Module 3

1. What are the components of automated manufacturing system.

An automated manufacturing system is an integrated system in which manufacturing operations are performed with minimal
human intervention using automated equipment and computer control. The major components of an automated manufacturing
system and their detailed explanation are given below.

i. Production Machines and Associated Hardware

This component performs the actual manufacturing operations on the workpiece.

(a) Production Machines

These are the machines where processing or assembly takes place. Examples include:

• CNC machines (lathe, milling, drilling)

• Automated assembly machines

• Industrial robots

• Presses, welding machines, injection molding machines

In automated systems, these machines are designed to operate automatically with high precision, repeatability, and consistency.

(b) Tools

Tools are used to perform operations such as cutting, shaping, or forming. Examples:

• Cutting tools (drills, end mills, turning tools)

• Welding torches

• Assembly tools (screwdrivers, grippers)

In automation, tools are often:

• Automatically changed using tool changers

• Monitored for wear and breakage using sensors

(c) Fixtures and Jigs

Fixtures hold and locate the workpiece accurately during machining or assembly. Their functions are:

• Proper positioning of the workpiece

• Reducing setup time

• Improving dimensional accuracy

In automated systems, fixtures are:

• Designed for quick loading/unloading

• Compatible with robotic handling

(d) Other Related Hardware

This includes:

• Sensors (position, temperature, pressure)

• Actuators (motors, pneumatic and hydraulic cylinders)

• Safety devices (interlocks, guards)

These elements help in monitoring, controlling, and ensuring safe operation.

ii. Material Handling System

The material handling system is responsible for moving, storing, loading, and unloading materials within the manufacturing system.
Functions:

• Transport raw materials to machines

• Move semi-finished parts between workstations

• Remove finished products

• Store parts temporarily (buffers)

Common Material Handling Equipment:

• Conveyors (belt, roller, chain)

• Automated Guided Vehicles (AGVs)

• Robots for loading and unloading

• Pallet systems

• Automated Storage and Retrieval Systems (AS/RS)

Importance:

• Reduces manual labor

• Minimizes production time

• Improves safety

• Ensures smooth and continuous flow of materials

iii. Computer Systems for Control and Coordination

Computer systems act as the brain of an automated manufacturing system.

(a) Control Systems

These systems directly control machines and equipment:

• PLCs (Programmable Logic Controllers)

• CNC controllers

• Robot controllers

Functions include:

• Sequence control of operations

• Motion control

• Monitoring machine status

(b) Supervisory and Coordination Systems

These systems manage and coordinate the entire system:

• Manufacturing Execution Systems (MES)

• Supervisory Control and Data Acquisition (SCADA)

• Production scheduling software

Functions:

• Production planning and scheduling

• Monitoring performance and productivity

• Quality control and data collection

• Fault detection and diagnostics

(c) Communication Networks

Communication systems connect all components:

• Fieldbus networks

• Industrial Ethernet

• Wireless networks

They ensure real-time data exchange between machines, computers, and sensors.

iv. Human Workers

Even in highly automated systems, human involvement is essential.

Roles of Human Workers:

• System design and programming

• Setup and calibration of machines

• Monitoring system performance

• Maintenance and troubleshooting

• Quality inspection and decision-making

Importance:

• Handle exceptions and unexpected situations

• Improve flexibility of the system

• Ensure safety and continuous improvement

Automation reduces direct labor, but increases the need for skilled workers such as engineers, technicians, and programmers.

2. Explain classification of manufacturing system.

Classification of Manufacturing Systems

Manufacturing systems are classified based on four fundamental factors that strongly influence system design, performance,
flexibility, and automation level. These factors are:

i. Types of operations performed

ii. Number of workstations and system layout

iii. Level of automation

iv. Part or product variety

i. Types of Operations Performed

Manufacturing systems are first classified according to the type of operations they perform. At the highest level, two broad
categories exist:

(a) Processing Operations

• These operations change the shape, size, or properties of a work unit.

• They are performed on individual parts.

Examples:

• Machining (turning, milling, drilling)

• Casting, forging

• Welding, heat treatment

Further classification based on part geometry:

• Rotational parts: Cylindrical or disk-shaped parts (e.g., shafts)

o Require turning and other rotational operations

• Non-rotational (prismatic) parts: Rectangular or cube-like parts

o Require milling, drilling, and related operations

(b) Assembly Operations

• These operations join two or more parts to form a complete product or subassembly.

Examples:

• Mechanical fastening

• Welding

• Soldering

• Adhesive bonding

Additional Product Parameters Affecting System Design

• Type of material processed

• Size and weight of the part

• Part geometry and complexity

These parameters influence the choice of machines, tooling, handling systems, and automation level.

ii. Number of Workstations and System Layout

The number of workstations (n) is a key measure of system size and complexity.

Importance:

• Influences production capacity and productivity

• Affects cost per unit and maintainability

• More stations → higher complexity and management difficulty

System Layout

Closely related to the number of stations is how the stations are arranged and how parts move between them.

Classification Based on Workstations and Layout

Type I: Single-Station System (n = 1)

• Simplest manufacturing system

• Consists of one workstation

• Can be:

o Manually operated

o Semi-automated

o Fully automated

Examples:

• Manual lathe

• CNC machining center

Type II: Multiple Stations with Variable Routing

 • Two or more stations (n > 1)

• Parts can follow different paths through the system

• Designed to handle different products or styles

Examples:

• Job shops

• Flexible manufacturing systems (FMS)

Characteristics:

• High flexibility

• Moderate production rate

Type III: Multiple Stations with Fixed Routing

• Two or more stations arranged in a fixed sequence

• Stations laid out as a production or transfer line

Examples:

• Automobile assembly lines

• Bottling plants

Characteristics:

• High production rate

• Low flexibility

iii. Level of Automation

Manufacturing systems are classified based on the extent of human involvement.

(a) Manual Systems (M)

• Operations performed entirely by human workers

• Machines may be hand-operated

Features:

• Low cost

• High flexibility

• Low productivity

(b) Automated Systems (A)

• Operations performed automatically

• Human involvement limited to supervision and maintenance

Features:

• High productivity

• High accuracy and consistency

• High initial investment

(c) Hybrid Systems (H)

• Combination of manual and automated stations

• Some stations are automated, others are manned

Features:

• Balanced cost and flexibility

• Common in modern manufacturing

iv. Part or Product Variety

This factor describes the ability of the manufacturing system to handle variations in the products produced.

Examples of Variations:

• Different colors or materials in injection-molded parts

• Different electronic components on a standard PCB

• Different models of the same product

Classification Based on Product Variety

System Type Symbol Typical Product Variety Flexibility

Single-model S No product variety Not required

Batch-model B Hard product variety Most flexible

Mixed-model X Soft product variety Some flexibility

Explanation of Product Variety Types

(a) Single-Model System

• Produces only one product

• No variation

• Example: Dedicated transfer line

(b) Batch-Model System

• Produces different products in separate batches

• Requires changeover between batches

• Example: Batch production in job shops

(c) Mixed-Model System

• Produces different product models simultaneously

• No changeover required between units

• Example: Modern automobile assembly lines

3. Explain cellular manufacturing.

Cellular manufacturing is an application of Group Technology (GT) in which dissimilar machines or processes are grouped into
manufacturing cells. Each cell is designed to produce a part family (or a limited number of part families) that have similar design
features and/or similar processing requirements.

Instead of arranging machines by function (as in a job shop), machines are arranged by product flow, so that parts move smoothly
within a cell.

Concept of Group Technology in Cellular Manufacturing

Group Technology is based on the principle that similar parts should be manufactured in a similar way. In cellular manufacturing:

• Parts are classified into families based on geometry, size, material, or process sequence.
 • Machines required to process a part family are placed close together in a cell.

• Each cell operates almost like a mini production line.

Structure of a Manufacturing Cell

A typical manufacturing cell consists of:

• Different types of machines (e.g., lathe, milling, drilling, grinding)

• Material handling devices (manual handling, conveyors, robots)

• One or more workers responsible for the entire cell

• Inspection and quality-control equipment

Cells are often arranged in U-shape or straight-line layouts to minimize material movement and improve visibility and control.

Objectives of Cellular Manufacturing (Explained in Detail)

i. Shortening Manufacturing Lead Time

Manufacturing lead time is the total time from release of an order to completion.

In cellular manufacturing:

• Parts move only within the cell

• Waiting time between operations is minimized

• Queues are reduced because machines are dedicated to a part family

➡ Result: Faster production and quicker delivery.

ii. Reducing Work-In-Process (WIP) Inventory

WIP inventory refers to parts waiting between operations.

In traditional job shops:

• Parts wait in long queues

• Material travels long distances

In cellular manufacturing:

• Continuous flow inside the cell

• Minimal waiting between machines

• Smaller batch sizes

➡ Result: Lower inventory cost and better shop-floor control.

iii. Improving Product Quality

Quality improves due to:

• Shorter feedback loops: defects are detected quickly

• Cell workers take responsibility for the complete part

• Less handling reduces chances of damage

• Easier implementation of in-process inspection

➡ Result: Reduced rework, scrap, and improved consistency.

iv. Simplifying Production Scheduling

In job shops:

• Scheduling is complex due to multiple routes and shared machines

In cellular manufacturing:

• Each cell acts as an independent production unit

• Fixed or near-fixed routing within the cell

• Easier planning and control

➡ Result: Simple scheduling, easier tracking of orders, and better adherence to deadlines.

v. Reducing Setup Times

Setup time is the time required to change from producing one part to another.

Cellular manufacturing reduces setup time because:

• Part families have similar processing requirements

• Tools, fixtures, and programs are standardized

• Machines are frequently used for similar parts

➡ Result: Faster changeovers and higher machine utilization.

Advantages of Cellular Manufacturing

• Reduced material handling

• Shorter production cycles

• Lower WIP inventory

• Improved quality and accountability

• Better utilization of space

• Increased worker involvement and skill development

Limitations of Cellular Manufacturing

• Initial effort required for part family formation

• Possible duplication of machines across cells

• Less flexibility if product design changes significantly

• Not economical for very low-volume production

4. Explain Flexible manufacturing system.

A Flexible Manufacturing System (FMS) is a highly automated manufacturing system based on group technology, consisting of
multiple processing workstations interconnected by an automated material handling and storage system and coordinated by a
distributed computer control system.

An FMS is designed to produce a variety of part styles simultaneously with minimum manual intervention and high adaptability to
changes in product mix and demand.

Definition (Standard)

A flexible manufacturing system is a computer-controlled arrangement of automated workstations, usually CNC machines, linked by
automated material handling, capable of processing different part types with minimal setup changes.

Main Features of a Flexible Manufacturing System

i. Flexibility

Flexibility is the most important characteristic of an FMS. It refers to the system’s ability to:

• Identify different part styles automatically

• Change production schedules quickly

 • Accommodate variations in demand

• Recover from machine failures or errors

• Introduce new part designs with minimum effort

This flexibility allows the system to respond effectively to uncertainty and variability in manufacturing.

ii. Automation

• Operations are highly automated

• Material movement, tool changes, and part identification are automatic

• Human involvement is limited to supervision, maintenance, and decision-making

iii. Group Technology Based

• Parts are grouped into part families with similar processing requirements

• Machines are selected and arranged to efficiently process these families

Flexibility in FMS

The flexibility of a manufacturing system includes:

i. Part Variety Flexibility

Ability to produce different part styles without major setup changes.

ii. Routing Flexibility

Ability to process a part through alternate machine routes if a machine fails.

iii. Volume Flexibility

Ability to operate efficiently at different production volumes.

iv. Expansion Flexibility

Capability to add machines or workstations in the future.

v. Error Recovery Flexibility

Ability to detect faults and recover automatically.

Types of Flexible Manufacturing Systems

FMS can be classified based on operations, number of machines, and level of flexibility.

(a) Based on Type of Operations

i. Processing FMS

o Used for machining operations

o Includes CNC lathes, milling machines, machining centers

ii. Assembly FMS

o Used for automated assembly operations

o Includes robots and assembly stations

(b) Based on Number of Machines

i. Single-Machine Cell (SMC)

o One CNC machine with automated handling

o Lowest level of FMS

ii. Flexible Manufacturing Cell (FMC)

o Two or more CNC machines

o Moderate flexibility
 iii. Flexible Manufacturing System (FMS)

o Four or more machines

o High flexibility and automation

(c) Based on Level of Flexibility

i. Dedicated FMS

o Designed to produce a limited part family

o High production rate

o Limited flexibility

ii. Random-Order FMS

o Can process parts in any sequence

o Highest flexibility

o Suitable for changing demand patterns

Components of an FMS

An FMS consists of three critical components:

i. Workstations

Workstations perform the actual manufacturing operations.

Types of Workstations:

• Load/Unload stations – for part entry and exit

• Machining stations – CNC lathes, milling machines

• Inspection stations – coordinate measuring machines (CMMs)

Characteristics:

• Programmable

• High precision

• Tool magazines and automatic tool changers

ii. Material Handling and Storage System

This system ensures the automatic movement and temporary storage of parts.

Functions:

• Random movement of parts between machines

• Compatibility with different part sizes and configurations

• Temporary storage using buffers or AS/RS

Examples:

• Automated Guided Vehicles (AGVs)

• Conveyors

• Robots

• Pallet systems

iii. Computer Control System

The brain of the FMS, responsible for coordination and decision-making.

Functions:

• Machine control and scheduling

• Tool management

• Traffic control of material handling

• Monitoring system performance

• Fault detection and recovery

The control system integrates CNC controllers, PLCs, and supervisory computers.

FMS Application Considerations

FMS is suitable where flexible automation is required.

Key Considerations:

• Definition of part families

• Processing requirements

• Physical characteristics of parts

• Production volume and demand variability

FMS Applications

• Machining operations (most common)

• Sheet metal processing

• Assembly operations

• Electronics manufacturing

FMS Planning and Implementation Issues

Planning an FMS requires:

• Proper part family selection

• Selection of machines and tools

• Layout and material handling design

• Management of resources after installation

Poor planning can reduce system effectiveness.

Benefits of FMS

• Higher machine utilization

• Reduced floor space

• Lower work-in-process inventory

• Faster response to design changes

• Improved product quality

• Increased productivity

Analysis of Flexible Manufacturing Systems

FMS performance is evaluated using analytical models.

i. Bottleneck Model

• Identifies the bottleneck workstation

 • Determines maximum production rate

• Helps estimate machine workloads

ii. Extended Bottleneck Model

• Considers queueing effects

• Accounts for WIP and waiting times

• More realistic than the basic model

iii. Sizing the FMS

• Determines number of machines required

• Ensures desired production rate

• Prevents under- or over-capacity

iv. What the Equations Tell Us

• System output is limited by the bottleneck

• Proper WIP levels are essential

• Balanced workloads improve efficiency

Alternative Approaches to Flexible Manufacturing

i. Mass Customization

• Produces customized products with mass-production efficiency

• Balances variety and productivity

ii. Reconfigurable Manufacturing Systems (RMS)

• Systems designed for easy modification

• Capacity and functionality can be changed as needed

iii. Agile Manufacturing

• Focuses on rapid response to market changes

• Emphasizes flexibility, speed, and collaboration

Conclusion

A Flexible Manufacturing System represents a key advancement in automated manufacturing. By integrating CNC workstations,
automated material handling, and computer control, FMS provides high productivity with flexibility. It plays a crucial role in modern
manufacturing environments where product variety, responsiveness, and efficiency are essential.

5. Explain FMS and its planning and implementation

A Flexible Manufacturing System (FMS) is a highly automated, group-technology-based manufacturing system consisting of multiple
processing workstations (usually CNC machines) interconnected by an automated material handling and storage system and
coordinated by a distributed computer control system.

An FMS is capable of producing different part styles simultaneously, adjusting to changes in product mix and demand with minimal
manual intervention.

Main Characteristics of FMS

• High level of automation

• Ability to process multiple part types

• Integrated material handling and storage

 • Computer-controlled coordination of machines, tools, pallets, and parts

• Based on group technology and part families

FMS Planning and Implementation Issues

The successful operation of an FMS depends on effective management of all system resources, including:

• Machines

• Tools

• Pallets

• Parts

• People

FMS issues are organized into two major categories:

i. FMS planning and design issues

ii. FMS operational issues

i. FMS Planning and Design Issues

Planning and design decisions are made before system installation and determine the long-term performance of the FMS.

Part Family Considerations

The initial phase of FMS planning must identify the parts to be produced by the system. These issues are similar to group
technology (GT) machine cell planning.

Important considerations include:

(a) Processing Requirements

• Types of operations required (milling, drilling, turning, etc.)

• Operation sequences

• Tool requirements

(b) Physical Characteristics of Work parts

• Part size and weight

• Shape and geometry

• Material type

These characteristics influence machine selection, fixtures, and handling systems.

(c) Production Volume

• Expected production rate

• Batch sizes

• Product mix over time

Production volume determines the number of machines and system capacity.

Key Design Factors in FMS

Once part families are defined, the following factors must be specified in FMS design:

i. Types of Workstations

• CNC machining centers

• Load/unload stations

• Inspection stations
 ii. Variations in Process Routings and FMS Layout

• Fixed vs. alternative routing

• Arrangement of machines (line, loop, ladder, open field layout)

iii. Material Handling System

• Conveyors, AGVs, robots

• Capability for random part movement

• Integration with computer control

iv. Work-in-Process (WIP) and Storage Capacity

• Buffer sizes

• Temporary storage locations

• Balance between flow efficiency and congestion

v. Tooling

• Tool magazines

• Tool sharing among machines

• Tool life monitoring

vi. Pallet Fixtures

• Standardized pallets

• Fixture accuracy and repeatability

• Compatibility with handling equipment

ii. FMS Operational Issues

Operational issues arise after the FMS is installed and focus on optimizing system performance.

The goal is to use existing resources efficiently to meet:

• Production targets

• Quality requirements

• Profit objectives

• Customer satisfaction

Major FMS Operational Issues

i. Scheduling and Dispatching

• Deciding which parts to process and when

• Sequencing jobs at workstations

• Managing priorities and due dates

ii. Machine Loading

• Assigning operations to machines

• Balancing workloads

• Avoiding bottlenecks

iii. Part Routing

 • Selecting the route a part follows through the system

• Utilizing alternative machines when breakdowns occur

iv. Part Grouping

• Determining which parts should be processed together

• Maintaining system flexibility while minimizing setups

v. Tool Management

• Ensuring correct tools are available at machines

• Tool inventory control

• Tool replacement and wear monitoring

vi. Pallet and Fixture Allocation

• Managing the number of pallets and fixtures

• Ensuring availability when needed

• Minimizing idle time due to pallet shortages

6. Explain Automated Assembly Systems.

Automated assembly systems refer to manufacturing systems in which mechanized and automated devices perform assembly
operations with minimal human intervention. These systems use special-purpose machines, robotics, and automated handling
equipment to assemble components into finished products.

With advances in robotics, sensors, and control systems, automated assembly has achieved much higher productivity, consistency,
and quality compared to manual assembly.

Conditions Favourable for Automated Assembly

Automated assembly systems are most effective under the following conditions:

• High product demand (mass or large-scale production)

• Stable product design (few design changes)

• Limited component variety (typically fewer than 10–15 parts)

• Parts designed for automation (DFA) principles

• Long production life cycles

When these conditions are met, automated assembly becomes economically viable and technically efficient.

System Configurations of Automated Assembly Systems

Automated assembly systems are classified based on physical layout and part flow.

i. In-Line Assembly Machines

• Consist of a series of workstations arranged in a straight line

• Parts are transferred sequentially from one station to the next

• Each station performs a specific assembly task

Characteristics:

• High production rate

• Fixed sequence of operations

• Suitable for large-volume products

Applications:

• Consumer products

• Automotive subassemblies

ii. Dial-Type Assembly Machines

• Use a rotating circular dial (indexing table)

• Workpieces are mounted on fixtures around the dial

• At each index, components are added at different stations

Characteristics:

• Compact layout

• Precise indexing

• Suitable for small parts

Applications:

• Fuel injectors

• Small mechanical assemblies

iii. Carousel Assembly Systems

• Hybrid configuration combining circular and straight-line movement

• Allows greater flexibility than pure dial-type machines

Characteristics:

• Moderate production rates

• Flexible routing

• Efficient use of floor space

iv. Single-Station Assembly Machines

• All assembly operations are performed at one workstation

• Multiple components are assembled sequentially

Characteristics:

• Lower production rate

• High flexibility

• Lower capital cost

Applications:

• Low-volume or specialized products

• Prototype and custom assemblies

Parts Delivery at Workstations

A critical aspect of automated assembly is the reliable and continuous delivery of components to workstations.

Each workstation performs:

• Component delivery

• Orientation

• Joining operations
Key Hardware Elements in Parts Delivery System

i. Hopper

• Stores bulk components

• Acts as a reservoir for continuous feeding

ii. Parts Feeder

• Transfers parts from hopper to the workstation

• Common types:

o Vibratory feeders

o Centrifugal feeders

iii. Selector / Orientor

• Ensures components are correctly oriented

• Incorrectly oriented parts are rejected or recycled

iv. Feed Track

• Guides components from feeder to the assembly head

• Maintains part alignment and spacing

v. Escapement / Placement Device

• Releases one part at a time

• Synchronizes component delivery with machine cycle time

Applications of Automated Assembly Systems

Automated assembly systems are widely used in:

• Alarm clocks

• Fuel injectors

• Electrical switches

• Printed circuit boards (PCBs)

• Automotive and electronics assemblies

Processes Well-Suited for Automation:

• Screw fastening

• Press fitting

• Soldering

• Electronic component placement

Processes requiring complex manipulation or variability are less suitable for full automation.

Analysis of Automated Assembly Systems

Analytical models help evaluate performance, productivity, yield, and downtime.

Parts Delivery System at Workstations

Performance of parts delivery depends on:

• Feeding rate

• Orientation success probability

 • Machine cycle rate

Key requirement:

The parts delivery rate must be equal to or greater than the assembly machine cycle rate.

If delivery is slower:

• Machine starves

• Production rate drops

Multi station Assembly Machines

In multi station systems:

• Each station has a constant processing time

• Overall cycle time is governed by the slowest station

Factors Affecting Performance:

• Defective components

• Station failures

• Jams in feeding systems

A single jam can stop the entire line, reducing productivity.

Single-Station Assembly Machines

Single-station analysis includes:

• Individual assembly task times

• Handling and positioning times

• Inspection time

Performance Measures:

• Cycle time

• Yield

• Downtime due to defects or jams

Single-station systems are easier to analyse but have lower throughput.

Partial Automation

Many real-world assembly lines are partially automated, combining:

• Automated stations

• Manual stations

Advantages:

• Improved flexibility

• Lower investment cost

• Easier handling of complex tasks

Analysis Focus:

• Balancing manual and automated tasks

• Maintaining uptime

• Cost-effectiveness
What the Equations Tell Us (Key Insights)

Mathematical analysis of automated assembly systems reveals:

i. Parts delivery systems must match or exceed assembly cycle rate

ii. Component quality strongly affects yield and downtime

iii. Overall production rate is limited by the slowest station

iv. Frequent jams drastically reduce system efficiency

v. Automation should focus on tasks that improve quality and reduce cost

Advantages of Automated Assembly Systems

• High production rates

• Consistent quality

• Reduced labor cost

• Improved safety

• Lower unit cost for high volumes

Limitations

• High initial investment

• Low flexibility for design changes

• Requires well-designed components

• Not suitable for low-volume production

7. Explain types of automated assembly system.

Automated assembly systems are classified based on the physical arrangement of workstations and the flow of parts. The major
types are:

i. Dial-type assembly machine

ii. In-line assembly machine

iii. Carousel assembly system

iv. Single-station assembly machine

i. Dial-Type Assembly Machine

A dial-type assembly machine uses a circular indexing table (dial) with fixtures mounted around its periphery. The dial indexes
intermittently, stopping at each station where a specific assembly operation is performed.

Working:

• Base parts are loaded onto fixtures on the rotating dial

• At each indexing step, the part stops at a workstation

• Components are added or operations performed automatically

• After completing a full cycle, the finished assembly is unloaded

Characteristics:

• Compact design

• High accuracy due to precise indexing

• Fixed sequence of operations

Applications:

• Fuel injectors

• Small mechanical and precision assemblies

Advantages:

• High production rate

• Good repeatability

• Efficient use of floor space

Limitations:

• Low flexibility

• Difficult to modify for design changes

ii. In-Line Assembly Machine

An in-line assembly machine consists of multiple workstations arranged in a straight line, connected by a transfer system such as a
conveyor.

Working:

• Base parts enter at the first station

• Each station adds one or more components

• Parts move sequentially from station 1 to station n

• Completed assemblies exit at the end of the line

Characteristics:

• Fixed routing

• Each station performs a specific task

• Production rate governed by the slowest station

Applications:

• Consumer products

• Automotive and electronic assemblies

Advantages:

• Very high production rate

• Simple material flow

 • Suitable for mass production

Limitations:

• Line stoppage if one station fails

• Low flexibility

iii. Carousel Assembly System

A carousel assembly system is a hybrid configuration that combines features of both dial-type and in-line systems.

Working:

• Parts move on a closed-loop conveyor or track

• Workstations are arranged on both sides of the loop

• Components are added as parts circulate through stations

Characteristics:

• Continuous or intermittent motion

• More flexible routing than in-line systems

• Efficient use of space

Applications:

• Medium-volume assemblies

• Products requiring more stations but limited space

Advantages:

• Balanced productivity and flexibility

• Reduced congestion

• Compact layout

Limitations:

• Moderate complexity

• Lower production rate than pure in-line systems

 iv. Single-Station Assembly Machine

In a single-station assembly machine, all assembly operations are performed at one workstation.

Working:

• Base part is positioned at a single station

• Multiple components are fed from different feeders

• Assembly operations are performed sequentially

• Completed assembly is removed

Characteristics:

• All components converge at one station

• Lower production rate compared to multi-station systems

Applications:

• Low-volume production

• Complex assemblies

• Prototype or customized products

Advantages:

• High flexibility

• Lower initial investment

• Easier maintenance

Limitations:

• Lower throughput

• Not suitable for mass production

Part Feeding Devices (Supporting System)

Automated assembly systems rely on efficient part feeding devices, which include:

• Hopper – stores bulk parts

• Parts feeder – transports parts from hopper

• Selector / Orientor – ensures correct orientation

• Feed track – guides parts to assembly head

• Escapement and placement device – releases parts in sync with cycle time

Proper part feeding is essential to avoid machine starvation and downtime.

Summary Table

System Type Layout Production Rate Flexibility

Dial-type Circular High Low

In-line Straight line Very high Very low

Carousel Loop Medium-High Medium

Single-station Single point Low High

8. Analysis of multi-station and single station assembly machines.

The analysis of assembly machines is done to evaluate:

• Production rate

• Cycle time

• System efficiency

• Effect of defects and jams

Assembly machines are mainly of two types:

i. Multi-station assembly machines

ii. Single-station assembly machines

i. Analysis of Multi-Station Assembly Machine

A multi-station assembly machine consists of several assembly stations arranged in a fixed sequence (in-line, dial-type, or carousel).
Each station performs one assembly operation during each machine cycle.

Basic Assumptions

• All stations have constant processing time

• Machine operates in indexed cycles

• One work unit moves to the next station per cycle

• A defect or jam at any station can stop the entire system

a. Cycle Time

The cycle time (Tc) of a multi-station assembly machine is determined by the slowest station.

𝑻𝒄 = 𝐦𝐚𝐱⁡(𝒕𝟏 , 𝒕𝟐 , 𝒕𝟑 , … , 𝒕𝒏 )
where
𝑡𝑖 = operation time at station i
n = number of stations

b. Production Rate

The ideal production rate is:

𝟏
𝑹=
𝑻𝒄

In practice, production rate is reduced due to:

• Defective components

• Jams in feeders

• Station failures

c. Effect of Defective Components

• If a defective component reaches a station, it may cause:

o Rejection of the part

o Machine stoppage

• Even a small defect probability can significantly reduce output

d. Effect of Jams and Downtime

• A jam at any one station stops the entire line

• Downtime increases rapidly as the number of stations increases

• Reliability decreases with increasing system complexity

e. Key Observations (Multi-Station)

• Output rate is limited by the slowest station

• More stations → higher productivity but lower reliability

• Suitable for high-volume, low-variety production

ii. Analysis of Single-Station Assembly Machine

In a single-station assembly machine, all assembly tasks are performed at one workstation. Components are delivered from multiple
feeders and assembled sequentially.
Basic Assumptions

• One base part is assembled at a time

• Multiple components are fed to the same station

• Assembly tasks occur sequentially

• Failures affect only one station

a. Cycle Time

The cycle time is the sum of all individual task times:

𝑻𝒄 = 𝒕𝟏 + 𝒕𝟐 + 𝒕𝟑 + ⋯ + 𝒕𝒎
where
𝑡𝑗 = time for jth assembly operation
m = number of components assembled

b. Production Rate
𝟏
𝑹=
𝑻𝒄

Production rate is generally lower than multi-station systems due to:

• Sequential operations

• Single handling location

c. Effect of Defects and Jams

• A defect affects only the current part

• Does not stop multiple stations

• Easier fault detection and recovery

• Higher operational flexibility

d. Yield Considerations

Yield depends on:

• Quality of incoming components

• Accuracy of feeding and placement

• Probability of successful assembly at each step

e. Key Observations (Single-Station)

• Lower production rate

• Higher flexibility

• Lower system complexity

• Easier maintenance and troubleshooting

Comparison: Multi-Station vs Single-Station Assembly

Aspect Multi-Station Assembly Single-Station Assembly

Number of stations Multiple One

Cycle time Max station time Sum of task times

Production rate High Low

Flexibility Low High

Effect of jams Stops entire system Localized

Investment cost High Lower

Suitability Mass production Low/medium volume