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Understand the existing process :-
• The obvious purpose of the first step in the USA approach is to comprehend the current process in all of its
details.
• What arc the inputs? What are the outputs? What exactly happens to the work unit between input and output?
What is the function of the process? How does it add value to the product? What are the upstream and
downstream operations in the production sequence, and can they be combined with the process under
consideration?
• Some of the basic charting tools used in methods Application of these tools to the existing process provide a
model of the process that can be analyzed and searched for weaknesses (and strengths).
• Mathematical models of the process may also be useful to indicate relationships between input parameters and
output variables.
2. Simplify the process :-
• Once the existing process is understood, then the search can begin for ways to simplify.
• This often involves a checklist of Questions about the existing process. What is the purpose of this step or this
transport? Is this step necessary? Can steps be combined? Can steps be performed simultaneously? Can steps be
integrated into a manually operated production line?
• Some of the ten strategies at automation and production systems are applicable to try to simplify the process.
3. Automate the process :-
• Once the process has been reduced to its simplest form, then automation can be considered.
• The possible forms of automation include the ten strategies.
• An automation migration strategy might be implemented for a new product that has not yet proven itself.
Automation Strategies:-
If automation seems a feasible solution to improving productivity, quality, or other measure of
performance, then the following ten strategies provide a road map to search for these improvements.
1. Specialization of operations:-
The first strategy involves the use of special-purpose equipment designed to perform one operation with the
greatest possible efficiency.
2. Combined operations:-
• Production occurs as a sequence of operations. Complex parts may require dozens, or even hundreds, of
processing steps.
• The strategy of combined operations involves reducing the number of distinct operation? Reduction machines
or workstations through which the part must be routed.
• This is accomplished by performing more than one operation at a given machine; thereby reducing the number
of separate machines needed which in turn reduces setup time.
3. Simultaneous operations:-
• A logical extension of the combined operations strategy is to simultaneously perform the operations that are
combined at one workstation.
• In effect, two or more processing (or assembly) operations are being performed simultaneously on the same
work part. Thus reducing total processing time.
Automation in Manufacturing
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4. Integration of operations:-
• Another strategy is to link several workstations together into a single integrated mechanism, using automated
work handling devices to transfer parts between stations.
• In effect, this reduces the number of separate machines through which the product must be scheduled with more
than one workstation.
• Several parts can be processed simultaneously, thereby increasing the overall output of the system.
5. Increased flexibility:-
• This strategy attempts to achieve maximum utilization of equipment for job shop and medium-volume
situations by using the same equipment for a variety of parts or products.
• It involves the use of the flexible automation concepts.
• Prime objectives are to reduce setup time and programming time for the production machine. This normally
translates into lower manufacturing lead time and less work-in-process.
6. Improved material handling and storage:-
• A great opportunity for reducing nonproductive time exists in the use of automated material handling and
storage systems.
• Typical benefits include reduced work-in-process and shorter manufacturing lead times.
7. On-line inspection:-
• Inspection for quality of work is traditionally performed after the process is completed which means that any
poor-quality product has already been produced by the time it is inspected.
• Incorporating inspection into the manufacturing process permits corrections to the process as the product is
being made.
• This reduces scrap and brings the overall quality of the product closer to the nominal specifications intended by
the designer.
8. Process control and optimization :-
• This includes a wide range of control schemes intended to operate the individual processes and associated
equipment more efficiently.
• By this strategy, the individual process times can be reduced and product quality improved.
9. Plant operations control:-
• This strategy is concerned with control at the plant level.
• It attempts to manage and coordinate the aggregate operations in the plant more efficiently.
• Its implementation usually involves a high level of computer networking within the factory.
10. Computer-integrated manufacturing (CIM) :-
• Taking the previous strategy one level higher, we have the integration of factory operations with engineering
design and the business functions of the firm.
• CIM involves extensive use of computer applications, computer data bases, and computer networking
throughout the enterprise.
Automation Migration Strategy:-
• If the product turns out to be successful and high future demand is anticipated, then it makes sense for the
company to automate production.
• The improvements are often carried out in phases.
• Many companies have an automation migration strategy: that is, a formalized plan for evolving the
manufacturing system, used to produce new products as demand grows.
• A typical automation migration strategy is as shown in fig.