Automation, Production Systems, and Computer-Integrated Manufacturing

by Groover, Mikell P.

• ISBN13: 9780130889782
• ISBN10: 0130889784
• Edition: 2nd
• Format: Hardcover
• Copyright: 2008-01-01
• Publisher: Prentice Hall

Summary

For advanced undergraduate/ graduate-level courses in Automation, Production Systems, and Computer-Integrated Manufacturing. This exploration of the technical and engineering aspects of automated production systems provides the most advanced, comprehensive, and balanced coverage of the subject of any text on the market. It covers all the major cutting-edge technologies of production automation and material handling, and how these technologies are used to construct modern manufacturing systems.

Table of Contents

Introduction	1	(23)
Production System Facilities	2	(5)
Manufacturing Support Systems	7	(2)
Automation in Production Systems	9	(5)
Manual Labor in Production Systems	14	(3)
Automation Principles and Strategies	17	(4)
Organization of the Book	21	(3)
Manufacturing Operations	24	(37)
Manufacturing Industries and Products	28	(3)
Manufacturing Operations	31	(4)
Product/Production Relationships	35	(5)
Production Concepts and Mathematical Models	40	(8)
Costs of Manufacturing Operations	48	(13)
PART I: AUTOMATION AND CONTROL TECHNOLOGIES	61
Introduction to Automation	66
Basic Elements of an Automated System	63
Advanced Automation Functions	71
Levels of Automation	76
Industrial Control Systems	79
Process Industries versus Discrete Manufacturing Industries	80
Continuous versus Discrete Control	82
Computer Process Control	88
Forms of Computer Process Control	96
Sensors, Actuators, and Other Control System Components	107
Sensors	108
Actuators	111
Analog-to-Digital Conversion	112
Digital-to-Analog Conversion	115
Input/Output Devices for Discrete Data	117
Numerical Control	120
Fundamentals of NC Technology	122
Computer Numerical Control	128
DNC	134
Applications of Numerical Control	137
NC Part Programming	145
Engineering Analysis of NC Positioning Systems	179
Appendix: APT Word Definitions	196
Industrial Robotics	210
Robot Anatomy and Related Attributes	212
Robot Control Systems	218
End Effectors	220
Sensors in Robotics	222
Industrial Robot Applications	222
Robot Programming	230
Engineering Analysis of Industrial Robots	240
Discrete Control Using Programmable Logic Controllers and Personal Computers	257
Discrete Process Control	257
Ladder Logic Diagrams	264
Programmable Logic Controllers	268
Personal Computers Using Soft Logic	275
Part II: MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES
Introduction to Material Handling	281
Overview of Material Handling Equipment	282
Considerations in Material Handling System Design	285
The 10 Principles of Material Handling	288
Material Transport Systems	292
Industrial Trucks	293
Automated Guided Vehicle Systems	295
Monorails and Other Rail Guided Vehicles	302
Conveyor Systems	303
Cranes and Hoits	309
Analysis of Material Transport Systems	311
Storage Systems	328
Storage System Performance	329
Storage Location Strategies	331
Conventional Storage Methods and Equipment	332
Automated Storage Systems	335
Engineering Analysis of Storage Systems	344
Automatic Data Capture	357
Overview of Automatic Identification Methods	358
Bar Code Technology	361
Other A DC Technologies	370
PART III: MANUFACTURING SYSTEMS
Introduction to Manufacturing Systems	375
Components of a Manufacturing System	376
Classification of Manufacturing Systems	381
Overview of the Classification Scheme	388
Manufacturing Progress Functions (Learning Curves)	392
Single Station Manufacturing Cells	397
Single Station Manned Workstations	398
Single Station Automated Cells	399
Applications	404
Analysis of Single Station Cells	409
Group Technology and Cellular Manufacturing	420
Part Families	422
Parts Classification and Coding	425
Production Flow Analysis	431
Cellular Manufacturing	434
Application Considerations in Group Technology	439
Quantitative Analysis in Cellular Manufacturing	442
Flexible Manufacturing Systems	460
What is an FMS?	462
FMS Components	469
FMS Applications and Benefits	480
FMS Planning and Implementation Issues	485
Quantitative Analysis of Flexible Manufacturing Systems	487
Manual Assembly Lines	514
Fundamentals of Manual Assembly Lines	516
Alternative Assembly Systems	523
Design for Assembly	524
Analysis of Single Model Assembly Lines	525
Line Balancing Algorithms	534
Mixed Model Assembly Lines	540
Other Considerations in Assembly Line Design	552
Transfer Lines and Similar Automated Manufacturing Systems	566
Fundamentals of Automated Production Lines	565
Applications of Automated Production Lines	575
Analysis of Transfer Lines with No Internal Storage	579
Analysis of Transfer Lines with Storage Buffers	587
Automated Assembly Systems	601
Fundamentals of Automated Assembly Systems	602
Design for Automated Assembly	606
Quantitative Analysis of Assembly Systems	610
PART IV: QUALITY CONTROL SYSTEMS
Introduction to Quality Assurance	631
Quality Defined	633
Traditional and Modern Quality Control	635
Taguchi Methods in Quality Engineering	638
ISO 9000	648
Statistical Process Control	654
Process Variability and Process Capability	655
Control Charts	658
Other SPC Tools	667
Implementing Statistical Process Control	672
Inspection Principles and Practices	681
Inspection Fundamentals	682
Sampling versus 100% Inspection	687
Automated Inspection	692
When and Where to Inspect	694
Quantitative Analysis of Inspection	698
Inspection Technologies	711
Inspection Metrology	712
Contact versus Noncontact Inspection Techniques	717
Conventional Measuring and Gaging Techniques	718
Coordinate Measuring Machines	720
Surface Measurement	736
Machine Vision	738
Other Optical Inspection Techniques	745
Noncontact Nonoptical Inspection Technologies	747
PART V: MANUFACTURING SUPPORT SYSTEMS
Product Design and CAD/CAM in the Production System	753
Product Design and CAD	755
CAD System Hardware	761
CAM, CAD/CAM, and CIM	764
Quality Function Deployment	767
Process Planning and Concurrent Engineering	775
Process Planning	776
Computer-Aided Process Planning (CAPP)	782
Concurrent Engineering and Design for Manufacturing	785
Advanced Manufacturing Planning	791
Production Planning and Control Systems	796
Aggregate Production Planning and the Master Production Schedule	798
Material Requirements Planning (MRP)	800
Capacity Planning	806
Shop Floor Control	808
Inventory Control	814
Manufacturing Resource Planning (MRP II)	822
Just-In-Time Production Systems	823
Lean Production and Agile Manufacturing	832
Lean Production	833
Agile Manufacturing	835
Comparison of Lean and Agile	843

Excerpts

Preface The first edition of this book was published in 1980 under the titleAutomation, Production Systems, and Computer-Aided Manufacturing.A revision was published in 1987 with about 200 more pages and a slightly different title:Automation, Production Systems, and Computer Integrated Manufacturing.The additional pages expanded the coverage of topics like industrial robotics, programmable logic controllers, material handling and storage, and quality control. But much of the book was very similar to the 1980 text. By the time I started work on the current volume (technically the second edition of the 1987 title, but in fact the third generation of the 1980 publication), it was clear that the book was in need of a thorough rewriting. New technologies had been developed and existing technologies had advanced, new theories and methodologies had emerged in the research literature, and my own understanding of automation and production systems had grown and matured (at least I think so). Readers of the two previous books will find this new volume to be quite different from its predecessors. Its organization is significantly changed, new topics have been added, and some topics from the previous editions have been discarded or reduced in coverage. It is not an exaggeration to say that the entire text has been rewritten (readers will find very few instances where I have used the same wording as in the previous editions). Nearly all of the figures are new. It is essentially a new book. There is a risk in changing the book so much. Both of the previous editions have been very successful for Prentice Hall and me. Many instructors have adopted the book and have become accustomed to its organization and coverage. Many courses have been developed based on the book. What will these instructors think of the new edition, with all of its new and different features? My hope is that they will try out the new book and find it to be a significant improvement over the 1987 edition, as well as any other textbook on the subject. Specifically, what are the changes in this new edition? To begin with, the organization has been substantially revised. Following two introductory chapters, the book is organized into five main parts: Automation and control technologies:Six chapters on automation, industrial computer control, control system components, numerical control, industrial robotics, and programmable logic controllers. Material handling technologies:Four chapters covering conventional and automated material handling systems (e.g., conveyor systems and automated guided vehicle systems), conventional and automated storage systems, and automatic identification and data capture. Manufacturing systems:Seven chapters on a manufacturing systems taxonomy, single station cells, group technology, flexible manufacturing systems, manual assembly lines, transfer lines, and automated assembly. Quality control systems:Four chapters covering quality assurance, statistical process control, inspection principles, and inspection technologies (e.g., coordinate measuring machines and machine vision). Manufacturing support systems:Four chapters on product design and CAD/CAM, process planning, production planning and control, and lean production and agile manufacturing. Other changes in organization and coverage in the current edition, compared with the 1987 book, include: Expanded coverage of automation fundamentals, numerical control programming, group technology, flexible manufacturing systems, material handling and storage, quality control and inspection, inspection technologies, programmable logic controllers. New chapters or sections on manufacturing systems, single station manufacturing systems, mixed-model assembly line analysis, quality assurance and statistical process control, Taguchi methods,