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CIM Module 2

The document discusses high volume production systems, focusing on automated flow lines used for mass production of goods with little variation. It outlines the advantages, such as reduced production costs and improved quality, as well as disadvantages like high initial investment and difficulty in switching products. Various transport mechanisms and configurations for work-part movement within automated systems are also described.

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MECH MAN
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14 views22 pages

CIM Module 2

The document discusses high volume production systems, focusing on automated flow lines used for mass production of goods with little variation. It outlines the advantages, such as reduced production costs and improved quality, as well as disadvantages like high initial investment and difficulty in switching products. Various transport mechanisms and configurations for work-part movement within automated systems are also described.

Uploaded by

MECH MAN
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ule- rok UNIT : 2 HIGH VOLUME PRODUCTION SYSTEMS CONTENTS : Introduction, Automated flow line symbols, Objectives, Work part trans- port (movement), Continuous, Syncronous, Pallet fixtures, Transfer Mechanism (a) Linear, (@) Walking beam, (ii) Roller Chain Drive (b) Rotary (i) Rack and Pinion, (ii) Geneva Wheel, (iii) Rachet and Pawl, Buffer Storage. Control Functions (i) Sequence, (ii) Safety, Gii) Quality. Automation for machining operation. 2.1 INTRODUCTION : > Some of the products have to be produced in large quantities as the demand is large and more and more customer are buying the pcoduets. Most of these products may be domestic type such as TY, washing machines, computers and small version automobile (Two wheelers and four wheels - Two wheelers for the asian market and four wheelers for both local and international market) and some of the parts which go to make a product on assemblySuch large quantities of production ay be termed as high volume production or large volume production). It may be dimicutttsa— drawaJine between different volumes af production such a low volume, inedium volume and high volume. Such high volume production necessiate a different and dedieatgd roduction system, such as automated production of continuous type. But in Asian Subcontinents some of the high valume_ prod is still produced manually as labour is cheap and the initial investment is high and cost ofthe product is very low (Ex. : Bricks, earthern wares ete) — G@eh volume manufacturing. is sau ass_ production using various types of processes and or operationfS High volume production system gre used for high production of parts or facts aquire multiple processing operations, Each processing operations performed ataworkstation and the stations are physically integrated by means of mechanized transport me form an aistometed production line? These lines are commonly referred as automated —eature or characteristic of High volume production : ~ Goods uced will have little or no variation, > Many number of work / machine centre producing or performing Advantages, 1, Product -d at a shorter interval of time. menus areproguceds — 2 Reduced-cost of production (Heonomicaly . 3. Improved quality. @ produ 4. Less human interference, ————_ 43 Computer Integrate M. 44 ‘any ctu, hi Disadvantages : 1. High initial inv tment, 2. More infastructure and equipment. 5. Difficult to switch aver from identical product/part to Jailormade or f W Number OF es desired product, . —e 22:2 AUTOMATED FLow LINE Definition : An automated flow line i DLS [Link] handling devices to transfer parts between m: roductic i p tion automatically, — ised in the processin; uration consists of am Processing operat in inane Tey Raw or Semi finished part (Eg. Engine blocky igh Volume Produetion Systems 45 ‘Table 2.1 Typical symbols used in automated flow lines. SYMBOL COMPONENT Workhead—>| Workstation: XXXxx may be: Machine___,|XXXX PROC : Processing Station \ Tooling ete | YYY ASBY : Assembly Station pina LIT INSP : Inspection Station LI 1s Nee Gy YYY may be : AUT = Automated Ke ‘ie - MAN = Manual A Bo — Material handling system. Arrow indicates direction of workflow. Raw workpart / Semifinished product Partially processed part Finished part _ 4 Buffer storage Data/Information flow Automated flow lines are used in high volume production for products that require multiple processing_opsratienwhich-may_inchide machining, Inspection or assembly[Awtomated flow lings are the most-appropriate means of prot uction in cases of stable production [ifé-high demand rite which requires high rates of producti ‘heneyer the alternative method a involves large labors, automated flow line is preferred, Objective of the flow line automation + Ty reduce labor costs ‘To increase production rates “simpe di he - + To minimize distance moved between operations ¥ + Jo achieve specialization of operations ~ + To achieve integration of operations . Gal abet abl akan Applications of automated flow line (Recommended) : Tr Stabte production. — Tho + High rate of production, . High rate of demands for the product, ED rate of demands for the produc 2. 3 4. Involves large labour fore. 46 oa) OH Cao-a “a INSP Ray [ro9 f pat AUT ct Part 0 Work or Work Work ( : Work : Semi- Siation 1 Station 2 Station 3 Station» finished product Fig. 2.2: Automatic Flow LIne using symbols oF semifinished product enters one end of the A raw workpart performed Saqu be incorpora dinto_the flow Tne it IMspection | Seat ty tion-sanalso be incorpe A ion oF ve Conveyor x Rav part of/lo =| oly Work station | Work station 2. Work station 3 ‘Operator i Fig. 2.10 : Synchronous in-line 3c Raw product » Conveyor (1) H_os ® Convey (2) | ows) O90 IZ Operator Workstati (ws)| <> (oP) ‘ws) i) Mo pI (ws)| <>} {g2) Fig. 2.11 : Synchronous segmented in-line Applications For large and heavy jobs. + Operation time is constant at workstations and takes longer time. * Most suitable for automated production line with mechanized workstations where the processing of constant Cycle time.) ————— ~”” Not suitable for manual assembly Ii @) Asynchronous transport : In this type of transport method, neither the v locity of the conveyor nor the processing. or Operation time at each workstation are constant Speration time is different for di partsavill nat move: 1 io the wor jou_only upon. ‘Sata particular works! rte tha part ore independently ‘any given instant oftime th partmay be either on th onveyor Teads to buffer slorage at some ead Computer Integrat : rated M, 52 ° s tu, shemtie ofa asynchronous work transport, Fig, 2.12 shows Velocity edi Q 122, hs] WS3} ws 1... : &) g hor t Processing time ting in queing up of the parts between WS2 & Ws3 t, is larger of all other processing time, result (6) Schematic diagram of asyneronous work transport Fig. 2.12 : Schematic diagram of asynchronous work transport 2.6 PALLET AND PALLET FIXTURE : A pallet is a platform on which the part is placed. This is made-out of either wood or plastic wi opening in between in the base. Fig. 2.13 shows the view of a pallet. Two-way entry De Four-way entry Ru Bottom deckboard ner, 4 Fig. 2.13 : Pallet ‘A fixture as the name indicates is a mechanical devices which fixes or holds the pati! parteoar location and orientation depending on the operatons tobe cre ot on te Pat are various types of fixture available and the selection depends on the sarproduct ‘geomet i size (voluine) of the part or the job, “ pallet fixture + Sis , is a combination of pallet and fixture used to place! vy one workstation fo another and for accurate process we chen it? and hold the job W ‘hen Pallet fixture ing operation. transported {rol High Volume Production Systems 53 A pallet fixture is a workholding device. workparts are attached to the pallet fixtures and the pallets are transferred between the stations. ‘The pallet fixtures is designed so that it can [Link] moved, located and clamped in position at the successive workstations. Since the parts accurately located on the pallet fixtures, it is therefore accurately positioned for each ‘operation. The term palletized transfer line is used to identify a transfer line that uses pallet fixtures. The alternate method of workpart ‘location of fixturing does not use pallets. With this method, the workparts indexed from station to station. This method is called a free transfer line. The benefit of this method is that it avoids the cost of the pallet fixtu When pallet fixtures are used, a means must be provided for them to be delivered back to the front of the line for re-use. (2-7 WOR RANSFER MECHANISM /‘In_automated flow line the workparts are transported from one workstation to another during processing ot from workstation to buffer storage or viceversa, using different (ypeS of Wranister~ mechanisms? < hese transfer mechanisms used in automated flow line which may be of gither synchronous Gasueonees type, depending on the type of workpart transport selegted) hese transfer mechanisit tay be broadly classified into e (© Linear transfer mechanism. (8 Rotary transfer mechanism. potary Hansfer snechanisg. (a) Linear transfer mechanism : As the name itself indicates that these mechanisms imparts linear motion to the workpart transportation system. The different types under this category are. : (i) Belt driven and Chain driven conveyor _ © Belt driven and Chain driven cony (ii) Powered-rollereonveyer (ii) Walking beam mechanism @® Beit driven and chain driven conveyor transfer mechanism : In this case the rotary , motion of the prime mavertgencrally electrical motor with speed controller) are converted “intq linear motion either using a belt driv hain drive. In the [Link] belt drive driving and driven pulleys _cai the workpart on it. For slipless motion of els are recomm In the case of chain drive which is a positive drive sprockets are used instead of pulleys. When the job is lighter belt drive is recommended and when the job is moderately heavy’ Dain Five is recommended, ‘The principle of operation in-both-the-cases-remain same-Fig-214 shows the principle of belt or chain-drive, a? Computer Integrated yy, P ‘ar MheA i led My, M4 Belt or chain, “ vel Forward travel pat fl re Pulley gp Sprocket I — Bare | | 7 Fig, 2.14 : Belt or Chain conveyor principle (ii) Power Roller Conveyor System: This pe of system is used in general stock handy, sygems and also in automated flow ie conveyor ca be yse Ne a possessing Hat surface gwered by {wo mechanisin LE itSt isa by drivin which af moving belt beneath th ion by friction, 4 chain drive is the secone mec . One of the major advantage being more number of workstation can be accommodated ‘i) Walking eam mechanism(s consis of wo be at the workstation] he other beam is called walking-beam as its motion is similar i ScMettent of the leg and This Taster the Teast gy Na ing work part from a Sorkstation to the next an hence also called Trans fer rail ee Working : The ‘ransfer rail in its inital position ig to the Je} fixed raiOnce the rocessing of the wi leted at the wer position than the workstation, the fee a r ill be vertical, As moves forward an g the work canter This is ho system. Fig. 2.15 shows th Note The rotation o the eg tke pl h © only When c Work stations are completed, 7 Mhen the proc pligh Volume Production Systems wisiueyrau weag Bupjjem Jo ydaouog : sT"z “B14 seq Surges sy 04 321 ‘rou jodupo of oy se ut og SepEA 3 torRsod sm uy pesesoond Suteq po adyzoa ya aE sous a9 [ea ee 1 pue proaugy wf axom os ‘Binoy Ta yor ay, owonN eng wspreyoou urea Supe nso rama “51a uve Supe woo a/ ites oo seg SEA D ee 1 IE ou A a Sr i a) Ls area es aes puatee (ag waqpeng (2000 nage Br ot | Nonmesoay ay 7 Computer Integratea 56 : acts, am: Asthenameitself indicates this method is (©) Rotary un msfermecha Sed for work, i d this is adopted When th AaVvailabif; iroumference"Fa circle an th ili vated along the circumference OF a circle tlralso mins = is limited and"the number of operations on as nimal, and Noe 1, =p : iscusse 7 method is used for rotary configuration as discuss ial is i angular position cory (i this thethod a eioular table or dial is indexed at equal ang ce ti i iphery ofthe table or di ; ne number of workstation on the peFiphery fanighttee ta used for indexing the table Tor rotary transfer mechani (i) Rack and Pinion Gi) Geneva mechanism Ratchet and Paul mechanism. Said Paul mechanism (i) Rack and Pinio One of the m isa and pinion mechan pet conversion oie {0 linear or viceversa is rack and inion mechani and nut Mechanisy, fie oe ne = . — Fig. 2.16 shows the principle of rack and pinion mechanism, iG Square threaded rod . re = Reversible! Electric 1 motor Pinion connected fable spindle os i . “Table or dial ‘ternal gear " “a with internal thread ‘ is Fig 2.16 : Rac| The motion to the rack is gi iven rt he mo ae nb the Motor through Sears which inturn transfer tothe ni pinion tom of the work nui he-cente OF axes of both coinciding! & indlexin, sil -Q2%E8 ofboth coining : ‘ack shou beof such a ich dep . : “di case of reversin, the rack t9 iy initial posit, 89 that only the rack moves back, SHON, the pinion 'S disengage from the 120k, Gi) Geneva mechanism ri ' ? The Gene a cam like mechanisy rol So refer ' ois *elerted sometime as Maltese cross | nt ratan aa sed ip bol! : developed AS a stop to prevent ov" tomatic machiner c.g, where? igh Volume Production Systems 37 Geneva wheel Connecting to the bottom of the dial Fig 2.17 : Geneva’Mechanism ‘This is one of the common method of conversion of Seitliout much shock and suitable for piceise indexing of the table Consists of wo wheels one with radial slog and the other vith a pin horizontal surface nearer to the circumference) The number of slots decide ing position and inturn number of workstations, he driven wheel i.e,.the one with radial slots are fixed to the base of the work table or Controlled depending Gi and the driveywheol-is-connected a. a. motorand jis speed if onthe cycle time-P, required for the motion of thedriven wheel. |. Fig 2.17. shows the geneva’mechanism. rotary motion, to rotary motion orthe dial tached on the < the mums Computer Integrateg Manus, Net taken for the movement of the slot called a as, finds: exin, i Se Etnri ation 'T, at each workstation hich i also tee ‘m i ¢ the oper and the time taken for time. i ‘Th Ic time T, is the reciprocal of the rpm of the driver wheel. IPN jg therm g he cycl driver wheel, then 1 0G. +e] This T= Time for indexing + Time available for processing or operation =(1,+T) If the number of slots in the driven wheel are ‘n’, then the angle of rotation OF the ta will be (=) : ( } raion andthe amount through which the driver wht hy - rotate to effect this (: is (2) ® gotation, medal) Then the remaining rotation ofthe driver wheel is ( =| , during which the slot 7 ‘wheel is stationary for processing and hence ths is called operation time T ie, T.=T,+ aT Bela n : 2 Chee 2 where, |(=)r, | is indexing tnieT and (-2)r| F , =| is the operation time T, ‘Angle of rotation 6, ofthe indexing wheel of ng ts for 1 rotation i.e, 360° is Angle of rotation of the driver 0, during j indexing a ( mo ” Angle of rotation of the driver during ws. Ag wheel is stationary is © Processing 0, (Dwell time where the indexit® igh Volume Production Systems Ratchet:and Paw1 Mechanism; Ratchet Paw Mechanism is atoothed- mechanism for motion into intermittent rotary motion ae it one direction only while preventin, wotion in the other directigh The F a cree + Toothed Arm ‘ction 1S similar to that of Rateliet a Wheel an electronic circuit or a che: wheel i iW water Tine\Commonly found in ; winches, cable cranes, bicycles etc, Fig 2-18 : Ratchet and Paw! Mechanism ie -Object_of the Tact Chee the action of certain portions of a machine and modify an otherwise continuous motion Into intermittent some for] (This has been used as one of the rotary work transport mechanism} Chis mechanism ‘consists of i, Ratchet_wheel, Pawl_and iii, Am Numerical examples 1. A rotary worktable is driven by a Geneva mechanism with 6 slots. The driver rotates at 30 rpm. Determine (a) Cycle time T,, (b) Available processing time T,, (¢) Lost time cach cycle to index the table T,, Data No. of slots n =6 RPM of the driver N = 30 Ty I 1 Soln. a =/—]=(—]= aa weave (4) =(-b) Also we have Ans. yr «0 Computer Integrated Manutaeturi, 61 " 2. A rotary work table is driven by a Geneva mechanism with 5 slots. The driver rota, ” at 48 rpm. Determine (a) Cycle time'T,, (b) Available process time T,, () Inde ing tin, on ofthe driver for indexing and (¢) Angle of rotation of he dnt T, (d) Angle of rot during processing time. Data: Number of slots n= 5 RPM of the driver N= 48 =? y=? Soin, We have, ce ‘@t. ) (2) -(3}i25- Sse ( Mo, =(2}300=(2} 00) 1.25=06x1.25= () t-(1-2}p, 2 seo = 0.6x360 n. 3. A Geneva with 4 slots is used to pener Generate the worktable of a dial index: i : eration time [Link]. a adial § machine has an ei ma ‘ime a 2. s a So that the table must be ina dwell Soden edits Find (a) AC what rotational speed must ; Clea one miaan ig : the driver or of aie {urned (o provide this dwvell time, (b) What is the indexing time on cs 5 ae oo ¢ of cach cycle, Data: Number of slots n=4 1,=2.5 see (@N=9 (b)T <9 Soln, We have, 1 — oO righ Volume Production Systems or = (0.2x60)= [apm We have, T,=T,+T, +25 i 2.5 sec! A 2.8 BUFFER ST‘ A storage buffer in a production line is a location,where parts can be collected and temporarily stored before p ugesie to subsequent workstations} fers can be manually operated. Then_autoniated, storage buffer should consisis of a meghanism to accept pacts to stare te pals and ‘a mechanism ta,supply parts to the Gutomated flow lines are [Link] additional features beyond the transfer mechanisms and workstations fit is common for flow lings to include storage zones for collecting workparts in between the workstations along the flow a (The principal reasons for the use of buffer storage zones is fp reduce the effect of individual station breakdowhs ju the lind Cihe continuous or iniemmittent transfer system acts as w single ntegrateimachines)When a breakdown occur al the individual stations, production must be stopped.) Common reasons for lin jes % Tool failures or tool adjustments at individual stations 2 Scheduled tool changes _ 3. Defective workparts or components at assembly stations & Any electrical-malfunction

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