Automation, production systems, and computer-integrated manufacturing [Fourth edition, fourth impression] 9789332572492, 9789332586062, 9332572496

Table of contents :
Cover......Page 1
Title......Page 4
Copyright......Page 5
Contents......Page 6
Preface ......Page 12
Chapter 1 Introduction ......Page 18
1.1 Production Systems ......Page 19
1.2 Automation in Production Systems ......Page 23
1.3 Manual Labor in Production Systems ......Page 28
1.4 Automation Principles and Strategies ......Page 30
1.5 About this Book ......Page 35
Chapter 2 Manufacturing Operations ......Page 38
2.1 Manufacturing Industries and Products ......Page 42
2.2 Manufacturing Operations ......Page 45
2.3 Production Facilities ......Page 49
2.4 Product/Production Relationships ......Page 54
Chapter 3 Manufacturing Metrics and Economics ......Page 63
3.1 Production Performance Metrics 63......Page 64
3.2 Manufacturing Costs 75......Page 76
APPENDIX 3A: Averaging Formulas for Equation (3.20) 89......Page 90
Chapter 4 Introduction to Automation ......Page 92
4.1 Basic Elements of an Automated System ......Page 95
4.2 Advanced Automation Functions......Page 103
4.3 Levels of Automation......Page 108
Chapter 5 Industrial Control Systems......Page 112
5.1 Process Industries versus Discrete Manufacturing Industries......Page 113
5.2 Continuous versus Discrete Control......Page 115
5.3 Computer Process Control......Page 121
Chapter 6 Hardware Components for Automation and Process Control......Page 138
6.1 Sensors......Page 139
6.2 Actuators......Page 143
6.3 Analog–Digital Conversions......Page 155
6.4 Input/Output Devices for Discrete Data......Page 160
Chapter 7 Computer Numerical Control......Page 166
7.1 Fundamentals of NC Technology......Page 169
7.2 Computers and Numerical Control......Page 175
7.3 Applications of NC......Page 180
7.4 Analysis of Positioning Systems......Page 187
7.5 NC Part Programming......Page 195
APPENDIX 7A: Coding for Manual Part Programming......Page 213
Chapter 8 Industrial Robotics......Page 221
8.1 Robot Anatomy and Related Attributes......Page 223
8.2 Robot Control Systems......Page 231
8.3 End Effectors......Page 233
8.4 Applications of Industrial Robots......Page 234
8.5 Robot Programming......Page 243
8.6 Robot Accuracy and Repeatability......Page 251
9.1 Discrete Process Control......Page 261
9.2 Ladder Logic Diagrams......Page 269
9.3 Programmable Logic Controllers......Page 273
9.4 Personal Computers and Programmable Automation Controllers......Page 280
Chapter 10 Material Transport Systems......Page 286
10.1 Overview of Material Handling......Page 287
10.2 Material Transport Equipment......Page 292
10.3 Analysis of Material Transport Systems......Page 308
Chapter 11 Storage Systems......Page 326
11.1 Introduction to Storage Systems......Page 327
11.2 Conventional Storage Methods and Equipment......Page 331
11.3 Automated Storage Systems......Page 334
11.4 Analysis of Storage Systems......Page 342
Chapter 12 Automatic Identification and Data Capture......Page 354
12.1 Overview of Automatic Identification Methods......Page 355
12.2 Bar Code Technology......Page 357
12.3 Radio Frequency Identification......Page 364
12.4 Other AIDC Technologies......Page 366
Part IV: Manufacturing Systems......Page 370
13.1 Components of a Manufacturing System......Page 371
13.2 Types of Manufacturing Systems......Page 376
Chapter 14 Single-Station Manufacturing Cells......Page 383
14.1 Single-Station Manned Cells......Page 384
14.2 Single-Station Automated Cells......Page 385
14.4 Analysis of Single-Station Cells......Page 394
Chapter 15 Manual Assembly Lines......Page 407
15.1 Fundamentals of Manual Assembly Lines......Page 409
15.2 Analysis of Single-Model Assembly Lines......Page 415
15.3 Line Balancing Algorithms......Page 422
15.4 Workstation Details......Page 428
15.5 Other Considerations in Assembly Line Design......Page 430
15.6 Alternative Assembly Systems......Page 433
APPENDIX 15A: Batch-Model and Mixed-Model Lines......Page 443
Chapter 16 Automated Production Lines......Page 458
16.1 Fundamentals of Automated Production Lines......Page 459
16.2 Applications of Automated Production Lines......Page 467
16.3 Analysis of Transfer Lines......Page 471
APPENDIX 16A: Transfer Lines with Internal Storage......Page 481
Chapter 17 Automated Assembly Systems......Page 489
17.1 Fundamentals of Automated Assembly Systems......Page 490
17.2 Analysis of Automated Assembly Systems......Page 496
Chapter 18 Group Technology and Cellular Manufacturing......Page 514
18.1 Part Families and Machine Groups......Page 516
18.2 Cellular Manufacturing......Page 523
18.3 Applications of Group Technology......Page 528
18.4 Analysis of Cellular Manufacturing......Page 530
APPENDIX 18A: Opitz Parts Classification and Coding System......Page 545
Chapter 19 Flexible Manufacturing Cells and Systems......Page 548
19.1 What is a Flexible Manufacturing System?......Page 550
19.2 FMC/FMS Components......Page 555
19.3 FMS Application Considerations......Page 562
19.4 Analysis of Flexible Manufacturing Systems......Page 566
19.5 Alternative Approaches to Flexible Manufacturing......Page 578
Chapter 20 Quality Programs for Manufacturing......Page 592
20.1 Quality in Design and Manufacturing......Page 593
20.2 Traditional and Modern Quality Control......Page 594
20.3 Process Variability and Process Capability......Page 597
20.4 Statistical Process Control......Page 600
20.5 Six Sigma......Page 613
20.6 Taguchi Methods in Quality Engineering......Page 617
20.7 ISO0......Page 622
APPENDIX 20A: The Six Sigma DMAIC Procedure......Page 629
Chapter 21 Inspection Principles and Practices......Page 635
21.1 Inspection Fundamentals......Page 636
21.2 Sampling versus% Inspection......Page 641
21.3 Automated Inspection......Page 645
21.4 When and Where to Inspect......Page 647
21.5 Analysis of Inspection Systems......Page 651
Chapter 22 Inspection Technologies......Page 664
22.1 Inspection Metrology......Page 665
22.3 Coordinate Measuring Machines......Page 670
22.4 Surface Measurement......Page 682
22.5 Machine Vision......Page 684
22.6 Other Optical Inspection Methods......Page 691
22.7 Noncontact Nonoptical Inspection Techniques......Page 694
APPENDIX 22A: Geometric Feature Construction......Page 699
Chapter 23 Product Design and CAD/CAM in the Production System......Page 702
23.1 Product Design and CAD......Page 703
23.2 CAM, CAD/CAM, and CIM......Page 710
23.3 Quality Function Deployment......Page 714
Chapter 24 Process Planning and Concurrent Engineering......Page 720
24.1 Process Planning......Page 721
24.2 Computer-Aided Process Planning......Page 726
24.3 Concurrent Engineering and Design for Manufacturing......Page 729
24.4 Advanced Manufacturing Planning......Page 733
Chapter 25 Production Planning and Control Systems......Page 738
25.1 Aggregate Production Planning and the Master Production Schedule......Page 740
25.2 Material Requirements Planning......Page 742
25.3 Capacity Planning......Page 748
25.4 Shop Floor Control......Page 750
25.5 Inventory Control......Page 756
25.6 Manufacturing Resource Planning (MRP II)......Page 760
25.7 Enterprise Resource Planning (ERP)......Page 761
Chapter 26 Just-In-Time and Lean Production......Page 767
26.1 Lean Production and Waste in Manufacturing......Page 768
26.2 Just-In-Time Production Systems......Page 772
26.3 Autonomation......Page 779
26.4 Worker Involvement......Page 783
Appendix A: Answers to Selected Problems......Page 793
Appendix B: Sections Present in the Third Edition that are not Present in the Fourth Edition......Page 799
Index......Page 806