Introduction to Industrial

Automation
RAT 282

Module 1
• Automation methodologies: Concept of Mechanization and
Automation – Types of Automation Detroit type Automation,
Automated flow lines, Fundamentals of Transfer Lines.
• Trends in manufacturing – GT and Cellular Manufacturing, Flexible
manufacturing systems – features of FMS, computer integrated
manufacturing – need for AI and expert systems in CIM, Automated
assembly system – flexible assembly automation.
Definition

Need for Automation

• Increased productivity
• Greater product variety
• Complete gain control of manufacturing process
• Improved quality and accuracy and consistency in manufacturing:
Automation not only produce parts at faster rates than their manual
counterparts, but they produce parts with greater consistency and
conform to quality specifications
• Working in difficult and hazardous environment : By automating and
transferring the operator from an active participant to a supervisory
role, work is made safer
Need for Automation cntd…
• High cost of labor : Higher investment in automated equipment has
become economically justifiable to replace manual operations.
Because machines can produce higher rates of output, automation
results in lower cost per unit of product
• Reduced manufacturing lead time: Automation allows the
manufacturer to reduce time between customer order and product
delivery
• Labor shortages

Types of automation
1. Fixed automation
2. Programmable automation
3. Flexible automation
Fixed automation
• It is a system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration.
• The operations in the sequence are usually simple.
• It is the integration and coordination of many such operations into
one piece of equipment that makes the system complex.
• Features of fixed automation are:
1. High initial investment for custom–Engineered equipment;
2. High production rates
3. Relatively inflexible in accommodating product changes
Eg: Machining transfer lines, automated assembly lines

Programmable automation
• In this the production equipment is designed with the capability to
change the sequence of operations to accommodate different
product configurations.
• The operation sequence is controlled by a program, which is a set of
instructions coded so that the system can read and interpret them.
• New programs can be prepared and entered into the equipment to
produce new products.
Programmable automation cntd…
• Some of the features that characterize programmable automation
are:
1. High investment in general-purpose equipment
2. Low production rates relative to fixed automation
3. Flexibility to deal with changes in product configuration
4. Most suitable for batch production.

Programmable automation cntd…

• Automated production systems that are programmable are used in low and
medium volume production.
• The parts or products are typically made in batches.
• To produce each new batch of a different product, the system must be
reprogrammed with the set of machine instructions that correspond to the
new product.
• The physical setup of the machine must also be changed over (tooling,
fixtures, and machine setting).
• This changeover procedure takes time. Consequently, the typical cycle for
given product includes a period during which the setup and
reprogramming takes place, followed by a period in which the batch is
produced.
• eg.: numerically controlled machine tools and industrial robots
FLEXIBLE AUTOMATION
• It is an extension of programmable automation.
• A flexible automated system is one that is capable of producing a
variety of products (or parts) with virtually no time lost for
changeovers from one product to the next.
• There is no production time lost while reprogramming the system and
altering the physical setup (tooling, fixtures, and machine setting).
• Consequently, the system can produce various combinations and
schedules of products instead of requiring that they be made in
separate batches.

FLEXIBLE AUTOMATION cntd…

• Features of flexible automation :
1. High investment for a custom-engineered system.
2. Continuous production of variable mixtures of products.
3. Medium production rates.
4. Flexibility to deal with product design variations.
• The essential features that distinguish flexible automation from
programmable automation are:
1. the capacity to change part programs with no lost production time

2. the capability to changeover the physical setup, again with no lost

production time.
Detroit Type of Automation
• Here we consider the automated equipment used in the processing of disc
rete parts in large volumes.
• The equipment is often in the configuration of mechanically
integrated flow lines, consisting of a number of workstations
that perform the processing operations on the line.
• These flow lines are called transfer machines or transfer lines.
• The methods used to transport parts between stations
are examined in this chapter as well as the other features
that characterize these production systems.
AUTOMATED FLOW LINES
• An automated flow line consists of several machines or workstations which
are linked together by work handling devices that transfer parts between
the stations.
• The transfer of workparts occurs automatically and the workstations carry
out their specialized functions automatically.
• A raw workpart enters one end of the line and the processing steps are
performed sequentially as the part moves from one station to the next.
• It is possible to incorporate buffer storage zones into the flow line, either
al a single location or between every workstation.
• It is also possible to include inspection stations in the line to automatically
perform intermediate checks on the quality of the workparts.
• Manual stations might also be located along the flow line to perform
certain operations which are difficult or uneconomical to automate.

AUTOMATED FLOW LINES

AUTOMATED FLOW LINES
The objectives of the use of flow line automation are:
• To reduce labor costs
• To increase production rates
• To reduce work-in-process
• To minimize distances moved between operations
• To achieve specialization of operations
• To achieve integration of operations

Configurations of automated flow line.

1. In-line type
2. Segmented In-Line Type
3. Rotary type
1) In-line type
• The in-line configuration consists of a sequence of workstations in a
more-or-less straight-line arrangement

2) Segmented In-Line Type

• The segmented in-line configuration consists of two or more straight-
line arrangement which are usually perpendicular to each other with
L-Shaped or Ushaped or Rectangular shaped
• The flow of work can take a few 90° turns, either for workpieces
reorientation, factory layout limitations, or other reasons, and still
qualify as a straight-line configuration
Segmented In-Line Type

Segmented In-Line Type

Segmented In-Line Type

3) Rotary type
• In the rotary configuration, the workparts are indexed around a
circular table or dial.
• The workstations are stationary and usually located around the
outside periphery of the dial.
• The parts ride on the rotating table and arc registered or positioned,
in turn, at each station for its processing or assembly operation.
• This type of equipment is often referred to as an indexing machine or
dial index machine
3) Rotary type

Selection between Inline and Rotary type

• Selection between the two types depends on the application
• Rotary type is limited to smaller work pieces and to fewer stations
• Not much flexibility in the design of rotary configuration
• Dial type design does not lend itself providing for buffer storage
capacity
• Rotary configuration usually involves a lower cost piece of equipment
and typically requires less factory floor space
Selection between Inline and Rotary type
• Inline preferred for larger workpieces and can accommodate a larger
number of workstations
• In line machines can be fabricated with a built-in storage capability to
smooth out the effect of work stoppages at individual stations and
other irregularities

Fundamentals of Transfer Lines

• The transfer mechanism of the automated flow line must not
only move the partially completed workparts or assemblies
between adjacent stations, it must also orient and locate the
parts in the correct position for processing at each station.
• The general methods of transporting workpieces on flow lines
can be classified into the following three categories:
1. Continuous transfer
2. Intermittent or synchronous transfer
3. Asynchronous or power-and-free transfer
Fundamentals of Transfer Lines
The most appropriate type of transport system for a given
application depends on such factors as:
• The types of operation to be performed
• The number of stations on the line
• The weight and size of the work parts
• Whether manual stations are included on the line
• Production rate requirements
• Balancing the various process times on the line

Transfer lines

Continuous Intermittent Asynchronous

transfer transfer transfer
1.Continuous transfer
• With the continuous method of transfer, the workparts are moved
continuously at constant speed.
• This requires the workheads to move during processing in order to
maintain continuous registration with the workpart.
• For some types of operations, this movement of the workheads during
processing is not feasible.
• It would be difficult, for example, to use this type of system on a
machining transfer line because of inertia problems due to the size and
weight of the workheads.
• In other cases, continuous transfer would be very practical.
• Examples of its use are in beverage bottling operations, packaging,
manual assembly operations where the human operator can move with the
moving flow line, and relatively simple automatic assembly tasks
• Continuous transfer systems are relatively easy to design and fabricate
and can achieve a high rate of production.

2) Intermittent transfer
• The workpieces are transported with an intermittent or
discontinuous motion.
• The workstations are fixed in position and the parts are moved
between stations and then registered at the proper locations for
processing.
• All workparts are transported at the same time and, for this
reason, the term "synchronous transfer system" is also used to
describe this method of workpart transport.
• Eg: Machining operations or progressive dies and mechanized
assembly
3) Asynchronous transfer
• This system of transfer, also referred to as a "power-and-free system,"
allows each workpart to move to the next station when processing at the
current station has been completed.
• Each part moves independently of other parts.
• Hence, some parts are being processed on the line at the same time that
others are being transported between stations.
• Asynchronous transfer systems offer the opportunity for greater flexibility
than do the other two systems, and this flexibility can be a great advantage
in certain circumstances.
• In-process storage of workparts can be incorporated into the
asynchronous systems with relative ease.
• Power-and-free systems can also compensate for line balancing problems
where there are significant differences in process times between stations.
• Parallel stations or several series stations can be used for the longer
operations, and single stations can be used for the shorter operations.
Therefore, the average production rates can be approximately equalized.

3) Asynchronous transfer
• Asynchronous lines are often used where there are one
or more manually operated stations and cycle-time variations
would be a problem on either the continuous or synchronous
transport systems.
• Larger workparts can be handled on the asynchronous
systems.
• A disadvantage of the power-and-free systems is
that the cycle rates are generally slower than for the other types
Fundamentals of Transfer Lines
• There are various types of transfer mechanisms used to move
parts between stations. These mechanisms can be grouped into
two types:
❑those used to provide linear travel for in-line machines, and
❑those used to provide rotary motion for dial indexing machines

Linear transfer mechanisms

Three of the typical mechanisms:
• the walking beam transfer bar system,
• the powered roller conveyor system, and
• the chain-drive conveyor system.
Walking beam systems
• With the walking beam transfer mechanism, the work-parts are
lifted up from their workstation locations by a transfer bar and
moved one position ahead, to the next station.
• The transfer bar then lowers the pans into nests which position
them more accurately for processing
Working of the beam mechanism

Powered roller conveyor system

• This type of system is used in general stock handling systems as
well as in automated flow lines.
• The conveyor can be used to move pans or pallets possessing
flat riding surfaces.
• The rollers can be powered by either of two mechanisms.
• The first is a belt drive, in which a flat moving belt beneath the rollers
provides the rotation of the rollers by friction.
• A chain drive is the second common mechanism used to power the
rollers.
• Powered roller conveyors are versatile transfer systems because
they can be used to divert work pallets into workstations or alternate
tracks
Powered roller conveyor system

Chain-drive conveyor system

• In chain-drive conveyor system either a chain or a flexible steel
belt is used to transport the work carriers.
• The chain is driven by pulleys in either an "over-and-
under" configuration, in which the pulleys turn about a
horizontal axis, or an "around-the-corner" configuration, in
which the pulleys rotate about a vertical axis.
Chain-drive conveyor system
• This general type of transfer system can be used for
continuous, intermittent, or nonsynchronous movement of
workparts.
• In the nonsynchronous motion, the workparts are pulled by
friction or ride on an oil film along a track with the chain or
belt providing the movement.
• It is necessary to provide some sort of final location
for the workparts when they arrive at their respective stations

Rotary transfer mechanisms

There are several methods used to index a circular table or dial
at various equal angular positions corresponding to workstation
locations:
Rack and pinion:
This mechanism is simple but is not considered especially suited
to the high-speed operation often associated with indexing
machines
Rotary transfer mechanisms
• Ratchet and pawl: A ratchet is a device that allows linear or rotary
motion in only one direction, while preventing motion in the opposite
direction.
• Ratchets consist of a gearwheel and a pivoting spring loaded finger
called a pawl that engages the teeth.
• Either the teeth, or the pawl, are slanted at an angle, so that
when the teeth are moving in one direction, the pawl slides up and
over each tooth in turn, with the spring forcing it back with a 'click'
into the depression before the next tooth.
• When the teeth are moving in the other direction, the angle of the
pawl causes it to catch against a tooth and stop further motion in that
direction
Rotary transfer mechanisms
• Geneva mechanism: The two previous mechanisms convert a
linear motion into a rotational motion.
• The Geneva mechanism uses a continuously rotating driver to index
the table
• If the driven member has six slots for a six-station dial
indexing machine, each turn of the driver will cause the table to
advance one-sixth of a turn.
• The driver only causes movement of the table through a portion of its
rotation.
• For a six-slotted driven member, 120° of a complete rotation of the
driver is used to index the table.
• The other 240° is dwell. For a four-slotted driven member, the ratio
would be 90° for index and 270° for dwell.
• The usual number of indexings per revolution of the table is four,
five, six, and eight

Geneva mechanism
Rotary transfer mechanisms
• CAM Mechanisms: Various forms of cam mechanism
provide probably the most accurate and reliable method of
indexing the dial.
• They are in widespread use in industry despite the fact that the
cost is relatively high compared to alternative mechanisms.
• The cam can be designed to give a variety of velocity and dwell
characteristics
 Transfer lines

Linear transfer Rotary transfer

Rack and Ratchet and Geneva CAM

pinion pawl mechanism mechanism
Powered roller Chain drive
Walking beam conveyor conveyor
system system

Group Technology
• Group technology is a manufacturing philosophy in which similar
parts are identified and grouped together to take advantage of their
similarities in manufacturing and design
• Similar parts are arranged into part families, where each part family
possesses similar design and/or manufacturing characteristics
• For example, a plant producing 10,000 different part numbers may be
able to group the vast majority of these parts into 30 or 40 distinct
families
• It is reasonable to believe that the processing of each member of a
given family is similar, and this should result in manufacturing
efficiencies
Group Technology
The following conditions are when GT is most appropriate:
• The plant currently uses traditional batch production and a process-
type layout, which results in much material handling, high in-process
inventory, and long manufacturing lead times
• It is possible to group into part families. This is a necessary condition.
• Each GT machine cell is designed to produce a given part family, or a
limited collection of part family
• Typical mid volume production plant, most of the parts can be
grouped into part families

Group Technology
• There are two major tasks that a company must undertake when it
undertakes GT:
1. Identifying the part families: If a plant makes 10,000 different parts,
reviewing all of the part drawings and grouping the parts into
families is a substantial and time-consuming task
2. Rearranging production machines into machine cells: it is time
consuming and costly to plan and accomplish this rearrangement
and the machines are not producing during the change over
Benefits of GT

Process type and plant layout

Group technology layout

Group technology layout results in:

Part families

Part families
Design attributes

Manufacturing attributes
Part design attributes

Part manufacturing attributes

Part family formation

Visual Inspection method / Intuitive grouping

Visual Inspection
Part classification and coding

Part classification and coding

• In parts classification and coding, similarities among parts are
identified and these similarities are related in a coding system that
usually includes both a part’s design and manufacturing attributes.
• Reasons for including coding scheme include:
1. Design retrieval: A designer faced with the task of developing a new
part can use a design retrieval system to determine if a similar part
already exists. Simply changing an existing part would take much
less time than designing a whole new part from scratch.
2. Automated process planning: The part code for a new part can be
used to search for process plans for existing parts with identical or
similar codes.
3. Machine cell design: The part codes can be used to design machine
cells capable of producing members of a particular part family,
using the composite part concept.
Part classification and coding
• The principle functional areas that would use parts classification and
coding system are design and manufacturing.
• Accordingly, parts classification and coding systems fall into one of
three categories:
1. Systems based on part design attributes
2. Systems based on part manufacturing attributes
3. Systems based on both design and manufacturing features

Part classification and coding

• The classification results in a code number that uniquely identifies the
part’s attributes.
• In terms of the meaning of the symbols in the code, there are 3
structures used in classification and coding schemes:
1. Hierarchical structure, also known as monocode, in which the
interpretation of each successive symbol depends on the values of
the preceding symbols
2. Chain-type structure, also known as a polycode, in which the
interpretation of each symbol in the sequence is always the same;it
does not depend on the values of preceding symbols
3. Mixed-mode structure, a hybrid of the two previous coding
schemes.
Part classification and coding
• Consider a two-digit code number for a part, such as 15 or 25. Suppose
the first digit stands for the general shape of the part: 1 means the part is
cylindrical (rotational), and 2 means the geometry is block-like.
• In a hierarchical structure, the interpretation of the second digit depends
on the value of the first digit.
• If preceded by 1, the 5 might indicate a length-to-diameter ratio; and if
preceded by 2, the 5 might indicate an aspect ratio between the length
and width dimensions of the part.

Part classification and coding

• In the chain-type structure, the symbol 5 would have the same
meaning whether preceded by 1 or 2.
• For example, it might indicate the overall length of the part.
• The advantage of the hierarchical structure is that in general more
information can be included in a code of a given number of digits.
• The mixed-mode structure uses a combination of hierarchical and
chain-type structures
Benefits of Part classification and coding
• It facilitates the formation of part families and machine cells
• It permits quick retrieval of designs, drawings and process plans
• It facilitates accurate estimation of machine tool requirements
• It reduces setup time and design time
• It helps in production, planning and scheduling procedures
• It provides for better machine tool utilization

Production Flow Analysis (PFA)

• PFA is an approach to part family identification and machine cell formation that
was pioneered by J.Burbidge
• This method for identifying part families and associated machine groupings, uses
information contained on process plans rather than on part drawings
• Work parts with identical or similar routings are classified into part families
• Since PFA uses manufacturing data rather than design data to identify part
families, it can overcome two possible anomalies that can occur in parts
classification and coding.
• First, parts whose basic geometries are quite different may nevertheless require
similar or even identical process routings.
• Second, parts whose geometries are quite similar may nevertheless require
process routings that are quite different.
 Production Flow Analysis (PFA)
• The procedure of Production flow analysis (PFA) consists of the
following steps:

1. Data Collection: The minimum data needed in the analysis are the part
number and operation sequence, which is obtained from process plans.

2. Sortation of process plans: A sortation procedure is used to group parts

with identical process plans. To facilitate this step, all operations or
machines included in the shop are reduced to code numbers. A sortation
procedure is then used to arrange parts into “packs,” which are groups of
parts with identical routings.

Production Flow Analysis (PFA)

3. PFA Chart: It is referred to as machine part incidence matrix. In this
matrix, the entries have a value xij = 1 or 0: a value of xij = 1 indicates
that the corresponding part i requires processing on machine j, and xij
= 0 indicates that no processing of component i is accomplished on
machine j.

4.Clustering Analysis: From the pattern of data in the PFA chart, related
groupings are identified and rearranged into a new pattern that brings
together groups with similar machine sequences
Ex: Machine part incidence matrix

Production Flow Analysis (PFA)

• The weakness of production flow analysis is that the data used in the
technique are derived from existing production route sheets
• The routings may contain operations and machine selections that are
biased by the process planners’ backgrounds, experiences, and
expertise.
• Thus, the final machine groupings obtained in the analysis may be
suboptimal.
• Notwithstanding this weakness, PFA has the virtue of requiring less
time than a complete parts classification and coding procedure
Cellular Manufacturing
• Cellular manufacturing is an application of group technology in which
dissimilar machines or processes have been aggregated into cells, each
of which is dedicated to the production of a part or product family, or a
limited group of families.
• Grouping the production equipment into machine cells,
where each cell specializes in the production of a part family,
is called cellular manufacturing
• The efficiencies are generally achieved by arranging the production
equipment into machine groups or cells to facilitate work flow.

Cellular Manufacturing - Objectives

• To shorten manufacturing lead times by reducing setup, work-part handling,
waiting times, and batch sizes.
• To reduce work-in-process inventory. Smaller batch sizes and shorter lead
times reduce work-in-process.
• To improve quality. This is accomplished by allowing each cell to specialize in
producing a smaller number of different parts. This reduces process variability.
• To simplify production scheduling. The similarity among parts in the family
reduces the complexity of production scheduling. Instead of scheduling parts
through a sequence of machines in a process-type shop layout, the system
simply schedules the parts through the cell.
• To reduce setup times. This is accomplished by using group tooling that have
been designed to process the part family, rather than part tooling, which is
designed for an individual part. This reduces the number of individual tools
required as well as the time to change tooling between parts
Flexible manufacturing systems
• The flexible manufacturing system (FMS) is a type of machine cell to
implement cellular manufacturing.
• It is the most automated and technologically sophisticated of the
group-technology (GT) cells.
• An FMS typically possesses multiple automated stations and is capable of
variable routings among stations.
• FMS is a highly automated GT machine cell, consisting of one or more
processing stations, interconnected by an automated material handling
and storage system and controlled by a distributed computer system.
• FMS is called flexible since it is capable of processing a variety of different
part styles simultaneously at various workstations, and the mix of part styles
and quantities of production can be adjusted in response to changing
demand patterns

Flexible manufacturing systems

FMS technology can be applied in production situations similar to those
identified for cellular manufacturing:
• Presently the plant either produces parts in batches or uses manned GT
cells, and management wants to automate.
• It is possible to group a portion of the parts made in the plant into part
families, whose similarities permit them to be processed on the
machines in the flexible manufacturing system.
• Part similarities can be interpreted to mean that (1) the parts belong to
a common product and/or (2) the parts possess similar geometries.
• In either case, the processing requirements of the parts must be
sufficiently similar to allow them to be made on the FMS.
Flexible manufacturing systems
• The parts or products made by the facility are in the mid-volume, mid-
variety production range
• The appropriate production volume range is 5,000–75,000 parts per
year.
• If annual production is below this range, an FMS is likely to be an
expensive alternative. If production volume is above this range, then a
more specialized production system should probably be considered.

Flexible manufacturing systems

The differences between installing a flexible manufacturing system and

implementing a manually operated machine cell are the following:
(1) the FMS requires a significantly greater capital investment because
new equipment is being installed, whereas the manually operated
machine cell might only require existing equipment to be relocated
(2) the FMS is technologically more sophisticated for the human
resources who must make it work
Benefits of Flexible manufacturing systems
• Increased machine utilization
• Reduced factory floor space
• Greater responsiveness to change
• Lower inventory and manufacturing lead times
• Higher labor productivity.

Tests of flexibility
• To qualify as being flexible, an automated manufacturing system should
satisfy the following four tests of flexibility:
1.Part-variety test. Can the system process different part or product styles in
a mixed-model (non-batch) mode?
2. Schedule-change test. Can the system readily accept changes in
production schedule, that is, changes in part mix and/or production
quantities?
3. Error-recovery test. Can the system recover gracefully from equipment
malfunctions and breakdowns, so that production is not completely disrupted?
4. New-part test. Can new part designs be introduced into the existing part
mix with relative ease if their features qualify them as being members of the
part family for which the system was designed? Also, can design changes be
made in existing parts without undue challenge to the system?
Tests of flexibility
• If the answer to all of these questions is “yes” for a given
manufacturing system, then the system is flexible.
• The most important tests are (1) and (2).
• Test (3) is applicable to multi-machine systems but in single-machine
systems when the one machine breaks down it is difficult to avoid a
halt in production.

Types of FMS

• Based on kinds of operations they perform: processing operations or

assembly operations.
• Based on number of machine cells:
1) single-machine cell
2) flexible manufacturing cell
3) flexible manufacturing system
• Based on level of flexibility:
1) Dedicated
2) Random-order
Single-machine cell
• consists of one CNC machining center combined with a parts-
storage system for unattended operation
• Completed parts are periodically unloaded from the parts-storage unit,
and raw work parts are loaded into it.
• The cell can be designed to operate in a batch mode, a flexible mode,
or a combination of the two.
• Satisfies test 1,2 and 4. Test (3), error recovery, cannot be satisfied
because if the single machine breaks down, production stops
Flexible manufacturing cell
• consists of two or three processing workstations (typically CNC
machining centers or turning centers) plus a parts-handling system.
• The parts-handling system is connected to a load/unload station. The
handling system usually includes a limited parts-storage capacity
• A flexible manufacturing cell satisfies the four flexibility tests
discussed previously
Flexible manufacturing system

• Four or more processing stations connected mechanically by a

common parts-handling system and electronically by a distributed
computer system. Thus, an important distinction between an FMS and
an FMC is the number of machines: an FMC has two or three
machines, while an FMS has four or more.
• FMS generally includes non-processing workstations that support
production but do not directly participate in it. These other stations
include part/pallet washing stations, inspection stations, and so on.
• Another difference is that the computer control system of an FMS is
generally more sophisticated, often including functions not always
found in a cell, such as diagnostics and tool monitoring.

Dedicated FMS
• Designed to produce a limited variety of part styles, and the
complete population of parts is known in advance
• Instead of being general purpose, the machines can be designed for the
specific processes required to make the limited part family, thus
increasing the production rate of the system.
• In some instances, the machine sequence may be identical or nearly
identical for all parts processed, so a transfer line may be appropriate,
in which the workstations possess the necessary flexibility to process
the different parts in the mix
Random order FMS
• It is more appropriate when:
(1) the part family is large
(2) there are substantial variations in part configurations,
(3) new part designs will be introduced into the system and engineering
changes will be made to parts currently produced, and
(4) the production schedule is subject to change from day-to-day.
• It is more flexible than the dedicated FMS and is equipped with general-
purpose machines
• A more sophisticated computer control system is required for this FMS
• The dedicated FMS is less flexible but capable of higher production
rates. The random-order FMS is more flexible but at the cost of lower
production rates.

FMC/FMS Components
• The three basic components of a flexible manufacturing system are:
(1) workstations,
(2)material handling and storage system, and
(3) computer control system
• Functions typically performed by humans include:
(1) loading raw work parts into the system,
(2) unloading finished parts (or assemblies) from the system,
(3) changing and setting tools,
(4) performing equipment maintenance and repair,
(5) performing NC part programming,
(6) programming and operating the computer system, and
(7) managing the system
FMC/FMS Components
Typical types of workstations found in an FMS:
• Load/Unload stations. The load/unload station is the physical
interface between the FMS and the rest of the factory. It is where raw
work parts enter the system and finished parts exit the system. Loading
and unloading can be accomplished either manually or by automated
handling systems.
• Machining Station: The workstations used in these systems are
therefore predominantly CNC machine tools. Most common are CNC
machining centers, which possess features that make them compatible
with the FMS, including automatic tool changing and tool storage, use
of palletized work parts, CNC, and capacity for distributed numerical
control

FMC/FMS Components
• Assembly: Some flexible manufacturing systems are designed to
perform assembly operations.
• Other stations and equipment: Inspection can be incorporated
into a flexible manufacturing system, either by including an inspection
operation at a processing workstation or by including a station
specifically designed for inspection. Other operations include cleaning
parts and/or pallet fixtures, central coolant delivery systems
ASSIGNMENT 1
• Write an essay on the “Need for Artificial Intelligence and expert
systems in Computer Integrated Manufacturing “

• Date of Submission : 20/04/2023