, which will beperformed until the robot is reprogrammed

to perform some other motion cycle.


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Parts handling

Pick and Place jobs

Machine loading and unloading

Production equipment

Metal-cutting machine tools

Spray Painting

Spray paint nozzle attached to the robots arm


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Welding

Spot Welding

Continuous welding

Assembly

Extension of pick-and-place motions

Documents

IEPM Automation