Automation, production systems, and computer-integrated manufacturing [Fifth edition] 9780133499612, 1292076119, 9781292076119, 0133499618, 9780134605463, 0134605462

Table of contents :
Cover......Page 1
Title Page......Page 5
Copyright......Page 6
Contents......Page 7
Preface......Page 13
Chapter 1: INTRODUCTION......Page 19
1.1 Production Systems......Page 20
1.2 Automation in Production Systems......Page 24
1.3 Manual Labor in Production Systems......Page 29
1.4 Automation Principles and Strategies......Page 31
1.5 About This Book......Page 36
Chapter 2: MANUFACTURING OPERATIONS......Page 39
2.1 Manufacturing Industries and Products......Page 43
2.2 Manufacturing Operations......Page 46
2.3 Production Facilities......Page 50
2.4 Product/Production Relationships......Page 55
Chapter 3: MANUFACTURING METRICS AND ECONOMICS......Page 64
3.1 Production Performance Metrics......Page 65
3.2 Manufacturing Costs......Page 77
APPENDIX 3A: Averaging Formulas for Equation (3.20)......Page 91
Chapter 4: INTRODUCTION TO AUTOMATION......Page 93
4.1 Basic Elements of an Automated System......Page 96
4.2 Advanced Automation Functions......Page 104
4.3 Levels of Automation......Page 109
Chapter 5: INDUSTRIAL CONTROL SYSTEMS......Page 113
5.1 Process Industries versus Discrete Manufacturing Industries......Page 114
5.2 Continuous versus Discrete Control......Page 116
5.3 Computer Process Control......Page 122
Chapter 6: HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL......Page 139
6.1 Sensors......Page 140
6.2 Actuators......Page 144
6.3 Analog–Digital Conversions......Page 156
6.4 Input/Output Devices for Discrete Data......Page 161
Chapter 7: COMPUTER NUMERICAL CONTROL......Page 167
7.1 Fundamentals of NC Technology......Page 170
7.2 Computers and Numerical Control......Page 176
7.3 Applications of NC......Page 181
7.4 Analysis of Positioning Systems......Page 188
7.5 NC Part Programming......Page 196
APPENDIX 7A: Coding for Manual Part Programming......Page 214
Chapter 8: INDUSTRIAL ROBOTICS......Page 222
8.1 Robot Anatomy and Related Attributes......Page 224
8.2 Robot Control Systems......Page 232
8.3 End Effectors......Page 234
8.4 Applications of Industrial Robots......Page 235
8.5 Robot Programming......Page 244
8.6 Robot Accuracy and Repeatability......Page 252
9.1 Discrete Process Control......Page 262
9.2 Ladder Logic Diagrams......Page 270
9.3 Programmable Logic Controllers......Page 274
9.4 Personal Computers and Programmable Automation Controllers......Page 281
Chapter 10: MATERIAL TRANSPORT SYSTEMS......Page 287
10.1 Overview of Material Handling......Page 288
10.2 Material Transport Equipment......Page 293
10.3 Analysis of Material Transport Systems......Page 309
Chapter 11: STORAGE SYSTEMS......Page 327
11.1 Introduction to Storage Systems......Page 328
11.2 Conventional Storage Methods and Equipment......Page 332
11.3 Automated Storage Systems......Page 335
11.4 Analysis of Storage Systems......Page 343
Chapter 12: AUTOMATIC IDENTIFICATION AND DATA CAPTURE......Page 355
12.1 Overview of Automatic Identification Methods......Page 356
12.2 Bar Code Technology......Page 358
12.3 Radio Frequency Identification......Page 365
12.4 Other AIDC Technologies......Page 367
Chapter 13: OVERVIEW OF MANUFACTURING SYSTEMS......Page 371
13.1 Components of a Manufacturing System......Page 372
13.2 Types of Manufacturing Systems......Page 377
Chapter 14: SINGLE-STATION MANUFACTURING CELLS......Page 384
14.1 Single-Station Manned Cells......Page 385
14.2 Single-Station Automated Cells......Page 386
14.4 Analysis of Single-Station Cells......Page 395
Chapter 15: MANUAL ASSEMBLY LINES......Page 408
15.1 Fundamentals of Manual Assembly Lines......Page 410
15.2 Analysis of Single-Model Assembly Lines......Page 416
15.3 Line Balancing Algorithms......Page 423
15.4 Workstation Details......Page 429
15.5 Other Considerations in Assembly Line Design......Page 431
15.6 Alternative Assembly Systems......Page 434
APPENDIX 15A: Batch-Model and Mixed-Model Lines......Page 444
Chapter 16: AUTOMATED PRODUCTION LINES......Page 459
16.1 Fundamentals of Automated Production Lines......Page 460
16.2 Applications of Automated Production Lines......Page 468
16.3 Analysis of Transfer Lines......Page 472
APPENDIX 16A: Transfer Lines with Internal Storage......Page 482
Chapter 17: AUTOMATED ASSEMBLY SYSTEMS......Page 490
17.1 Fundamentals of Automated Assembly Systems......Page 491
17.2 Analysis of Automated Assembly Systems......Page 497
Chapter 18: GROUP TECHNOLOGY AND CELLULAR MANUFACTURING......Page 515
18.1 Part Families and Machine Groups......Page 517
18.2 Cellular Manufacturing......Page 524
18.3 Applications of Group Technology......Page 529
18.4 Analysis of Cellular Manufacturing......Page 531
APPENDIX 18A: Opitz Parts Classification and Coding System......Page 546
Chapter 19: FLEXIBLE MANUFACTURING CELLS AND SYSTEMS......Page 549
19.1 What Is a Flexible Manufacturing System?......Page 551
19.2 FMC/FMS Components......Page 556
19.3 FMS Application Considerations......Page 563
19.4 Analysis of Flexible Manufacturing Systems......Page 567
19.5 Alternative Approaches to Flexible Manufacturing......Page 579
Chapter 20: QUALITY PROGRAMS FOR MANUFACTURING......Page 593
20.1 Quality in Design and Manufacturing......Page 594
20.2 Traditional and Modern Quality Control......Page 595
20.3 Process Variability and Process Capability......Page 598
20.4 Statistical Process Control......Page 601
20.5 Six Sigma......Page 614
20.6 Taguchi Methods in Quality Engineering......Page 618
20.7 ISO 9000......Page 623
APPENDIX 20A: The Six Sigma DMAIC Procedure......Page 630
Chapter 21: INSPECTION PRINCIPLES AND PRACTICES......Page 636
21.1 Inspection Fundamentals......Page 637
21.2 Sampling versus 100% Inspection......Page 642
21.3 Automated Inspection......Page 646
21.4 When and Where to Inspect......Page 648
21.5 Analysis of Inspection Systems......Page 652
Chapter 22: INSPECTION TECHNOLOGIES......Page 665
22.1 Inspection Metrology......Page 666
22.3 Coordinate Measuring Machines......Page 671
22.4 Surface Measurement......Page 683
22.5 Machine Vision......Page 685
22.6 Other Optical Inspection Methods......Page 692
22.7 Noncontact Nonoptical Inspection Techniques......Page 695
APPENDIX 22A: Geometric Feature Construction......Page 700
Chapter 23: PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM......Page 703
23.1 Product Design and CAD......Page 704
23.2 CAM, CAD/CAM, and CIM......Page 711
23.3 Quality Function Deployment......Page 715
Chapter 24: PROCESS PLANNING AND CONCURRENT ENGINEERING......Page 721
24.1 Process Planning......Page 722
24.2 Computer-Aided Process Planning......Page 727
24.3 Concurrent Engineering and Design for Manufacturing......Page 730
24.4 Advanced Manufacturing Planning......Page 734
Chapter 25: PRODUCTION PLANNING AND CONTROL SYSTEMS......Page 739
25.1 Aggregate Production Planning and the Master Production Schedule......Page 741
25.2 Material Requirements Planning......Page 743
25.3 Capacity Planning......Page 749
25.4 Shop Floor Control......Page 751
25.5 Inventory Control......Page 757
25.6 Manufacturing Resource Planning (MRP II)......Page 761
25.7 Enterprise Resource Planning (ERP)......Page 762
Chapter 26: JUST-IN-TIME AND LEAN PRODUCTION......Page 768
26.1 Lean Production and Waste in Manufacturing......Page 769
26.2 Just-In-Time Production Systems......Page 773
26.3 Autonomation......Page 780
26.4 Worker Involvement......Page 784
Appendix: Answers to Selected Problems......Page 794
A......Page 800
C......Page 801
F......Page 803
I......Page 804
M......Page 805
P......Page 807
Q......Page 808
S......Page 809
U......Page 810
Z......Page 811