INE 439

Fundamentals of Manufacturing Systems

Lecture 8: Automated Production Lines

 Ch 16 Automated Production Lines
Sections:
1. Fundamentals of Automated Production Lines
2. Applications of Automated Production Lines
3. Analysis of Transfer Lines

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Fourth Edition, by Mikell P. Groover.
 Automated Production Lines

● High production of parts requiring multiple processing

operations
● Fixed automation
● Applications:
● Transfer lines used for machining
● Robotic spot welding lines in automotive final assembly
● Sheet metal stamping
● Electroplating of metals

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Where to Use
Automated Production Lines
● High product demand
● Requires large production quantities
● Stable product design
● Difficult to change the sequence and content of processing operations
once the line is built
● Long product life
● At least several years
● Multiple operations required on product
● The different operations are assigned to different workstations in the line

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Benefits of
Automated Production Lines
● Low direct labor content
● Low product cost- equipment cost spread on many units
● High production rates
● Production lead time and work-in-process are minimized
● Factory floor space is minimized

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Automated Production Line - Defined
Fixed-routing manufacturing system that consists of multiple
workstations linked together by a material handling system
to transfer parts from one station to the next
● Slowest workstation sets the pace of the line
● Workpart transfer:
● Palletized transfer line
● Uses pallet fixtures to hold and move workparts between stations
● Free transfer line
● Part geometry allows transfer without pallet fixtures

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Automated Production Line

General configuration of an automated production line

consisting of n automated workstations that perform
processing operations

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 System Configurations

● In-line - straight line arrangement of workstations

● Segmented in-line – two or more straight line segments,
usually perpendicular to each other
● Rotary indexing machine (e.g., dial indexing machine)

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Segmented In-Line Configurations

L-shaped layout

U-shaped layout

Rectangular configuration

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Two Machining Transfer Lines

On the left is a segmented in-line palletized transfer line using pallet

fixtures to locate work parts. The return loop brings the pallets back to
the front of the line. On the right is an in-line free transfer line. Parts are
represented by ovals, pallet fixtures by rectangles.
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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Rotary Indexing Machine

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Workpart Transfer Mechanisms
● Linear transfer systems:
● Continuous motion – not common for automated systems
● Synchronous motion – intermittent motion, all parts move
simultaneously
● Asynchronous motion – intermittent motion, parts move
independently
● Rotary indexing mechanisms:
● Geneva mechanism- uses a continuously rotating driver to index
the table through a partial rotation

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Belt-Driven Linear Transfer System

Side view of chain or steel belt-driven conveyor (over and under

type) for linear transfer using work carriers

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Walking Beam Transfer System

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Geneva Mechanism with Six Slots

https://en.wikipedia.org/wiki/File:Geneva_mechanism_6spoke_animati
on.gif

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Storage Buffers in Production Lines
A location in the sequence of workstations where parts
can be collected and temporarily stored before
proceeding to subsequent downstream stations
● Reasons for using storage buffers:
● To reduce effect of station breakdowns
● To provide a bank of parts to supply the line
● To provide a place to put the output of the line
● To allow curing time or other required delay
● To smooth cycle time variations
● To store parts between stages with different production rates

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Control Functions in an
Automated Production Line
● Sequence control
● To coordinate the sequence of actions of the transfer system and
workstations
● Safety monitoring
● To avoid hazardous operation for workers and equipment
● Quality control
● To detect and possibly reject defective work units produced on the line

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Applications of
Automated Production Lines
● Transfer lines for machining
● Synchronous or asynchronous workpart transport
● Transport with or without pallet fixtures, depending on part geometry
● Various monitoring and control features available
● Rotary transfer machines for machining
● Variations include center column machine and trunnion machine

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Rotary Transfer Machine (Plan View)

https://www.youtube.com/watch?
v=xY1YfwssoaI

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Center Column Machine (Plan View )

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Analysis of Transfer Lines

● Three problem areas must be considered:

• Line balancing
● To divide the total work load among workstations as evenly as
possible
• Processing technology
● Theory and principles about the manufacturing or assembly
processes used on the line
• System reliability - two cases:
● Transfer lines with no internal parts storage
● Transfer lines with internal storage buffers

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Analysis of Transfer Lines
● Cycle Time Analysis
● Parts are introduced into the first workstation and are processed
and transported at regular intervals to succeeding stations.

● In the operation of a transfer line, random breakdowns and

planned stoppages cause downtime on the line.
● Downtime occurrences cause the actual average production cycle
time of the line to be longer than the ideal cycle time.
At 1001 efficiency
where F = downtime frequency, y line stops/cycle; and Td =
Qdown
frequencyofitbreakingdown
average downtime per line stop, min.time
● The frequency of line stops per cycle is obtained by merely
summing the frequencies Pi over the n stations,

Tp To
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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 Analysis of Transfer Lines
● Performance Measures
● Production rate

● Ideal production rate

● Line efficiency
● Proportion of downtime on the line D
● Cost per unit produced
where Cpc = cost per piece, $/pc; Cm = cost of starting material, $/pc; Co =
cost per minute to operate the line including capital equipement cost,
$/min; Tp = average production time per piece, min/pc; and Ct = cost of
tooling per piece, $/pc.

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 In Class Activity 12
A machine tool builder submits a proposal for a 20-station transfer line to
machine a certain component currently produced by conventional
methods. The proposal states that the line will operate at a production
rate of 50 pc/hr at 100% efficiency. On similar transfer lines, the
probability of station breakdowns per cycle is equal for all stations: p =
0.005 breakdowns/cycle. It is also estimated that the average downtime
per line stop will be 8.0 min. The starting casting that is to be machined
on the line costs $3.00 per part. The line operates at a cost of $75.00/hr.
The 20 cutting tools (one tool per station) last for 50 parts each, and
average cost per tool is $2.00 per cutting edge. Determine (a) production
rate, (b) line efficiency, and (c) cost per piece produced on the line.

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 In Class Activity 12 Solution

Solution:

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.
 What the Equations Tell Us –
Lines with No Storage Buffers

● As the number of workstations increases

● Line efficiency and production rate are adversely affected
● As reliability of individual workstations decreases
● Line efficiency and production rate are adversely affected

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or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing,
Fourth Edition, by Mikell P. Groover.