Contents Preface xi Chapter 1 IntroduCtIon 1 1.1 Production Systems 2 1.2 Automation in Production Systems 6 1.3 Manual Labor in Production Systems 11 1.4 Automation Principles and Strategies 13 1.5 About This Book 18 Part I: overvIew of ManufaCturIng 21 Chapter 2 ManufaCturIng oPeratIons 21 2.1 Manufacturing Industries and Products 25 2.2 Manufacturing Operations 28 2.3 Production Facilities 32 2.4 Product/Production Relationships 37 Chapter 3 ManufaCturIng MetrICs and eConoMICs 46 3.1 Production Performance Metrics 47 3.2 Manufacturing Costs 59 APPENDIX 3A: Averaging Formulas for Equation (3.20) 73 Part II: autoMatIon and Control teChnologIes 75 Chapter 4 IntroduCtIon to autoMatIon 75 4.1 Basic Elements of an Automated System 78 4.2 Advanced Automation Functions 86 4.3 Levels of Automation 91 Chapter 5 IndustrIal Control systeMs 95 5.1 Process Industries versus Discrete Manufacturing Industries 96 5.2 Continuous versus Discrete Control 98 5.3 Computer Process Control 104 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Part III: Chapter 10 Chapter 11 Chapter 12 Contents hardware CoMPonents for autoMatIon and ProCess Control 121 6.1 Sensors 122 6.2 Actuators 126 6.3 Analog–Digital Conversions 138 6.4 Input/Output Devices for Discrete Data 143 CoMPuter nuMerICal Control 149 7.1 Fundamentals of NC Technology 152 7.2 Computers and Numerical Control 158 7.3 Applications of NC 163 7.4 Analysis of Positioning Systems 170 7.5 NC Part Programming 178 APPENDIX 7A: Coding for Manual Part Programming 196 IndustrIal robotICs 204 8.1 Robot Anatomy and Related Attributes 206 8.2 Robot Control Systems 214 8.3 End Effectors 216 8.4 Applications of Industrial Robots 217 8.5 Robot Programming 226 8.6 Robot Accuracy and Repeatability 234 dIsCrete Control and PrograMMable logIC Controllers 244 9.1 Discrete Process Control 244 9.2 Ladder Logic Diagrams 252 9.3 Programmable Logic Controllers 256 9.4 Personal Computers and Programmable Automation Controllers 263 MaterIal handlIng and IdentIfICatIon 269 MaterIal transPort systeMs 269 10.1 Overview of Material Handling 270 10.2 Material Transport Equipment 275 10.3 Analysis of Material Transport Systems 291 storage systeMs 309 11.1 Introduction to Storage Systems 310 11.2 Conventional Storage Methods and Equipment 314 11.3 Automated Storage Systems 317 11.4 Analysis of Storage Systems 325 autoMatIC IdentIfICatIon and data CaPture 337 12.1 Overview of Automatic Identification Methods 338 12.2 Bar Code Technology 340 12.3 Radio Frequency Identification 347 12.4 Other AIDC Technologies 349 A01_GROO9612_04_SE_FM.indd 6 18/06/14 7:41 PM Contents vii Part Iv: ManufaCturIng systeMs 353 Chapter 13 overvIew of ManufaCturIng systeMs 353 13.1 Components of a Manufacturing System 354 13.2 Types of Manufacturing Systems 359 Chapter 14 sIngle-statIon ManufaCturIng Cells 366 14.1 Single-Station Manned Cells 367 14.2 Single-Station Automated Cells 368 14.3 Applications of Single-Station Cells 377 14.4 Analysis of Single-Station Cells 377 Chapter 15 Manual asseMbly lInes 390 15.1 Fundamentals of Manual Assembly Lines 392 15.2 Analysis of Single-Model Assembly Lines 398 15.3 Line Balancing Algorithms 405 15.4 Workstation Details 411 15.5 Other Considerations in Assembly Line Design 413 15.6 Alternative Assembly Systems 416 APPENDIX 15A: Batch-Model and Mixed-Model Lines 426 Chapter 16 autoMated ProduCtIon lInes 441 16.1 Fundamentals of Automated Production Lines 442 16.2 Applications of Automated Production Lines 450 16.3 Analysis of Transfer Lines 454 APPENDIX 16A: Transfer Lines with Internal Storage 464 Chapter 17 autoMated asseMbly systeMs 472 17.1 Fundamentals of Automated Assembly Systems 473 17.2 Analysis of Automated Assembly Systems 479 Chapter 18 grouP teChnology and Cellular ManufaCturIng 497 18.1 Part Families and Machine Groups 499 18.2 Cellular Manufacturing 506 18.3 Applications of Group Technology 511 18.4 Analysis of Cellular Manufacturing 513 APPENDIX 18A: Opitz Parts Classification and Coding System 528 Chapter 19 flexIble ManufaCturIng Cells and systeMs 531 19.1 What Is a Flexible Manufacturing System? 533 19.2 FMC/FMS Components 538 19.3 FMS Application Considerations 545 19.4 Analysis of Flexible Manufacturing Systems 549 19.5 Alternative Approaches to Flexible Manufacturing 561 A01_GROO9612_04_SE_FM.indd 7 Part v: QualIty Control systeMs 575 Chapter 20 QualIty PrograMs for ManufaCturIng 575 20.1 Quality in Design and Manufacturing 576 20.2 Traditional and Modern Quality Control 577 20.3 Process Variability and Process Capability 580 20.4 Statistical Process Control 583 20.5 Six Sigma 596 20.6 Taguchi Methods in Quality Engineering 600 20.7 ISO 9000 605 APPENDIX 20A: The Six Sigma DMAIC Procedure 612 Chapter 21 InsPeCtIon PrInCIPles and PraCtICes 618 21.1 Inspection Fundamentals 619 21.2 Sampling versus 100% Inspection 624 21.3 Automated Inspection 628 21.4 When and Where to Inspect 630 21.5 Analysis of Inspection Systems 634 Chapter 22 InsPeCtIon teChnologIes 647 22.1 Inspection Metrology 648 22.2 Conventional Measuring and Gaging Techniques 653 22.3 Coordinate Measuring Machines 653 22.4 Surface Measurement 665 22.5 Machine Vision 667 22.6 Other Optical Inspection Methods 674 22.7 Noncontact Nonoptical Inspection Techniques 677 APPENDIX 22A: Geometric Feature Construction 682 Part vI: ManufaCturIng suPPort systeMs 685 Chapter 23 ProduCt desIgn and Cad/CaM In the ProduCtIon systeM 685 23.1 Product Design and CAD 686 23.2 CAM, CAD/CAM, and CIM 693 23.3 Quality Function Deployment 697 Chapter 24 ProCess PlannIng and ConCurrent engIneerIng 703 24.1 Process Planning 704 24.2 Computer-Aided Process Planning 709 24.3 Concurrent Engineering and Design for Manufacturing 712 24.4 Advanced Manufacturing Planning 716 A01_GROO9612_04_SE_FM.indd 8 Chapter 25 ProduCtIon PlannIng and Control systeMs 721 25.1 Aggregate Production Planning and the Master Production Schedule 723 25.2 Material Requirements Planning 725 25.3 Capacity Planning 731 25.4 Shop Floor Control 733 25.5 Inventory Control 739 25.6 Manufacturing Resource Planning (MRP II) 743 25.7 Enterprise Resource Planning (ERP) 744 Chapter 26 Just-In-tIMe and lean ProduCtIon 750 26.1 Lean Production and Waste in Manufacturing 751 26.2 Just-In-Time Production Systems 755 26.3 Autonomation 762 26.4 Worker Involvement 766 appendix: answers to selected Problems 776 Index 782
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