Summary

For advanced undergraduate/graduate-level courses in Automation, Production Systems, and Computer-Integrated Manufacturing.

Provides the most up-to-date coverage of automated production systems

Automation, Production Systems, and Computer-Integrated Manufacturing provides up-to-date coverage of production systems, how they are sometimes automated and computerized, and how they can be mathematically analyzed to obtain performance metrics. The text is designed primarily for engineering students at the advanced undergraduate or beginning graduate levels in industrial, mechanical, and manufacturing engineering. The book is also useful for practicing engineers and managers who wish to learn about automation and production systems technologies in modern 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. The 5th Edition has consolidated and reorganized many of the topics, eliminated material that is no longer relevant, and revised end-of-chapter problems.

Author Biography

Mikell P. Groover is Professor Emeritus of Industrial and Systems Engineering at Lehigh University, where he taught and did research for 44 years. He received his B.A. in Arts and Science (1961), B.S. in Mechanical Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from Lehigh. His industrial experience includes several years as a manufacturing engineer before embarking on graduate studies.

His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems. He has received a number of teaching awards at Lehigh University, as well as the Albert G. Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001). His publications include over 85 technical articles and books. His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese. The first edition of Fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996).

Dr. Groover is a member of the Institute of Industrial Engineers (IIE) and the Society of Manufacturing Engineers (SME). He is a Fellow of IIE and SME.

Chapter 1 INTRODUCTION

1.1 Production Systems

1.2 Automation in Production Systems

1.3 Manual Labor in Production Systems

1.4 Automation Principles and Strategies

1.5 About This Book

PART I OVERVIEW OF MANUFACTURING

Chapter 2 MANUFACTURING OPERATIONS

2.1 Manufacturing Industries and Products

2.2 Manufacturing Operations

2.3 Production Facilities

2.4 Product/Production Relationships

Chapter 3 MANUFACTURING METRICS AND ECONOMICS

3.1 Production Performance Metrics

3.2 Manufacturing Costs

PART II AUTOMATION AND CONTROL TECHNOLOGIES

Chapter 4 INTRODUCTION TO AUTOMATION

4.1 Basic Elements of an Automated System

4.2 Advanced Automation Functions

4.3 Levels of Automation

4.4 Automation and Artificial Intelligence

Chapter 5 INDUSTRIAL CONTROL SYSTEMS

5.1 Process Industries versus Discrete Manufacturing Industries

5.2 Continuous versus Discrete Control

5.3 Computer Process Control

Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL

6.1 Sensors

6.2 Actuators

6.3 Analog—Digital Conversions

6.4 Input/Output Devices for Discrete Data

Chapter 7 COMPUTER NUMERICAL CONTROL

7.1 Fundamentals of NC Technology

7.2 Computers and Numerical Control

7.3 Applications of NC

7.4 Analysis of Positioning Systems

7.5 NC Part Programming

7.6 CNC Trends and Developments

Appendix 7A: Coding for Manual Part Programming

Chapter 8 INDUSTRIAL ROBOTICS

8.1 Robot Anatomy and Related Attributes

8.2 Robot Control Systems

8.3 End Effectors

8.4 Applications of Industrial Robots

8.5 Economic Justification of Industrial Robots

8.6 Robot Programming

8.7 Robot Accuracy and Repeatability

Chapter 9 DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS

9.1 Discrete Process Control

9.2 Ladder Logic Diagrams

9.3 Programmable Logic Controllers

9.4 Personal Computers and Programmable Automation Controllers

PART III MATERIAL HANDLING AND IDENTIFICATION

Chapter 10 MATERIAL TRANSPORT SYSTEMS

10.1 Overview of Material Handling

10.2 Material Transport Equipment

10.3 Analysis of Material Transport Systems

Chapter 11 STORAGE SYSTEMS

11.1 Overview to Storage Systems

11.2 Conventional Storage Methods and Equipment

11.3 Automated Storage Systems

11.4 Analysis of Storage Systems

Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE

12.1 Overview of Automatic Identification Methods

12.2 Bar Code Technology

PART IV MANUFACTURING SYSTEMS

Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS

13.1 Components of a Manufacturing System

13.2 Types of Manufacturing Systems

Chapter 14 SINGLE-STATION MANUFACTURING CELLS

14.1 Single-Station Manned Cells

14.2 Single-Station Automated Cells

14.3 Applications of Single-Station Cells

14.4 Analysis of Single-Station Cells

Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: MANUAL ASSEMBLY LINES

15.1 Fundamentals of Manual Assembly Lines

15.2 Analysis of Single-Model Assembly Lines

15.3 Line Balancing Algorithms

15.4 Workstation Details

15.5 Other Considerations in Assembly Line Design

15.6 Alternative Assembly Systems

Appendix 15A Batch-Model and Mixed-Model Lines

Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES

16.1 Fundamentals of Automated Production Lines

16.2 Applications of Automated Production Lines

16.3 Analysis of Transfer Lines

Appendix 16A Transfer Lines with Internal Storage

Chapter 17 AUTOMATED ASSEMBLY SYSTEMS

17.1 Fundamentals of Automated Assembly Systems

17.2 Analysis of Automated Assembly Systems

Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING

18.1 Part Families and Machine Groups

18.2 Cellular Manufacturing

18.3 Applications of Group Technology

18.4 Analysis of Cellular Manufacturing

Appendix 18A Opitz Parts Classification and Coding System

Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY

19.1 Manufacturing Flexibility Defined

19.2 Components of an FM

19.3 Analysis of Flexible Manufacturing Systems

19.4 Alternative Approaches to Flexible Manufacturing

PART V QUALITY CONTROL SYSTEMS

Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING

20.1 Quality in Design and Manufacturing

20.2 Traditional and Modern Quality Control

20.3 Process Variability and Process Capability

20.4 Statistical Process Control

20.5 Six Sigma

20.6 Taguchi Methods in Quality Engineering

20.7 ISO 9000

Appendix 20A The Six Sigma DMAIC Procedure

Chapter 21 INSPECTION PRINCIPLES AND PRACTICES

21.1 Inspection Fundamentals

21.2 Sampling versus 100% Inspection

21.3 Automated Inspection

21.4 When and Where to Inspect

21.5 Analysis of Inspection Systems

Chapter 22 INSPECTION TECHNOLOGIES

22.1 Inspection Metrology

22.2 Conventional Measuring and Gaging Techniques

22.3 Coordinate Measuring Machines

22.4 Surface Measurement

22.5 Machine Vision

22.6 Other Optical Inspection Methods

22.7 Noncontact Nonoptical Inspection Techniques

Appendix 22A Geometric Feature Construction

PART VI MANUFACTURING SUPPORT SYSTEMS AND COMPUTER-INTEGRATED MANUFACTURING

Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM

23.1 Product Design and CAD

23.2 CAM, CAD/CAM, and CIM

Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING

24.1 Process Planning

24.2 Computer-Aided Process Planning

24.3 Concurrent Engineering and Design for Manufacturing

24.4 Advanced Manufacturing Planning

Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS

25.1 Aggregate Production Planning and the Master Production Schedule

25.2 Material Requirements Planning

25.3 Capacity Planning

25.4 Shop Floor Control

25.5 Inventory Control

25.6 Manufacturing Resource Planning (MRP II)

25.7 Enterprise Resource Planning (ERP)

Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION

26.1 Lean Production and Waste in Manufacturing

26.2 Just-in-Time Production Systems

26.3 Autonomation

26.4 Worker Involvement

Appendix Answers to Selected Problems

Supplemental Materials

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