CHAPTER 3: PROCESS LAYOUT

Inadequate part families

Poorly balanced cells
Expanded training and
scheduling of workers
Increased capital
investment

`

MACHINE CELL

4. Automated
processing and
1. Single 3. Multiple integrated 5. Automated
machine machines with handling processing and
semi integrated - Flexible integrated handling
- Flexible
handling Manufacturing Manufacturing system
Cell

2. Multiple
machines with
manual handling

Single machine cell

single machine cell consists of one machine plus
supporting fixtures and tooling
This type of cell can be applied to work parts whose
attributes allow them to be on one basis type of process,
such as turning or milling

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Machine Cell with Manual Handling

Group machine cell with manual handling is arrangement
of more than one machine used collectively to produce
one or more part families
There is no provision for mechanized parts movement
between the machine in the cell. Instead, the human
operators who has run the cell perform the material
handling function.
The cell is organized into u shaped layout

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

In- line layout

Loop layout

Rectangular layout Machine cell with semi-
integrated material
handling

Group machine cell with semi-integrated material handling uses a mechanical handling system, such
conveyors, to move parts between machine in the cell

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Flexible Manufacturing Cell (FMC)
A flexible manufacturing cell consists of two or
three processing workstations (typically CNC
machining centers) plus a part handling system
The part handling system is connected to
load/unload station

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Automated processing
and integrated handling

Flexible manufacturing system combines a fully integrated material handling system with automated processing stations
The FMS is the most highly automated of GT machine cell

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Some of the distinguishing characteristics of the three categories of FMC, FMS and single machine cell

Material handling is Work-in-process and Higher quality work
reduced manufacturing lead time
are reduced
- Parts are moved within a
machine cell rather than the
entire factory

Standardization of Process planning and Improved worker
tooling, fixtures, and production scheduling satisfaction in a GT cell
setups is encouraged are simplified

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Different ways of forming machine cells:
❑ Informal scheduling and routing of similar parts through selected machines to minimize

setups
❑ Virtual machine cells –dedication of certain machines in the factory to produce part families,

but no physical relocation of machines
❑ Formal machine cells –machines are physically relocated to form the cells
Automated process planning
Modular fixtures
Parametric programming in NC



FLEXIBLE MANUFACTURING SYSTEM
(FMS)

FMS consists of numerous programmable machine tools connected by an automated
material handling system and controlled by a common computer network

FMS combines flexibility with efficiency
FMS layouts differ based on
variety of parts that the system can process
size of parts processed
average processing time required for part completion

SLIDE 65

Types of Flexible Manufacturing 1 Sequential FMS
System : 2 Random FMS
3 Dedicated FMS
4 Engineered FMS
5 Modular FMS

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

A random FMS is more appropriate when
1. The part family is large
2. There are substantial variations in part

configurations
3. There will be new part design introduced

into the system and engineering changes in
parts currently produced
4. The production schedule is subjected to
change from day-to day

AI dedicated FMS is designed to produce
a limited variety of part syste, and the
complete universe of parts to be made
on the system is known in advance

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

There are several basic components of FMS

Workstations

Material handling and storage systems

Computer control system
People are required to manage and
operate the system

67

Following are the type of workstations
typically found in an FMS
1. Load/unload stations
2. Machining stations
3. Other processing

stations(punching, shearing,
welding, etc)
4. Assembly station
5. Other station and equipment
(inspection, vision, etc)

Function of station of the handling system Material handling equipment
1. Independent movement of workparts between The material handling function in FMS is often shared between two system
• Primary handling system establishes the basic layout of FMS and is responsible for
stations
2. Handle a variety of work part configuration moving work parts between stations in the system (conveyor)
3. Temporary storage • Secondary handling system consists of transfer devices automatic pallet changing and
4. Convenient access for laoding and unloading
similar mechanism located at the workstation in the FMS
workparts • The function of secondary handling system is to transfer work from the primary
5. Compatible with computer control
system to the machine tool or other processing station and to position the parts with
The material handling system establishes the FMS sufficient accuracy and repeatability to perform the process or assembly operation
layout
1. In line layout 69
2. Loop layout
3. Rectangular layout

FMS LAYOUTS

Line Layout/Progressive Layout

Best for producing a variety of parts

Closed Loop Layout

-Parts can skip stations for flexibility
-Used for large part sizes
-Best for long process times

Ladder Layout

-Parts can be sent to any machine in any sequence
-Parts not limited to particular part families

Open Field Layout

- Most complex FMS layout
-Includes several support stations

FMS IN LINE LAYOUT

Linear transfer system with
secondary parts handling system at
each workstation to facilitate flow
in two directions

• Straight line flow, well-defined processing
sequence similar for all work units

• Work flow is from left to right through the
same workstations

• No secondary handling system

• One direction flow, but variations in processing sequence possible for different part types
• Secondary handling system at each workstation

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

•Rectangular layout allows recirculation of pallets back to the first station in
the sequence after unloading at the final station.

FMS LADDER LAYOUT

Loop with rungs to allow greater
variation in processing sequence

MULTIPLE LOOP LAYOUT

Multiple loops and ladders, suitable for
large part families

Suited to the handling of rotational parts
and turning operations

The FMS includes a distributed computer A typical FMS computer system consicts of a central computer
system that is interfaced to and microcomputer
1. The workstation • Microcomputer controlling the individual machine and
2. Material handling components
3. Other hardware components other components
• The central computer coordinates the activities of the

components to achieve smooth overall operation of the
system

77

Load/unload stations

Machine tools, for example, machining Inspection facilities like Guided vehicles
centers, turning centers, etc. coordinate measuring machines

Robots Programmable Logic Controllers (PLC).

DESIGN FUNCTION EXTRINSIC FUNCTION INTRINSIC FUNCTION
Design sotware is used to : Extrinsic function is used to : Extrinsic function is used to :
▪ identify the major ▪ to plan and control the • Load and control the

components of system function that take place components within the
concepts outside the physical physical boundaries of
▪ To evalute design boundaries of FMS FMS
sensitivities
▪ Trade off for a given
concept
▪ To demostrate that the
system is capable of
meeting the planned
production requirement

Human are needed to manage the operation of the FMS

Function typically performed by human includes :
❑Loading raw work parts into the system
❑Unloading finished parts(or assemblies) from the sytem
❑Changing and setting tool
❑Equipment maintained and repair
❑NC part programming in a machining system
❑Programming and operation the computer system

80

ASSEMBLY

INSPECTION METAL
AND TESTING FORMING

APPLICATION
IN FMS

SURFACE METAL CUTTING
TREATMENT MACHINING

JOINING-WELDING
(ARC , SPOT),
GLUING

Selecting operations needed to make the product.
Putting the operations in a logical order.
Selecting equipment to make the product.
Arranging the equipment for efficient use.
Designing special devices to help build the product.
Developing ways to control product quality.
Testing the manufacturing system

Limited ability to adapt to changes in

Produce a variety of Items under one roof Product or product mix
Produce more product more quickly
Improve efficiency -(ex:machines are of limited capacity and the tooling
Improve product routing necessary for products, even of the same family, is not
Improve product quality always feasible in a given FMS)

Substantial pre-planning activity

Expensive, costing millions of dollars

To reduce setup and queue times Technological problems of exact component
Reduce time for product completion positioning and precise timing necessary t
Utilize human workers better process a component
Serve a variety of vendors simultaneously
Sophisticated manufacturing syste

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

PREPARED BY : SULLYFAIZURA BINTI MOHD RAWI ~ JKM ~ PSMZA (DJF5022~ MANUFACTURING SYSTEM)

Computer-integrated manufacturing (CIM) is the manufacturing
approach of using computers to control entire production
process. This integration allows individual processes to
exchange information with each other and initiate actions.

Computer-integrated manufacturing (CIM) makes the use of
computer-controlled machineries and automation systems in
manufacturing products. CIM combines various technologies
like CAD and CAM to provide an error-free manufacturing
process that reduces manual labor and automates repetitive
tasks.

The term "computer-integrated manufacturing" is both a method of
manufacturing and the name of a computer-automated system in
which individual engineering, production, marketing, and support
functions of a manufacturing enterprise are organized.

In a CIM system functional areas such as design, analysis,
planning, purchasing, cost accounting, inventory control, and
distribution are linked through the computer with factory
floor functions such as materials handling and management,
providing direct control and monitoring of all the
operations.

A computer control room directs all operation inside the factory. The computer system is in
control of every stage from design and ordering of materials to the manufacturing processes
and distribution to customers.



A group of CNC machine An automated materials
connected together by handling system

Machine tools Material
and related Handling
equipment System (MHS)

CIM system consists 01 02 CIM refer to production
of basic components 03 04 system that consists of

components

And operating under Computer Human factor human worker operates
computer control Control /labor powered equipment's such as
System machines tool or other

production machines.

• CNC, Computer numerical • Computer Aided Design (CAD)
controlled machine tools • Computer Aided Manufacturing (CAM)
. • Flexible Manufacturing Systems (FMS)
• Computer Aided Process Planning (CAPP)
• DNC, Direct numerical control Computer • Computer Aided Engineering (CAE)
machine tools aided • Computer-Aided Quality Assurance (CAQ)
• PLCs, Programmable logic • Production Planning and Control (PPC)
techniques • Enterprise Resource Planning (ERP)

controllers
• Robotics
• Computers
• Software
• Controllers
• Networks . • FMS, (flexible manufacturing
DEVICES AND system)
• Interfacing EQUIPEMNT Technologies
REQUIREMENT • ASRS, automated storage and
• Monitoring equipment retrieval system

• AGV, automated guided vehicle
• Robotics
• Automated conveyance systems

SUBSYSTEM IN
CIM

COMPUTER AIDED ENGINNERING (CAE) Computer Aided Computer Aided
Design (CAD) Manufacturing (CAM)
• Computer-aided engineering refers to the use of
software to simulate the effects of different • Engineers and draftsmen use computer-aided • Computer-aided Manufacturing (CAM)
conditions on the design of a product or structure design software to create illustrations or 3D is commonly defined as the use of
using simulated loads and constraints. models. While most engineers should be software to automate manufacturing
proficient with CAD, the amount of time they processes.
• CAE tools are often used to analyze and optimize spend using it may depend on their specific
the designs created within CAD software. role and level of experience. • CAM software can translate CAD
designs into instructions for machines,
• Major categories of CAE tools include finite • For example, in some environments, designers increasing the efficiency of producing
element analysis (FEA), computational fluid may be responsible for creating the initial parts and optimizing the number of
dynamics (CFD) and multi-disciplinary design design in a CAD program, while analysis and materials used.
optimization (MDO). release engineers will review and analyze it to
make sure there are no errors.
• These tools are used to perform design iterations
using virtual prototypes (sometimes called “digital
twins”) prior to building physical prototypes.
requirements.

PRODUCT CYLE IN A Computer
manufacturing environment

PRODUCT CYLE Awesome

PRODUCT CYLE

The common database various
for computerized application

Awesome

01 02 03

INTEGRATION OF Data Process
COMPONENTS FROM integrity control
DIFFERENT SUPPLIER
The higher the degree of automation, the Computers may be used to assist the
• When different machines such cnc, more critical is the integrity of the data human operators of the
conveyors and robot are using used to control the machines. While the manufacturing facility, but there
different communications protocols. CIM system saves on labor of operating must always be a competent engineer
In the case of AGVs (Automated the machines, it requires extra human on hand to handle circumstances
Guided Vehicles)_ even differing labor in ensuring that there are proper which could not be foreseen by the
length of time for changing the safeguards for the data signals that are designers of the control software.
batteries may causes problems. used to control the machines.

Error reduction speed flexibility integration

Elimination of human error in CIM environments reduce the With CIM companies CIM offers a degree of integration
many assignment and reporting time it takes to perform quickly react to market that enables the flexibility, speed
functions on factory floor manufacturing fabrication and conditions and then return and error reduction required to
operations drastically reduces the assembly, allowing quicker flow of to previous settings when compete and lead markets.
error rate.ar product to customers and market conditions change. Integrating factory floor operations
increased capacity. with enterprise software enables
employees to do higher value
functions for their companies.

Industrial and Production Engineering

Mechanical Engineering

INFORMATION AND TECHNOLOGY
(ICT)

Electronic Design Automation
1) Printed Circuit Board design
2) Integrated Circuit design

VIDEO FOR PROCESS LAYOUT

PROCESS LAYOUT BY : GROUP TECHNOLOGY ~ FLEXIBLE MANUFACTURING COMPUTER INTEGRATED
JKM ~ PSMZSAYS(DTJEFM5022~ MANUFACTURINMGASNYSUTFEAMC)TURING
PREPARED SULLYFAIZURA BINTI MOHD RAWI

VIDEO FOR PROCESS LAYOUT

PROCESS LAYOUT BY : GROUP TECHNOLOGY ~ FLEXIBLE MANUFACTURING COMPUTER INTEGRATED
JKM ~ PSMZSAYS(DTJEFM5022~ MANUFACTURINMGASNYSUTFEAMC)TURING
PREPARED SULLYFAIZURA BINTI MOHD RAWI

VIDEO FOR PROCESS LAYOUT

PROCESS LAYOUT BY : GROUP TECHNOLOGY ~ FLEXIBLE MANUFACTURING COMPUTER INTEGRATED
JKM ~ PSMZSAYS(DTJEFM5022~ MANUFACTURINMGASNYSUTFEAMC)TURING
PREPARED SULLYFAIZURA BINTI MOHD RAWI

VIDEO FOR PROCESS LAYOUT

PROCESS LAYOUT BY : GROUP TECHNOLOGY ~ FLEXIBLE MANUFACTURING COMPUTER INTEGRATED
JKM ~ PSMZSAYS(DTJEFM5022~ MANUFACTURINMGASNYSUTFEAMC)TURING
PREPARED SULLYFAIZURA BINTI MOHD RAWI