+Shafia Automation Strategies

8/3/2019 +Shafia Automation Strategies

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Automation Strategies

Henry C. Co

Technology and Operations Management,

California Polytechnic and State University


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Operations Strategies 2

Automation Strategies

1. Specializing Operations

2. Combining Operations

3. Simultaneously Executing Operations

4. Integrating Operations

5. Reducing Setup Time

6. Streamlining Material Handling

7. Controlling/Optimizing Processes

8. Implementing ManufacturingDatabase and Information System


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1. Specializing Operations

The key concept of mass production

Low unit cost by extreme specialization ofequipment.

Example (automobile engine or

transmission production): The plant would consists of a set of giant

multiple-spindle machines, generally withbetween 100 to 1000 tools, mainly drills,

cutting simultaneously. The spindles are clustered in stations that

are synchronously linked togethermechanically via indexing transfer lines.


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2. Combining Operations

Production occurs as a sequence of

operations. Some complicated partsmay require as many as 50 distinctsteps.

Combining operations To reduce the number of distinct steps by

performing more than one operation at agiven workstation.

Combining operation reduces the numberof setups.


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3. Simultaneously Executing Operations

The strategy is to perform multiple

operations at the same workstationssimultaneously. Multi-spindlemachining center utilize this concept.


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4. Integrating Operations

A series of workstations are linked together as a

single integrated mechanism by automatic workhandling devices.

To achieve high rates of production, dial indexingmachines, trunnion machines, and transfer lines havebeen designed to perform a great variety of manydifferent metal-cutting processes.

For example, the rotary indexing machine performs asequence of machining operations on several work-parts simultaneously.

Radial machining heads are located around theperiphery of a horizontal circular table or dial. Parts

are fixtured on the table and indexed betweensuccessive stations.


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5. Reducing Setup Time

Whereas the strategy of combined operation

reduces the number of setups, this strategyis concerned with reducing the setup time.This is accomplished by Group Technology(e.g., scheduling of similar parts through theproduction machine, use of common fixtures

for different but similar parts) and designinggreater flexibility into the manufacturingsystem.

Reduce setup time means lower economic

quantity (smaller lot sizes). Reduced lotsizes means lower work-in-process inventoryand faster turnaround time.


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The hydraulic-valve division of Parker-Hannifin Corporationrecently installed a flexible manufacturing cell (FMC) at its

Forest City, North Carolina plant. The FMC consists of a twin-spindle CNC turning center, an

angle-elongate hole mill, a wash station, and a gantryrobot to handle the work piece through the cell. This cell isused to produce a specific family of hydraulic valves.

Prior to the FMC, the valves were manufactured using a

number of ACME six spindle bar machines and Kingsburycenter column machines (a type of dial indexingmachines), which involved up to 54 setup hours and alarge number of work-in-process (WIP) inventory.

The FMC was installed to reduce product lead time,inventory cost, scrap, and indirect labor cost; and toimprove quality. Setup time along was reduced to two

hours and WIP inventory to zero.


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6. Streamlining Material Handling

A great opportunity for reducing

nonproductive time exists through the use ofmechanized and automated materialshandling methods. The typical benefits ofimproved handling are reduced work-in-

process and shorter throughput times. Thesebenefits are generally achieved byminimizing the distances over which thework-parts must be moved, providing for

smooth flow through adjacent stations,handling the parts in larger unit loads, andother common sense principles.


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The Harris Corporation in Kennedale, Texas

has one of the most sophisticated flexiblemanufacturing systems in existence. Utilizing the group technology concept, Harris has

logically grouped together in one area, themachines that perform most of the necessary

manufacturing operations required for similarfamilies of parts.

Cylindrical print rolls, are automatically loaded bya robot into a double-end machining station,where both ends of the roll are machinedsimultaneously.

When this machining operation has beencompleted, the robot removes the work piece, andreplaces it on the carrier of a car track system.


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After all work pieces on the carrier have beenmachined, the carrier is directed to a robot serviced,

numerically controlled lathe station. These standard carriers transport over 600 different

parts which can be manufactured in the system. Precisecarrier positioning of the car track system enablesrobots to perform consistently. Again the robotremoves a roll from the carrier and places into one ofthe two available NC lathes. These robots areprogrammed with a flexibility to handle each of thedifferent part sizes that are manufactured in thesystem.

When the lathe operations have been completed for allof the rolls on the carrier, the carrier is directedthroughout the remainder of its manufacturing

operations, and then to inspection and shipping areas. Work-in-process storage stations of the car track

systems are strategically integrated throughout themanufacturing area to ensure rapid work piece deliveryand maximum production efficiency.


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7. Controlling/Optimizing Processes

On the factory floor, CAM systems

perform machine monitoring andadjustments as well as controlledmaterials movement. Process control

includes conventional analog feedbackcontrol or computer control, whichallows more flexibility in the type ofcontrol exercised over the process.

Control strategies that can beimplemented by computer includeoptimal control, feedback control,sequencing control, and adaptivecontrol.


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8. Implementing Manufacturing Database &Information System

Development of a manufacturing database andinformation system is an essential function inmanufacturing. The manufacturing databaseinclude:

1. Part drawings, material specifications, and bills ofmaterials (from design engineering);

2. Route sheets which specify the process plans for the

parts, tool lists for the route sheets, tool inventoryrecord (from manufacturing engineering);

3. Methods description, time standards, equipmentjustification document (from industrial engineering);

4. Master schedules, production schedules, exceptionreport (from production planning and control);

5. Inventory records (from inventory control andshipping).


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CAD/CAM stands for Computer-Aided Design

(CAD) and Computer-Aided Manufacturing(CAM). A CAD/CAM system generates acommon data base which can beaugmented, modified, used, and distributedover networks of terminals and computers.The data generated in the CAD designprocess is used in CAM to generate machineinstructions for parts manufacturing.

Major advantages can be realized byintegrating information and sharing theinformation among the variousorganizations, thereby reducing the needlessduplication of information and of theactivities necessary to generate it.


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For example, at the K-2 Ski Company of Kent,Washington, the use of CAD/CAM has helped them build

an extensive data base that is available for referenceand review at all times by their designers and consultingexperts.

Their computer-aided manufacturing program helpsthem produce top quality tooling, dies, and fixtures onsight, providing the precision quality they require and

the assured delivery schedule they need. Andthroughout the assembly process, bar code readersprovide computer input on production flow and materialrequirements to their MRP (material requirementsplanning) system.

This combination of a CAD/CAM and MRP system helpsK-2 shorten the development and production time ofnew products. It also allows them to take advantage ofthe knowledge gained in previous designs and programsto constantly improve their products and maintain theircompetitive position in the rapidly growing leisureproducts and sports equipment field.

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