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Automation, Production Systems, and Computer-"Integrated Manufacturing
Third Edition
Mikell P. Groover
Professor of Industrial and Systems Engineering Lehigh University
PEARSON .. .
Prentice Hall International
, I
Contents
Chapter 1 INTRODUCTION
1.1 Production Systems 19 1.2 Automation in Production Systems 25 1.3 Manual Labor in Production Systems 29
C)
1.4 Automation Principles and Strategies 31 1.5 Organization of this Book 36
PART I: OVERVIEW OF MANUFACTURING
Chapter 2 MANUFACTURING OPERATIONS
2.1 Manufacturing Industries and Products 43 2.2 Manufacturing Operations 46 2.3 Production Facilities 50 2.4 Product/Production Relationships 55 2.5 Lean Production 60
Chapter 3 MANUFACTURING MODELS AND METRICS
PART 11:
3.1 "Mathematical Models of Production Performance 65 3.2 Manufacturing Costs 73 APPENDIX Averaging Procedures for Production Models 82
AUTOMATION AND CONTROL TECHNOLOGIES
Chapter 4 INTRODUCTION TO AUTOMATION
4.1 Basic Elements of an Automated System 87 4.2 Advanced Automation Functions 95 4.3 Levels of Automation 100
Chapter 5 INDUSTRIAL CONTROL SYSTEMS
5.1 Process Industries Versus Discrete Manufacturing Industries 105 5.2 Continuous Versus Discrete Control 107 5.3 Computer Process Control 113
17
39
39
64
85
85
104
5
6 Contents
Chapter 6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL 130 6.1 Sensors 131 6.2 Actuators 135 6.3 Analog-to-Digital Converters 144 6.4 Digital-to-Analog Converters 147 6.5 Input/Output Devices for Discrete Data 150
Chapter 7 NUMERICAL CONTROL 7.1 Fundamentals of NCTechnology 158 7.2 Computer Numerical Control 164 7.3 Distributed Numerical Control 169 7.4 Applications ofNC 172 7.5 Engineering Analysis of NC Positioning Systems 179 7.6 NC Part Programming 187 Appendix A 7: Coding for Manual Part Programming 205 Appendix B 7: Part Programming with Apt 213
. Chapter 8 INDUSTRIAL ROBOTICS 8.1 Robot Anatomy and Related Attributes 231 8.2 Robot Control Systems 237 8.3 End Effectors 239 8.4 Sensors in Robotics 240 8.5 Industrial Robot Applications 241 8.6 Robot Programming 249 8.7 Robot Accuracy and Repeatability 257
Chapter 9 DISCRETE CONTROL USING PROGRAMMABLE LOGIC CONTROLLERS /AND PERSONAL COMPUTERS 9.1 Discrete Process Control 266 9.2 Ladder Logic Diagrams 274 9.3 Programmable Logic Controllers 278 9.4 Personal Computers Using Soft Logic 285
PART Ill: MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES
Chapter 10 MATERIAL TRANSPORT SYSTEMS 10.1 Introduction to Material Handling 290 10.2 Material Transport Equipment 295 10.3 Analysis of Material Transport Systems 312
Chapter 11 STORAGE SYSTEMS 11.1 Storage System Performance and Location Strategies 330 11.2 Conventional Storage Methods and Equipment 334
155
229
266
289
289
329
Contents
11.3 Automated Storage Systems 337 11.4 Engineering Analysis of Storage Systems 345
Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE 12.1 Overview of Automatic Identification Methods 359 12.2 Bar Code Technology 362 12.3 Radio Frequency Identification 370 12.4 Other AIDC Technologies 372
PART IV: MANUFACTURING SYSTEMS
Chapter 13 INTRODUCTION TO MANUFACTURING SYSTEMS 13.1 Components of a Manufacturing System 377 13.2 A Classification Scheme for Manufacturing Systems 382 13.3 Overview of the Classification Scheme 389
Chapter 14 SINGLE-STATION MANUFACTURING CELLS 14.1 Single-Station Manned Cells 395 14.2 Single-Station. Automated Cells 396 14.3 Applications of Single-Station Cells 401 14.4 Analysis of Single-Station Systems 406
Chapter 15 MANUAL ASSEMBLY LINES 15.1 Fundamentals of Manual Assembly Lines 419 15.2 Analysis of Single Model Assembly Lines 426 15.3 Line Balancing Algorithms 433 15.4 Mixed Model Assembly Lines 438 15.5 Workstation Considerations 450 15.6 Other Considerations in Assembly Line Design 451 15.7 Alternative Assembly Systems 454
Chapter 16 AUTOMATED PRODUCTION LINES 16.1 Fundamentals of Automated Production Lines 465 16.2 Applications of Automated Production Lines 474 16.3 Analysis of Transfer Lines 478
Chapter 17 AUTOMATED ASSEMBLY SYSTEMS
17.1 Fundamentals of Automated Assembly Systems 498 17.2 Quantitative Analysis of Assembly Systems 504
Chapter 18 CELLULAR MANUFACTURING
18.1 Part Families 525 18.2 Parts Classification and Coding 528 18.3 Production Flow Analysis 532
· ..
7
358
375
375
394
417
464
497
523
8
;1 I'
18.4 Cellular Manufacturing 534 18.5 Applications of Group Technology 539 18.6 Quantitative Analysis in Cellular Manufacturing 541
Chapter 19 FLEXIBLE MANUFACTURING SYSTEMS 19.1 What is a Flexible Manufacturing System? 556 19.2 FMS Components 561 19.3 FMS Applications and Benefits 571 19.4 FMS Planning and Implementation Issues 574 19.5 Quantitative Analysis of Flexible Manufacturing Systems 576
Contents
554
PART V: QUALITY CONTROL IN MANUFACTURING SYSTEMS 601 [1
Chapter 20 QUALITY PROGRAMS FOR MANUFACTURING 20.1 Quality in Design and Manufacturing 602 20.2 Traditional and Modern Quality Control 603 20.3 Process Variability and Process Capability 606 20.4 Statistical Process Control 610 20.5 Six Sigma 621 20.6 The Six Sigma DMAIC Procedure 624 20.7 Taguchi Metho~s in Quality Engineering 631 20.8 ISO 9000 636
Chapter 21 INSPECTION PRINCIPLES AND PRACTICES 21.1 Inspection Fundamentals 646 21.2 Sampling vs. 100% Inspection 651 21.3 Automated Inspection 655 21.4 When and Where to Inspect 657 21.5 Quantitative Analysis of Inspection 661
Chapter 22 INSPECTION TECHNOLOGIES 22.1 Inspection Metrology 675 22.2 Contact vs. Noncontact Inspection Techniques 679 22.3 Conventional Measuring and Gaging Techniques 680 22.4 Coordinate Measuring Machines 681 22.5 Surface Measurement 695 22.6 Machine Vision 698 22.7 Other Optical Inspection Methods 704 22.8 Noncontact Nonoptical Inspection Techniques 707
PART VI: MANUFACTURING SUPPORT SYSTEMS
Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM 23.1 Product Design and CAD 715 23.2 CAD System Hardware 721
601
645
674
713
713
Contents
23.3 CAM, CAD/CAM, and CIM 724 23.4 Quality Function Deployment 728
Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING 24.1 Process Planning 736 24.2 Computer-Aided Process Planning 742 24.3 Concurrent Engineering and Design for Manufacturing 744 24.4 Advanced Manufacturing Planning 748
Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS 25.1 Aggregate Production Planning and the Master Production Schedule 756 25.2 Material Requirements Planning 757 25.3 Capacity Planning 763 25.4 Shop Floor Control 765 0
25.5 Inventory Control 771 25.6 Extensions of MRP 778
Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION 26.1 Lean Production and Waste in Manufacturing 786 26.2 Just-in-Time Production Systems 790 26.3 Autonomation 797 26.4 Worker Involvement 801
9
735
753
785
Index 812
Index
A Aberrations, 98 Absolute positioning, incremental
positioning vs., 163 AC motors, 139-141
induction, 140 step motors/stepping motors,
140-141 synchronous, 140
Accelerometer, 133 Acceptable quality level (AQL), 652 Acceptance number, 651 Acceptance sampling, 651 Accessibility, 331 Accuracy:
inspection, 648-649 measuring instruments, 675-676 in robots, 257-258
defined, 259 Acquisition distance, 304 Active sensors, 132 Actual work, 788 Actuators, 90, 135-144
classification of, 135 defined, 135
812
o
electric motors, 135, 136-141 hydraulic, 135, 142-144 pneumatic, 135, 142-144 solenoids, 141-142
Adaptive control, 110-111 decision function, 111 identification function, 110-111 modification function, 111
Adaptive control machining, 111 Addressable points, 184,257 Adhesive bonding, 41, 49 Adhesive devices, 239 Advanced manufacturing planning,
748-751 facilities planning, 750 investment project management, 750 manufacturing research and
development, 750-751 technology evaluation, 749-750
Aggregate production planning, 754,756
AGVS, See Automated guided vehicle system (AGVS)
American National Standards Institute (ANSI), 636
American Society for Quality (ASQ),636-637
American system of manufacture, 42 Ammeter, 133 Amplifier, 135, 145 Analog:
defined, 106 measuring device, 131
Analog versus digital instruments, 677 Analog-to-digital converters, 144-147
resolution of, 146 Andon board, 802-803 Anodizing, 49 APT, See Automatically programmed
tool system (APT) Arc welding, 244-245 Arc-on time, 245 Armature, DC motor, 137 AS/RS, See Automated
storage/retrieval system (AS/RS)
Assembly, 46 and industrial robots, 247-248 process planning for, 739-740
Assembly by worker teams, 455
Index
Assembly line, 42, 378 Assembly operations, 46, 49 Assignable variations, 606, 632 Asynchronous conveyors, 308-309 Asynchronous transport systems, 423 Attributes sampling plan, 651 AutoCAD, 195 Automated assembly.:
defined,497 technology, 498
Automated assembly systems, 376, 456,497-522
applications, 503-504 capital expense, 498 fundamentals of,498-504 multi-station assembly machines,
505-510 partial automation, 511-515 practical guidelines from equations,
515-516 quantitative analysis of,504-516 single-station assembly machines,
510-512 subsystems, 498 system configurations, 498-500
carousel assembly system, 499-500
dial-type machine, 499 in-line assembly machine,
498-499 single-station assembly
machine, 500 workstations, parts delivery at,
500-503 quantitative analysis of, 504-505
Automated drafting, 720 Automated guided vehicle system
(AGVS), 298-304, 455 applications, 299-300 assembly line applications, 299-300 defined, 298 determining number of vehicles in,
315-316 driverless trains, 298-299 flexible manufacturing systems, 300 storage and distribution
operations, 299 unit load carriers, 299 vehicle guidance technology,
300-302 vehicle management and safety,
303-303 vehicle safety, 304
vehicles, types of,298-299 Automated inspection, 655-657 Automated integrated production, 35 Automated manufacturing systems,
25-26 Automated process planning, 528 Automated production, 34 Automated production lines, 464-496
applications of,474-478 machining operations, 475-476 system design, 476:-478
capital investment required by, 465
cycles, 466 defined, 465 fundamentals of, 465-474 line controllers, 474 requirements for application of,465 storage buffers, 472-473 system configurations, 466-468
rotary configuration, 467-468 segmented in-line configuration,
466-467 transfer lines, analysis of,478-480 workpart transfer system, 468-472
linear transfer systems, 469-470 rotary indexing mechanisms,
471-472 Automated stations, 389-390 Automated storage/retrieval system
(AS/RS), 291, 337-343 applications of, 340-342 automated item retrieval
system,340 components and operating features
of, 342-343 deep-lane AS/RS, 339-340 defined, 337 man-on-board AS/RS, 340 miniload AS/RS, 340 rack structure sizing, 345-347 throughput, 347-350 types of, 338-339 unit load AS/RS, 338-339 work-in-process (WIP) storage,
340-342 Automated systems, 22
basic elements of, 87-95 power required for, 88-90
Automated transfer line, 376 Automated turning operation
(example), 91 Automatic dimensioning, 719
813
Automatic identification and data capture (AIDC), 358-374
automatic identification methods, 359
bar codes, 370 defined, 358 first read rate (FRR), 361 machine vision, 373 magnetic stripes, 372 optical character recognition
(OCR),372-373 radio frequency identification
technology (RFID), 370-372 radio frequency methods, 360 substitution error rate (SER) , 361 technologies, 360-361
reasons for using, 360-361 Automatic identification and data
collection (AIDC) technologies, 770
Automatic identification systems, compatibility of automated storage systems with, 341
Automatic pallet changer (APC), 399,404
Automatic tool-changer (ATC), 404 Automatic workpart positioner, 404 Automatically programmed tool
system (APT), 87, 157-158 contouring motion commands,
221-225 geometry statements, 213-219
circles, 217-218 lines, 215-217 planes, 217 points, 214"":215 round rules, 218-219
motion commands, 220-225 contouring motions, 221-225 point-to-point commands,
220-221 part programming with, 213-221
examples, 211-212 Automation, 19, 42, 95-203
advanced functions, 95-100 common measuring devices used
in, 132 defined, 85 error detection and recovery,
97-100 fixed, 26 historical note, 86-87 levels of, 100-102
If I
814
maintenance and repair diagnostics, 97-98
migration strategy, 34-35 power for, 89-90 principles and strategies, 31-36 in production systems, 25-28 programmable, 26-27 reasons to.justify automation, 28 safety monitoring, 95-96
Automation systems development, 751
Automobile body checking software, 692
Autonomation,797-801 defined, 797 error prevention, 799-800 jidoka,798 poka-yoke devices, 799-800 total productive maintenance
(TPM),800-801 Auxiliary activities, 61 Auxiliary statements, 226-227 Auxiliary work, 788 Availability, 69-71,313,331-332,800
and workstation requirements, 407, 409-410
Average outgoing quality curve (AOQ curve), 653-654
Average outgoing quality limit (AOQL),653
Average workload, FMS workstations,578
Axis, 231
B Back lighting, 701 Back-emf, 137 Backtracking move, parts, 537 Balance delay, 432 Bar codes, 360, 362-370
bar code printers, 366-367 bar code readers, 362, 364-365 contact bar code readers, 364 height-modulated, 362 linear (one-dimensional), 363-368 moving beam bar code
scanners, 366 noncontact bar code readers, 364 optical, 770 stacked, 369 standard, adoption of, 363 symbol, 363-364 two-dimensional (2-D), 368-370
Universal Product Code (UPC),363
width-modulated, 362 Basic data analysis, Six Sigma,
628-630 Basic process, 737 Batch, 46
defined, 44 Batch and job shop production, 65-66 Batch model assembly lines, 425-426 Batch production, 44-45, 53-54 Belt conveyors, 306 Bending, 48 Bill of materials (BOM) file, 759 Bimetallic switch, 133 Bimetallic thermometer, 133 Binary, defined, 107 Binary sensors, 132 Binary vision system, 700 Binary-coded decimal (BCD)
system, 187 Bins, 336 Biometric technologies, 360 Black belts, 625 Blue collar workers, 20 Body-and-arm configurations,
industrial robots, 233 Boeing Commercial Airplane
Company, 55 Boole, George, 268 Boolean algebra, 268-269
laws/theorems of, 271 NOT function, 269 OR function, 269 push-button switch (example),
271-272 robotic machine loading
(example), 271 Boring machine, 41 Bottleneck model, 577-586
terminology/symbols, 577-578 FMS operational parameters,
578-579 operation frequency, 578 part mix, 577 process routing, 578 system performance measures,
579-586 transport time, 578 work handling system, 578 workstations/servers,577
Bottleneck station, 66 Bottom-driven unit, 344
Boulton, Matthew, 86 Brainstorming, 629 Brazing, 49 Bridge crane, 311 Bronze Age, 41 Brushless DC motor, 136 Buffer storage in zone, 341 Bulk storage, 334 Burbidge, J., 532 Burden iate, 75 Business functions, 23 Bypassing move, parts, 537
C CAD, See Computer-aided
design (CAD)
Index
CAD/CAM (computer-aided design and computer-aided manufacturing), 714, 726
CAD/CAM system, defined, 192 computer-automated part
programming, 193-195 geometry definition using, 192-193 Mastercam, 194 part programming using, 192-195 tool path generation using, 193
Calibration, of measuring devices, 134-135
Cam, 86 CAM, See Computer-aided
manufacturing (CAM) Cam:
cam checking software, 692 drive mechanisms, 472
Cameras, 700-701 CAN-Q;577 Cantilever racks, 336 Capacity planning, 34, 754, 763-795
capacity adjustments, 764-765 capacity requirements planning
(CRP),764 defined, 764 rough-cut capacity planning
(RCCP),764 Capek, Karel, 230 Capital goods, 46 Capital recovery factor, 77 CAPP, See Computer-aided process
planning (CAPP) Cardamatic milling machine, 156 Carousel assembly systems, 499-500 Carousel storage systems, 343-345,
350-352
Index
applications, 344-356 horizontal system, 344 storage capacity, 351 technology, 344 throughput analysis, 351-352 vertical syst~m, 344
Carrying costs, 771 Cartesian coordinate robot, body
and-arm assembly, 233-234 Cart-on-track conveyors, 307-309 Casting, 41, 48
power form, 89 Cause-and-effect diagrams, 620 Cell (system) level, of automation,
101 Cellular layout, 53-54 Cellular manufacturing, 52, 392,
523-553 arranging machines in a GT cell,
544-546 composite part concept, 535-536 defined, 524, 534 group technology (GT), 523-524 Hollier method, 545-546 machine cell design, 536-539 objectives in, 534-535 part families, 523-527 parts classification and coding
systems, 528-532 performance measures for machine
sequences in a GT cell (example),545-546
production flow analysis (PFA), 532-534
quantitative analysis in, 541-546 rank order clustering, grouping
parts/machines by, 541-543 Central computer control, 303 Central processing unit (CPU),
280,722 Centralized terminal, 770 Chain conveyors, 306, 343 Chain-type structure, 529 Check sheets, 618 Chemical vapor deposition, 49 China, 18-19 Chip card, 370 CIM, See Computer-integrated
manufacturing (CIM) CLDATA,192 Cleaning, 48 CLFILE,192 Closed loop control systems, 93-94
compared to an open loop system, 94-95
Closed-loop positioning systems, 179-190,182-184
CMMs, See Coordinate measuring machines (CMMs)
CNC, See Computer numerical control (CNC)
CNC machining centers, 403-406 machining centers, 403-404
classifications of, 404 defined, 403 numerical control, 404
CNC Software, Inc., 195 Coating, 48-49 Code,359 :J
Coils, ladder logic diagrams, 274 Combinational logic control,
113,267 Combined operations, 33 Comment cards, 730 Common use items, 760 Commutator, 136 Complaint studies, 730 Composite parts, 535-536 Computerized machinability data
systems, 724 Computer control system, 381-382
flexible manufacturing systems (FMSs),567-570
diagnostics, 570 performance monitoring and
reporting, 570 shuttle control, 569 tool control, 569-570 tool life monitoring, 570 tool location, 569-570 workpiece monitoring, 569 workstation control, 567-568
Computer integrated manufacturing (CIM),19
Computer numerical control (CNC), 158,159,164-169
application software, 168 defined, 164 features of, 164-166 machine control unit for, 166-168
central processing unit (CPU),166
I/O interface, 167 machine tool axes, controls
for, 167 memory, 166-167
personal computers (PCs) and,168
sequence controls, 168
815
spindle speed, controls for, 167 machine interface software, 168 operating system software, 168 software, 168-169
Computer process control, 113-128 computer control, capabilities of,
116-117 computer process monitoring,
120-121 control requirements, 115-116 direct digital control (DDC),
121-123 distributed control system (DCS),
124-125 enterprise-wide integration of
factory data, 127-128 exception handling, 119 forms of, 120-128 historical note, 114 interlocks, 117 interrupt system, 117-119 numerical control and robotics, 123 personal computers (PCs), 125-126 polling (data sampling), 116-117 programmable logic controllers
(PLCs),123 supervisory control, 123-124
Computer process monitoring, 120-121
Computer vision, See Machine vision
Computer-aide~ design (CAD), 27,713
automated drafting, 720 defined,716 design evaluation and review,
719-720 design workstations, 721-722 digital computer, 722-723 engineering analysis, 718-719 geometric modeling, 717-718 plotters, 723 printers, 723 and product design, 715-720 storage devices, 723 system hardware, 721-723 systems, 30
Computer-aided engineering (CAE) , 718
Computer-aided line balancing, 725
, ! ~ I
i '11
I
!'
816
Computer-aided manufacturing (CAM), 27, 724-725, 742
generative CAPP systems, 744 manufacturing control, 715 manufacturing planning, 714-715 retrieval CAPP system, 742-743
Computer-aided process planning (CAPP), 195,724-725, 742-743
Computer-aided design and computer-aided manufacturing, See CAD/CAM (computeraided design and computeraided manufacturing)
Computer-assisted NC part programming, 724
Computer-assisted part programming, 189-192
arithmetic module, 192 CLDATA,192 CLFILE,192 computer tasks, 191-192 input translation module, 191-192 part programmer's job, 189-191 postprocessing, 192
Computer-automated part programming, 193-195
Computer-integrated manufacturing (CIM),27-28, 34, 713-714, 726-728
Computerized manufacturing support systems, 27-28
Computers, 86 Concurrent engineering, 714, 744-745
components of, 745 Conditional scanning, 117 Configurations, industrial robots,
233-236 Congestion, 445-446 Consumer goods, 46 Consumer's risk, 652 Contact bar code readers, 364 Contact input interface, 150 Contact output interface, 150 Contacts, ladder logic diagrams, 274 Continuous control:
compared to discrete control, 107 defined, 107
Continuous control systems, 108-112 adaptive control, 110-111 feedforward control, 109 on-line search strategies, 111-112
other specialized techniques, 112 regulatory control, 108-109 steady-state optimization, 109-110
Continuous improvement, 61 Continuous loop ·conveyors, 309
analysis of, 319-320 Continuous motion conveyors, 308 Continuous path systems, 161 Continuous production, 44 Continuous transport system,
422-423 Continuous variable, 106-107 Contouring, 161 Contract manufacturing, 18 Control, See also Quality
contrQ,1 (QC) adaptive, 110-111 central computer, 303 combinational logic, 113,267 computer control system, 381-382 computer numerical control
(CNC),158, 159, 164-169 computer process, 123-128 cursor, 722 direct, 126 direct digital control (DDC),
121-123 direct numerical control (DNC),
158,169-172 discrete, 107, 113 feedforward,109 industrial, 104 inventory, 24, 725, 755, 771-778 logic, 266-273 machine control unit (MCU), 159,
166-168 manufacturing, 24 motion, 160-164 numerical control (NC), 123,
155-228 plant operations, 34 priority, 767 process, 34, 725 regulatory, 108-109 sequential, 113 set point, 114 shop floor control (SFC), 24,121,
725,754,765-771 statistical process control (SPC),
24,610-621 supervisory, 123-124 zone, 302-303
Control charts, 610-616
for attributes, 613-615 defined, 610 as feedback loop, 616 interpreting, 615-616 types of, 611 for variables, 611-613
Index
Control program, CNC operating system software, 168
Control resolution, 184-186, 2"57-258
Control system, 85, 93-95 Controller unit, 89-90 Conventional measuring and gauging
techniques, 680-681 Conventional storage methods, 291 Conversational programming,
195-196 Conversion time, 145 Conveyor analysis, 317-321
continuous loop conveyors, 319-320
re circulating conveyor, 320-321 single direction conveyor,
318-319 Conveyors, 305-310
asynchronous, 308-309 belt, 306 cart-on-track,307-308 chain, 306 continuous loop, 309 continuous motion, 308 defined, 305 in-floor towline, 307 nonpowered,305 operations and features, 308-309 overhead trolley, 307 power-and-free overhead
trolley, 307 powered, 305 recirculating,309 roller, 305 screw, 307 single direction, 309 skate-wheel, 305 vertical lift, 107-108 vibration-based, 107-108
Coordinate measuring machines (CMMs), 679, 681-695
applications and benefits, 692-694 components, 682 construction, 683-686 controls, 687 DCC programming, 687-688
Index
defined, 682 mechanical structure, 685-686
cantilever, 685-686 column, 686 fixed bridge, 686 gantry, 686 horizontal arm, 686 moving bridge, 686
off-line programming, 687-688 operation and programming,
687-688 portable, 695 probes, 683-685
on machine tools, 694--695 software, 688
application-specific software, 691-692
core software, 688-691 post-inspection software, 691 reverse engineering software, 691
Coordinate metrology, 681-682 Coordination and control, 50 Corporate overhead, 74 Corporate overhead rate, 75 Cost estimating, 725 Counters, 273-274 Cranes,310-311 Critical ratio, 767 Cursor control, 722 Customer returns, 730 Cutoff length, 696-697 Cutter offset, 209 Cutting conditions, 172 Cycle time, 65, 804--809 Cylindrical configuration, robot
D
body-and-arm assembly, 233-234
DAC, See Digital-to-analog converter (DAC)
Data acquisition and information processing, 90
Data decoder, 359 Data encoder, 359 Data Matrix, 373 Data Matrix ECC200, 370 DC motors, 136-139 DCC programming, 687-688 DCSs, See Direct numerical
control (DNC) DDC, See Direct digital
control (DDC)
Dead reckoning, 301-302 Dedicated FMS, 561 Defect concentration diagrams,
618-619 Defect rate:
defined, 409 in a sequence of operations,
compounding effect of, 662 in serial production, effect of,
661-663 and workstation requirements, 407,
409-410 Defective parts production, 801 Defective units per million (DUPM), J
627-628 Defects per million COPM), 627 Defects per million opportunities
(DPMO),627 Deformation processes, 48 Degree-of-freedom (d.o.f.) of
motion, 231 Delay-off timer, 273 Delay-on timer, 273 Depalletizers,291 Depalletizing, and industrial
robots, 243 Dependent demand, 757 Design for life cycle, 748 Design for manufacturing and
assembly (DFMlA), 746-748 design principles and guidelines,
746-747 organizational changes in, 746
Design for product cost (DFC), 748 Design for quality (DFQ), 748 Design retrieval, 528 Design workstations, 721-722 Device level, of automation, 100-101 Devol, George c., 86, 230, 231 DFMlA, See Design for
manufacturing and assembly (DFM/A)
Dial indexing machine, 467 Dial-type machine, 499 Die casting, and industrial robots, 243 Digital transducers, 132 Digital-to-analog converter (DAC),
147-149 conversion steps, 147 data holding, 147 decoding, 147 first-order hold, 148-149 zero-order hold, 147-149
Direct control, 126 Direct digital control (DDC),
121-123 system, 114 system components, 122
Direct labor, 382 Direct labor cost, 74, 77
817
Direct numerical control (DNC), 158, 169-172
behind the tape reader (BTR), 169 defined, 169 local area networks (LANs),
171-172 switching network, configuring, 171 system configuration, 169-170
Direct thermal printing, and bar codes, 367
Direct transport, 381 Discrete control:
compared to continuous control, 107
defined, 107 use of, 113
Discrete control systems, 112-113 Discrete data:
contact input interface, 150 contact output interface, 150 input/output devices for, 150-151 pulse counters, 151 pulse generator, 151
Discrete manufacturing industries: levels of automation in, 105-106 process industries vs., 105-107 variables and parameters in,
105-106 Discrete process control systems,
266--274 logic control, 267-273 sequencing,273-274
Discrete sensor devices, 132 Discrete variable, 107 Discrete-event simulation, 719-720 Distributed control systems (DCSs),
123,124--141 Distributed inspection, 660-661,
664-666 Distributed numerical control (DNC)
systems, 570 defined, 170
Division of labor, 418-419 DNC, See Direct numerical
control (DNC) Down counter, 274
"
'I ill
I I ,
I,:: ",
818
Downstream allowance, 424 Drawer storage, 336 Drawing, 48 Drift, 678 Drilling, 41, 48
and industrial robots, 247 Driverless trains, 298-299 Drive-through racks, 336 Dual comniand cycles, 331 Dual grippers, 239-240 Dyeing, 40 Dynamometer, 133
E Earliest due date, 767 Economic order quantity formula,
771-774 Edge detection, 703 Editor, CNC operating system
software, 168 Electric discharge machining (EDM),
power form, 89 Electric drive systems, and robot
joints, 236 Electrical actuators, 135 Electrical actuators (electric motors),
136-141 AC motors, 139-141 DC motors, 136-139
Electrical actuators (electrical field inspection techniques), 707
Electrical power, and automated/nonautomated processes, 88
Electrification, 42,70 Electromagnetic technologies, 360 Electromechanical relay, 142 Electronic gages, 681 Electronic Product Code (EPC)
standard,370 Electroplating, 49 Electrostatic plotters, 723 Emergency maintenance, 800 Employee time sheets, 769 End effector, 233, 239-240
gripp.ers,239-240 tools, 240
Engelberger, Joseph, 230-231 Engineering project work, 31 Engineering workstation, 723 Enterprise level, of automation, 101 Enterprise resource planning (ERP),
127,714,728,755,779-781
Enterprise-wide integration of factory data, 127-128
Equipment maintenance, 31 Equipment usage cost, 77-79 ERP, See Enterprise resource
planning (ERP) Error checking, 719 Error detection and recovery, 97-100
in an automated machining cell (example),98-99
error recovery, defined, 99 Error prevention, 62 Error recovery:
in an automated machining cell (example), 99-100
test,557 ,., Escapement device, 501-502 European Article Numbering system
(EAN),364 Event-driven change, 112, 115 Exception handling, 119 Exception reports, 768 Exciter, 140 Executive program, CNC operating
system software, 168 Expansion fits, 49 Expert system, defined, 744 Extended bottleneck model, 586-590
equations/guidelines for, 588 External interrupts, 118 External logistics, 290 External noise factors, 632 External sensors, 240-241 Extrusion, 48
F Facilities, 19-22
automated systems, 22 manual work systems, 19-20 worker-machine systems, 21-22
Facilities planning, 750 Factory data collection (FDC)
systems, 768-771 automated and semi-automated
data collection systems, 770-771
manual (clerical) data input techniques, 769-770
purpose of,768 Factory operations, manuallabor in,
29-30 Factory overhead, 74 Factory overhead rate, 75
Factory system, 41 Failure diagnostics, 97 Faro gage, 695 Feature extraction, 703 Feature weighting, 703 Feed track, 500-501
Index
Feedback control system, 93-94 Feedback process control, 656-657 Feedforward control, 109 Field intelligence, 730 Final inspection, 660-661, 663-664
distributed inspection vs. (example),664-665
Fingernail test, 698 Finishing operations, 738 Finite element analysis (FEA) , 719 Finite element modeling (FEM), 719 Firing, 40 First-come-first served priority, 767 First-order hold, 148-149 Fitter, 245 Five5S system, 803-804 Fixed automation, 26 Fixed beam bar code readers, 365 Fixed costs, 73 Fixed routing, 379 Fixed-position layout, 52-53 Fixed-rate launching, 445-450
for three or more models, 447-450 for two models, 445-447
Flanders, R., 524 Flexibility, increased, 33 Flexible assembly systems, 388 Flexible automated manufacturing
system, use of term, 556 Flexible automated systems, 27 Flexible machining system, use of
term,556 Flexible manufacturing, 19 Flexible manufacturing cell (FMC),
392,559 Flexible manufacturing systems
(FMSs), 86, 300, 376, 388, 392,537,554-600
Allen-Bradley Company assembly FMS (example), 572-573
applications, 571-573 benefits, 573-574 components of, 561-571 computer control system, 567-570 dedicated,561 defined,556-561 diagnostics, 570
Index 819 t
flexibility, 557-558 Forging, 48 H level of, 560--561 and industrial robots, 243-244 Hand tools, 20-21
flexible fabricating system power form, 89 Hand trucks, 295-296 (example), 572 Forklift trucks, 297 Hard disk, 87
historical note, 555 Form code, 530 Hard product variety, 52 human resources, 570-571 Formal machine cells, 540 Hard real-time control system, 286 material handling and storage Formal surveys, 730
system, 5640-566 Forming, 40, 48 Harder, Del, 86
number of machines, 558-560 Forrester,Jay,156 Harris-Intertype (Langston Division),
operational issues, 576 FORTRAN, 87 524,527
performance monitoring and Forward sensing, 302 Heat treating:
reporting, 570 Fraction defect rate, 801 and industrial robots, 244
performance reports, 570 Frame buffer, 700 power form, 89
planning and design issues, 558-559 Free transfer line, 466 Heat treatment, 41
quantitative analysis of, 576-592 Frequency select method, 301 Height-modulated bar code, 362
bottleneck model, 577-586 From/To charts, 312, 545 Hierarchical structure, 529
extended bottleneck model, From/To ratio, 544-545 High production, 51, 54-55
586-590 Front lighting, 701 High reliability, 677
FMS sizing problem, 590-592 Fully automated machine, 22, 377 High-energy laser beams, 705
random-order, 561 Function block diagrams High-level and low-level scanning,
shuttle control, 569 (FBDs),283 116-117
stations, 559 Fusion welding, 41 Histograms, 617
tool control, 569-570 Hoists, 310-311
tool life monitoring, 570 G Holding cost rate, 772
tool location, 569-570 Gages, 680-681 Holding costs, 771
types of, 558-561 Gaging, 680-681 Honeywell, 115
VoughtAerospace FMS (example), Gantry crane, 311 TDC 2000, 141
571-572 Gear, 86 Hopper, 500
workpiece monitoring, 569 Gear checking software, 692 Horizontal machining center
workstation control, 567-568 Generative CAPP systems, 744 (HMC),404
workstations,562-564 Geneva mechanism, 471-472 Human mistakes, 98
assembly, 563-564 Geometric modeling, 717-718 Human resources, manufacturing
load/unload stations, 562-563 Germany, 18 systems, 382 I,
machining stations, 563 Globalization, 18 Humans and machines, relative I ,~ I
sheet-metal fabrication, 563 Grafcet method, 283 strengths and attributes of, 22 Flexible transfer line, 561 Gravity feed tracks, 501 Hydraulic actuators, 135, 142-144 Flip-flops, 151 Grayscale vision systems, 700 Hydraulic drive systems, and robot Float transducer, 133 Grinding, 40, 48 joints, 236 Flow line production, 54 and industrial robots, 247
I Flow rate, 277 Group technology (GT), 38, 523-524, Flow-through racks, 336 See also Machine cells Identification and tracking systems, 291 Fluid flow sensor, 133 applications, 539-541 Idle time, 445-446 Fluid flow switch, 133 manufacturing, 540 illumination, 701-702 Fluid-powered rotary motors, 144 product design, 540-541 In statistical control, use of term, 606 FMC, See Flexible manufacturing benefits of, 525 Incremental positioning, absolute
cell (FMC) biggest obstacle in changing over positioning vs., 162-163 FMS, See Flexible manufacturing to, 527 Independent demand, 757
systems (FMSs) defined, 523 Index of performance, 108 Focus groups, 730 historical note, 524 Indexing machine, 467 Focused factories, 59 part families, 523-527 Industrial control, 104 "'I
11
Ford, Henry, 42, 420 defined, 525 Industrial control systems, 104-129 I'll
Ford Motor Company, 85, 86, 777 identifying, 524 continuous vs. discrete control, Ill!
I! Forge welding, 41 GT, See Group technology (GT) 107-113 I:
II1
'I
820
Industrial Revolution, 41 Industrial robots, 86, 114,229-265, See
also Roboraccuracy and repeatability; Root programming
applications, 241-248 assembly and inspection, 247-248 body-and-anp configurations, 233 commercial/technological
qualities, 230 configurations, 233-236 defined, 229 end effector, 233, 239-240 human-like characteristics, 229-230 joint drive systems, 236-237 joint notation system, 235 joints, 230, 231-233
actuation of, 236 links, 231-233 manipulator, 231 material handling applications,
242-244 processing operations, 244-247
arc welding, 244-245 spot welding, 244 spray coating, 245-246
robot anatomy/attributes, 231-237 robot control systems, 237-238
intelligent control, 238 limited sequence control, 237 point-to-point control, playback
with, 237-238 sensors, 240-241 short history of, 230-231 work volume, 235 wrist configurations, 234-235
Industrial towing tractors, 298 In-floor towline conveyors, 307 Ingersoll-Rand Company, 555 Injection molding, power form, 89 Ink-jet printers, 723
and bar codes, 367 In-line assembly machine, 498-499 In-line layout, 565 Input interlock, 117 Input scan, 281 Inputs, ladder logic diagrams, 274-275 In-sequence move, parts, 537 Insertion operations, and industrial
robots, 242 Inspection, 645-673, See also
Coordinate measuring machines (CMMs)
100% manual, 653-655 accuracy, 648-650 for attributes, 646-647 automated, 655-657 contact inspection techniques,
679-680 conventional measuring and
gauging techniques, 680-681 coordinate measuring machines
(CMMs),681-695 defect rate in serial production,
effect of, 661-663 distributed, 660-661, 664-666 distributed vs. final, 660-661 final, 660-661, 663-664 fundamentals,c,646-651 and industrial robots, 247-248 machine vision, 698-704 and machine vision, 703-704 manual, 647-648 metrology, 675-678 no inspection vs., 666-668 noncontact inspection
techniques, 680 noncontact optical inspection
methods, 707-708 off-line, 657-658 on-line/in-process inspection,
658-659 partially distributed, 665-666 practical guidelines from
equations, 669 procedure, 647-648 product, process monitoring vs.,
659-660 quantitative analysis of, 661-669 sampling, 651-653
cost of (example), 668 sampling plans, types of, 651-652 stylus instruments, 696-697 surface measurement, 695-698 technologies, 674-675 testing vs., 650-651 Type I and Type II errors, 648 types of, 646-647 for variables, 646-647
Inspection and testing, 50 Instruction list (IL), 283-285 Integrated circuit card, 360 Integrated circuits, 87 Integration of operations, 33 Intelligent robot, 238 Interchangeable fingers, 240
Index
Interchangeable parts, 86, 418, 419 Interference checking, 719 Interlock and sensor commands,
255-256 Interlocks, 117 Intermittent transport, 423 Internal interrupts, 118 Internal logistics, 291 Internal noise factors, 632 Internal sensors, 240 International Organization for
Standardization (ISO), 636 International outsourcing, 18 International Standard for
Programmable Controllers (IEC 1131-3),282
International Standard Industrial Classification (ISIC) of industries, 44
International System of Units (SI), 678 Internet, and customer requirements,
methods of capturing, 730 Interrupt feature, 114 Interrupt system, 117-119
external, 118 internal, 118 multilevel,118-119 single-level, 118-119 single-level vs. multilevel interrupt
systems (example), 118-119 Interviews, and customer
requirements, methods of capturing, 730
Inventory control, 24, 725, 755, 771-778
order pciint inventory systems, 771-775
work-in-process inventory costs, 775-778
Inventory planning, 725 Inventory status, 759 Inversion of a variable, 269 Inverters, 140 Investment project management, 750 Iron Age, 41 ISO 9000, 636-637 Item location file, 343 Item master data, 759
J Jacquard loom, 86 Japan, 18 JAVA programming language, 87
- 1
p -- I'
Index 821 ,I
:1
Jefferson, Thomas, 42 L Line pacing, 418, 423-425 Jib crane, 311 Ladder layout, 566 levels of pacing, 424 lidoka,798 Ladder logic diagrams, 274-278, no pacing, 424-425 "
, Job sequencing,767 283,285 pacing with margin, 424 Job shop, 51 coils, 274 rigid pacing, 424 Job traveler, 769 contacts, 274 Linear array measuring scheme, 706 Joint drive systems, 236-237 control relay operation (example), Linear joint, 232 Joint notation system, 235 276-277 Linear (one-dimensional) bar codes, Jointed-arm robot, body-and-arm inputs, 274-275 362-368
assembly, 233-234 nodes, 274 Linear solenoids, 141-142 Joints: push-button switch (example), 276 Linear transfer systems, 469-470
industrial robots, 230, 231-233 simple lamp circuits (example), 276 Linear variable differential types of, 232-233 symbols used in, 275 transformer, 133
Juran, 1., 618fn Largest candidate rule, 433-435 Linear width-modulated bar code Just-in-time (HT) production, 61, 341, technology, 362 I,
Laser beam cutting, power form, 89 1
785-807 Laser cutting, and inClustrial robots, 247
Links, industrial robots, 231-233 autonomation,797-801 Little's formula, 587 elements of, 787
Laser etching, and bar codes, 367 Load/unload stations, 562-563
kanban system, 789, 791 Laser printing, and bar codes, 367 Local outsourcing, 118 manufacturing activities, 788-790 Laser systems, 705-706 Locked-step mode, 141 rnuda, 788-790, 798 Launching discipline, 444 Logic control, 267-273 on-time deliveries, zero defects, and Lead time, 760-761 boolean algebra and truth tables,
reliable equipment, 797 Lean production, 19,60-62,739,802 268-269 production leveling, 796-797 defined, 61, 786 elements of, 268 as pull system of production mass production compared to, 786 using robotics to illustrate, 267-268
control, 791 system ingredients, 786-787 Logical algebra, 268 setup time reduction for smaller Lever, 86 Logical product, 269
batch sizes, 793-796 Lights out operation, 399 Logical sum, 269 systems, 725, 790-797 Limit switch (mechanical), 133-134 Logistics, 290 worker involvement, 801-807 Line balancing, 740 Loop layout, 566
continuous improvement, 802 mixed model assembly lines, Lot sampling, 651 visual management and 5s, 440-443 Lot tolerance percent defective
" 802-803 Line balancing algorithms, 433-438 (LTPD),652 i I'
workforce and supplier base, 797 Kilbridge and Wester method, Low production, 51, 52-53 ,I
435-437 Low-energy laser beams, 705 K largest candidate rule, 433-435
Kaizen, 800, 802 ranked positional weights (RPW) M circles, 802 method, 437-438 Machine annual cost, 77 events, 802 Line balancing efficiency, 433 Machine cell design, 528
Kanban systems, 789, 791 measures of, 432-433 Machine cells, 376, 378, 392, 410-411 electronic, 793 Line balancing problem, 429-433 design, 536-539 kanban cards, 793 automated production lines, 478-479 formal, 540 operation of, 791-792 example, 431-432 group, with manual handling, and visual management, 802 line balance efficiency, measures of, 536-537
Kenward, Cyril w., 230 432-433 group, with semi-integrated Key characteristics (KCs), 648 minimum rational work elements, handling, 536 Key machines, 539 429-430 key machines, 539 Kilbridge and Wester method, precedence constraints, 430-431 layouts, 536-539
435-437,453 worker requirements, 432-433 and part movement, 537 Kinematic analysis, 719 Line controllers, 474 U-shape layout, 538 Kitting of parts for assembly, 341 Line efficiency, 433 single, 536 i, Knowledge base, 744 manual assembly lines, 451 types of, 536
! Korling, A, 524 single model assembly lines, 426 virtual, 540
822
Machine clusters, 376, 395, 410-413 Machine control unit (MCU), 159,
166-168 central processing unit (CPU), 166 I/O interface, 167 machine tool axes, controls for, 167 memory, 166-167 personal c.omputers (PCs) and, 168 sequence controls, 168 spindle speed, controls for, 167
Machine level, of automation, 101 Machine loading, 767 Machine reader or scanner, 359 Machine tools, 41, 86 Machine vision, 241, 373, 698-704
applications, 703-704 binary vision system, 700 cameras, 700-701 conventional optical instruments, 705 defined, 698 grayscale system, 700 illumination, 701-702 image acquisition and digitization,
698-701 and inspection, 703-704 interpretation, 703 laser systems, 705-706 lighting, categories of, 701 linear array measuring scheme, 706 object recognition, 703 optical comparator, 705 optical triangulation techniques,
706-723 part identification applications, 704 pattern recognition, 703 system, basic functions of, 699
Machine-mounted inspection probes, 694-695
Machining, 48, 474 power form, 89
Machining centers, 403-404 classifications of, 404 defined, 403 numerical control, 404
Machining processes, 41 and industrial robots, 247
Machining stations, 563 Magnetic stripes, 372 Magnetic technologies, 360 Magnetized devices, 239 Maintenance and repair diagnostics,
97-98 Major words, 213
Make or buy decision, 740-742 Make-to-stock situation, 771-772 Manned workstations, 389 Manning levels, 385-386, 420-421 Manometer, 133 Manual assembly lines, 376, 417-463
adjacent stations, sharing work elements between, 452
alternative assembly systems, 454-456
assembly workstations, 420-421 defined, 419 design of, 451-452 fundamentals of, 419-426 levels of pacing, 424 line efficieney, 451 line pacing, 423-425 mechanized stations, changing
workhead speeds at, 452 methods analysis, 451-452 origins of, 419-420 parallel stations, 453 preassembly of components, 452 product variety, coping with,
425-426 storage buffers, 452-453 subdividing work elements, 452 utility workers, 452 work transport systems, 421-423 workstations,450-451 zoning/constraints, 453
Manual data input (MDI), 195-196 Manual inspection, 647-648 Manual labor:
in factory operations, 29-30 in production systems, 29-31
Manual part programming, 187-189, 205-212
Manual production, 34 Manual work systems, 19-20 Manually operated machines, 377 Manually operated station, 395-396 Manufactured products, 45-46 Manufacturing:
defined, 39-40 historical note, 17-18,40-41 origin of word, 17
Manufacturing activities, 788 Manufacturing capability, 59 Manufacturing control, 24 Manufacturing costs, 64, 73-78
direct labor cost, 74 estimating, 76
fixed costs, 73 material cost, 74 overhead costs, 74 variable costs, 73
Index
Manufacturing execution systems (MESs), 754, 765
Manufacturing industries, 43-45 Manufacturing lead time (MLT),
"70-72,760-761,775 Manufacturing metrics, 64-84 Manufacturing operations, 39-63
assembly operations, 46, 49 processing operations, 46-49
Manufacturing planning, 24, 724-725 Manufacturing R&D, 751 Manufacturing resource planning
(MRP U), 755, 778-779 Manufacturing support systems,
19-20,697 business functions, 23 labor in, 30-31 manufacturing control, 24 manufacturing planning, 24 product design, 23-24
Manufacturing systems, 19,20, 375-393
classification scheme for, 382-392 automation and manning levels,
385-386 factors in, 382 number of workstations, 383-384 part or product variety, 386-389 system layout, 384-385 types of operations
.performed, 383 components of, 377-382 computer control system, 381-382 defined, 102 human resources, 382 material handling system, 378-379 mixed model, flexibility in, 387-389 multi-station manufacturing
systems with fixed routing, 391-392
multi-station systems with variable routing, 392
production machines, 377-378 reconfigurable,389 single-station cells, 389-391
MARKI,86 Mass production, 42, 54, 66-67 Mass properties analysis, 718 Master black belts, 625
Index 823
Master production planning, 754 Material removal processes, 48 Mechanical grippers, 239 Master production schedule (MPS), Material requirements planning Mechanized work transport, 422-423
24,754,756-757 (M~P),24,30,754,757-763, asynchronous transport systems, 423 Mastercam, 195 785,775 continuous transport system, Material characteristics, 292-293 capacity planning, 763-795 422-423 ",
11,
Material cost, 74 defined,757 intermittent transport, 423 Material handling: extensions of,778-781 synchronous transport systems, 423
cost of, 290 enterprise resource planning Medium production, 51, 53-54 defined, 289 (E~P), 779-781 Memory chips, 87 design, 292-295 manufacturing resource planning Merchant, Eugene, 49
flow rate, 293 (M~P II), 778-779 Metal machining operations, and material characteristics, 292-293 how it works, 759-763 industrial robots, 243 plant layout, 292-293 inputs to the M~P system, Metallurgy, 40-41 routing, 292 758-759 Metalworking, 40-41 scheduling, 292 outputs and benefits, 763 Metrology, defined, 675 unit load principle, 294-295 Material transport equipment, Microcomputers, 114
equipment, 291-292 291-310 Microsensors, 132 identification and tracking automated guided vehicle system Milling, 41, 48
systems, 292 (AGVS),298-304 Milling machine modules, 563 importance of,289-290 conveyors, 305-310 Mill-turn center, 404-405 logistics, 290 cranes/hoists, 310-311 operation of, 406 material transport equipment, 291 industrial trucks, 295-298 Minicomputers, 114 storage systems, 291 layout types, 294 Minor words, 213 unit loads, 294-295 monorailslrail-guided vehicles, Mitrofanov, S., 524 unitizing equipment, 291 304-305 Mixed model assembly lines, 425-426,
Material handling and storage, 33, 49 Material transport systems, 289-328 438-440 Material handling and storage analysis of,312-321 defined, 438
system, 564-567 conveyor analysis, 317-321 fixed-rate launching, 445-450 equipment, 565 vehicle-based systems, 312-317 for three or more models, FMS layout configurations, Matrix symbology, two-dimensional 447-450
565-567 (2-D) bar codes, 369 for two models, 435-447 in-line layout, 565 McDonough, James, 156 line balancing, 440-443 ladder layout, 566 MCD, See Machine control unit model launching, 443-450 loop layout, 566 (MCD) number of workers required, open field layout, 566 Mean time between failures (MTBF), deteI1llining, 439-440 robot-centered layout, 567 69-70 variable-rate launching, 444-445
functions of, 564 Mean time to repair (MTT~), 69-70 workload,439 Material handling applications, Measurement, defined, 675 Mixed model manufacturing systems,
robots, 242-244 Measurement standards and systems, flexibility in, 387-389 machine loading and/or unloading, 678-679 Mixed-mode structure, 529
243-244 Measuring devices, 680-681 Mixed-model production line, 54 material transfer, 242-243 Measuring instruments: MODI CON, 279
Material Handling Industry of accuracy, 675-676 Modular fixture, 540 America (MHIA), 289 analog versus digital Modular pallet fixtures, 380
Material Handling Institute, Inc., 359 instruments, 677 Molding,48 Material handling system, 378-381 calibration, 677-678 Monocode, 529
loading, positioning, and characteristics of, 675 Monorail, 304 unloading, 379 high reliability, 677 Monorailslrail-guided vehicles,
pallet fixtures, 380 precision, 675-676 304-305 work carriers, 380-381 resolution, 676 Morley, llichard, 279 work transport between stations, sensitivity, 676 Motion control systems, 160-164
379-380 speed of response, 676 absolute vs. incremental Material handling technologies, 19 wide operating range, 677 positioning, 162-163
824
interpolation methods, 162-163 point-to-point vs. continuous path
control,160-161 Motion programming, 253-254 Motion study, 42 Moving assembly line, 86 Moving beam bar code scanners, 366 Moving ram de.sign, 686 Moving table design, 686 MRP, See Material requirements
planning (MRP) Aiuda, 788-790, 798 Multilevel interrupt system, 118-119 Multiple fingered grippers, 240 Multiplexers, 144-145 Multi-station manufacturing systems
with fixed routing, 391-392 assembly machine as a game of
chance, 506-507 performance measures, 507-510
Multitasking, 115 Multitasking machine, 405
N Nailing, 41 National Retail Merchants Association
(NRMA),372-373 NC, See Numerical control (NC) NC positioning systems:
addressable points, 184 closed-loop systems, 179-180,
182-184 control resolution, 184-186 defined, 179 engineering analysis of, 179-186 open-loop systems, 179, 180-182 precision in, 184-186
NC turning center, 404 Near net shape processes, 738 Negation of a variable, 269 Negative zoning constraint, 453 Net shape processes, 738 Netting, 760 Network diagrams, 312 New part test, 558 No pacing (pacing level), 424-425 Noise factors, 631-632 Noncontact bar code readers,364 Noncontact optical inspection
methods, 707-708 electrical field techniques, 707 radiation techniques, 707-708 ultrasonic inspection methods, 708
Nondestructive evaluation methods, 707
Nondestructive evaluation (NDE), 651 Nondestructive testing (NDT), 651 Nonoptical inspection technologies, 679 Nonpowered conveyors, 305 Nontraditional processes, 48 Normally closed contact, 275 Normally open contact, 275 North American Free Trade
Agreement (NAFTA), 29 Numerical control machine, 86 Numerical control (NC), 123,
155-228, See also Computer numerical control (CNC); Direct gumerical control (DNC); Part programming
advantages of, 177-178 applications, 172-179 basic components of an NC system,
158-159 component insertion machines, 176 computer numerical control
(CNC), 158, 159, 164-169 coordinate measuring machines, 177 coordinate systems, 159-160 defined, 156 direct numerical control (DNC),
158,169-172 disadvantages of, 178-179 drafting machines, 176 electrical wire wrap machines, 176 filament winding machines for
polymer composites, 177 historical note, 156-158 machine tool applications, 172-176 machine tools, 114 and metalworking processes, 175-176 motion control systems, 160-164 part program, 158, 168 part programmer, 158 part programming, 187-196 processing equipment, 159 straightcut NC, 161 tape laying machines for polymer
composites, 177 technology fundamentals, 158-164
o Object recognition, 703 Obstacle detection sensor, 304 Occupational Safety and Health Act
(OSHA),28
Off-line inspection, 657-658 Ohmmeter, 133
Index
Ohno, Taiichi, 786-788, 797 On-board vehicle sensing, 302 100% manual inspection, 653-655 On-line inspection, 33 On-line search strategies, 111-112 On-line/in-process inspection,
658-659 On-line/post-process inspection, 659 On-machine inspection, 694 Open architecture philosophy, trend
toward,126 Open field layout, 566 Open loop control system, 94
compared to a closed loop system, 94-95
Open-loop positioning systems, 179, 180-182
Operating capability, 801 Operating point, 138 Operation sheet, See Route sheet Operation tear strips, 769 Operational efficiency, need for, 18 Operations research, 751 Operations to enhance
properties, 738 Operator-initiated events, 116 Opitz, H., 530-531 Opitz parts classification and coding
system, 530-532 example, 531-532
Optical bar codes, 770 Optical character recognition (OCR),
372-373 Optical encoders, 133, 182 Optical inspection technologies, 679 Optical sensors, 241 Optical technologies, 360 Optical triangulation techniques,
706-707 Optimum batch sizes, 774 Order point inventory systems,
771-775 economic order quantity formula,
771-774 reorder point systems, 774-775
Order progress, 767-768 Order release, 765-766 Order scheduling, 766-767 Ordering lead time, 760 Orientor, 500 Orthogonal joint, 232
Index
Out of statistical control, use of term, 606
Output interlock, 117 Output scan, 281 Outsourcing, 18 Overall equipment effectiveness
(OEE),801 Overhead costs, 74--75
allocation of, 75 Overhead rate:
defined, 75 determining, 75-76
Overhead trolley conveyors, 307
p Pacing, 418 Pacing with margin, 424 Painting, 49 Pallet fixtures, 380, 466 Pallet rack, 334 Palletized transfer line, 466 Palletizers,291 Palletizing, and industrial robots,
242-243 Parallel stations, 453-454 Parametric programming, 540 Parents, use of term, 759 Pareto charts, 617 Pareto, Vilfredo, 618 Pareto's Law, 617-618 Parsons, John, 86, 156-157 Part families, 523-527
defined, 525 identifying, 524
Part production capacity chart, 804 Part programming, 187-196
with APT, 213-221 computer-assisted, 189-192 manual, 187-189 manual data input (MDI), 195-196 using CAD/CAM, 192-195
Part variety test, 557 Partial automation:
example, 514--515 storage buffers ( example), 515
Partially distributed inspection, 665-666
Particulate processing, 48 Part-machine incidence matrix, 533 Parts classification and coding
systems, 528-532 chain-type structure, 529 features of, 528-529
hierarchical structure, 529 mixed-mode structure, 529 Opitz system, 530-521
Parts delivery hardware, 500-503 Parts feeder, 500 Parts selector, 503 Parts sortation, 657 Part-shaping operations, 48 Passive sensors, 132 Path switch select method, 301 Pattern recognition, 703 PC-based CAD system, 723 PDF-417,373 Pease, William, 156 Pen plotters, 723 Pentium microproce~sors, 87 Personal computers (PCs), 86,
115,770 control software, 474 and MCU, 168 and process control, 125-126 using soft logic, 285-286
PFA, See Production flow analysis (PFA)
Photoelectric sensor array, 133 Photoelectric switch, 133 Photometer, 133 Physical product limitations,
plants/companies, 60 Physical vapor deposition, 49 "Pick and load" operations, 344 Pick-and-place operation, and
industrial robots, 242 Pickup-and-deposit (P&D)
stations, 338 Piece rate system, 42 Piezoelectric transducer, 133 Pitch, robot wrist assembly, 234--235 Pixels,698 Placement device, 502 Planning:
advanced manufacturing planning, 748-751
aggregate production planning, 754,756
automated process planning, 528 capacity planning, 24, 754, 763-765 computer-aided process planning
(CAPP), 724--725, 742-744 enterprise resource planning
(ERP), 127,714,728,755, 779-781
facilities planning, 750
inventory planning, 725 manufacturing planning, 24,
724--725
825
manufacturing resource planning (MRP II), 755, 778-779
master production planning, 754 material requirements planning
(MRP),24, 30, 754, 757-763, 785,775
process planning, 24, 728, 736-742 production planning and control
(PPC), 725, 743-784 defined, 753
rough-cut capacity planning (RCCP),764
Plant capacity: effect of utilization and availability
on, 70 quantitative >measures of, 67
Plant layout, 20, 53, 293-294 Plant layout design scores, 720 Plant level, of automation, 101 Plant management, 31 Plant operations control, 34 Plastic extrusion, 401 Plastic injection molding, 400 Plastic molding, and industrial
robots, 243 Playback control, robot control
systems, continuous path control, playback with, 238
PLCs, See Programmable logic controllers (PLCs)
Pneumatic actuators, 135, 142-144 Pneumatic drive systems, and robot
joints; 236 Point-to-point systems, defined, 161 Polar configuration, robot body-and-
arm assembly, 233-234 Polishing, 40 Polling (data sampling), 116-117 Polycode, 529 Portable CMMs, 695 Portable racks, 336 Portable scanners, 366 Position constraint, 453 Position sensors, robot joints, 236 Positioning systems, 94--95
defined, 161 Positive zoning constraint, 453 Postprocessor statements, 225-227 Potentiometer, 133 Power, 85
, 1
826
Power loom, 41 Power supply, 280 Power-and-free overhead trolley
conveyors, 307 Powered conveyors, 305 Powered trucks, 297 Precedence diagram, 430-431
Predictive maintenance, 800 Preparatory words, 188 Prepunched cards, 769 Press fitting, 49 Presses, and numerical control, 176
Pressing, 48 Pressworking, and industrial
robots,244 Preventive maintenance, 800
Primary handling system, 565
Primary industries, 43 Priority control, 767 Probes, 699-701
on machine tools, 694-695 Process:
defined,88 power for, 88-89
Process analysis, Six Sigma, 629 Process capability:
defined, 508 and tolerances, 608-609
Process capability index, 609
Process control, 34, 725 Process fine-tuning, 751 Process industries:
discrete manufacturing industries vs., 105-107
levels of automation in, 105-106
variables and parameters in, 105-106
Process layout, 52-53 Process mapping, 626 Process monitoring, 659-660, 725
Process parameters, 90 Process planning, 24, 728, 736-742
advanced manufacturing planning, 748-751
for assemblies, 739-740 computer-aided,742-744 defined, 735 make or buy decision, 740-742
for parts, 737-739 Process sequences, 738-739 Process technology, 479 Process variables, 90 Processing operations, 46-49
defined, 47 industrial robots:
arc welding, 244-245 spot welding, 244 spray coating, 245-246
part-shaping operations, 48 property-enhancing operations, 48
surface processing operations, 48-49
Process-initiated interrupts, 115
Producer's risk, 648 Product commonality, 575 Product data management (PDM)
system, 717 Product design, 23-24
and CAD,7J?5-720 and group technology (GT),
540-541 Product inspection, process
monitoring vs., 659-660
Product layout, 53, 54 Product variety, 51
coping with, 425-426 Production capacity, 67-68
defined,67 plants/companies, 60
Production control, 754 Production facilities, 50-55
high production, 51, 54-55 low production, 51, 52-53 medium production, 51, 53-54
Production flow analysis (PFA), 532-534
cluster analysis, 533-534 data collection, 532 PFA chart, 533-534 sortation of process routings,
532-533 Production kanban (P-kanban), 791
Production lines, 378,391 origins of, 419
Production machines, 377-378 stopping automatically, 62
Production models, averaging procedures,82~84
Production performance, mathematical models of, 65-72
Production planning, defined, 754
Production planning and control (PPC) , 725, 753-784
defined,753 Production quantity, 51
Index
Production rate, 65-67 batch and job shop production,
65-66 cycle time, 65 mass production, 66-67
Production systems, 18, 19-24 automation in, 25-28 defined, 19, 102 facilitie~, 19-22 manuallabor in, 29-31 manufacturing support systems, 19
Product/production relationships, 55-60
limitations and capabilities of a manufacturing plant, 59-60
part complexity, 56-59 product complexity, 56-57 production quantity and product
variety,55-56 PROFIL,192 Program of instructions, 85, 86, 90-93
part programs, 90 programmed work cycle, decision
making in, 92-93 work cycle program, 80-82
Program-initiated event, 116 Programmable automation, 26--27
Programmable logic controllers (PLCs), 86, 114, 123, 278-285,464
analog control,282 arithmetic functions, 282 components of, 280-281 data processing and reporting, 282
input/.output module, 281 matrix functions, 282 memory unit, 280 operating cycle, 281-282 power supply, 280 processor, 280 programming,281,282-285
function block diagrams (FBDs),283
instruction list (lL), 283-285 ladder logic diagrams, 283, 285
sequential function chart (SFCs),283
structured text (ST), 285
Programmable parts feeder, 503
Programming and computer operation, 31
Programming, defined, 282 Programs, 26
Index 827
Progress reports, 768 Quenching, 41 control resolution, 257-258 Property-enhancing operations, 48 Quiet zone, 364 example, 259 Proportional-integral-derivative repeatability, defined, 258 1 ,
(PID) control, 282 R Robot control systems, 237-238 Proximity sensors, 241 Rack systems, 334 Robot-centered layout, 567 Proximity switch, 134 Radiation inspection techniques, Robotics, 123 Pulse counters, 151 707-708 Robots, origin of word, 230 Pulse data, 107 Radiation pyrometer, 134 Robust design, 631-632,728 Pulse generator, 151 Radio frequency data communication defined, 632 Pulse train, 151 (RFDC),372 Roll, robot wrist assembly, 234-235 Punch presses, and numerical Radio frequency identification (RFID), Roller conveyors, 305
control, 176 292,360,370-372,770 Rolling Stones tour plan (2005-2006) Purchase orders, 763 Radio frequency (RF), 303 example, 48
Q Rail-guided vehicles, 304-305 Root cause analysis, Six Sigma, 629-630 Random access memory (RAM), 87 Root programming, 248-257
QC, See Quality control (QC) Random errors, 98 computations and program logic, 256 Quality circles, 802 Random variations, 606 interlock and sensor commands, Quality control (QC), 24, 725, See Random-order FMS, 561 255-256
also Six Sigma; Statistical Rank order clustering, 534 languages, 251-256 process control (SPC) grouping parts/machines by, 541-543 leadthrough programming, 249-252
defined, 602 Ranked positional weights (RPW) motion programming, 253-254 freedom from deficiencies, 602-603 method, 437-438 simulation and off-line and inspection, 646 Rapid prototyping, 720 programming, 256-257 ISO 9000, 636-637 Real-time controller, 115 Roots, industrial, 114 modern, 605-606 Recirculating conveyors, 309 Ross, Douglas, 157-158 process variability/process analysis of, 320-321 Rossum's Universal Robots
capability, 622-625 Reconfigurable manufacturing (Capek),230 product features, 602-603 systems, 389 Rotary configuration, automated Six Sigma, 621-631 Reduced setup times, 61 production lines, 467-468 statistical process control (SPC), Regulatory control, 108-109 Rotary indexing mechanisms,
610-621 Relationship matrix, 730 471-472 technologies, 606 Remote call stations, 303 cam drive mechanisms, 472 total quality management (TQM), Reorder point inventory systems, Geneva mechanism, 471-472
605-606 774-775 Rotary indexing systems, 467-468 traditional, 603, 604-605 Repair procedure recommendation, 97 Rotational jon:t, 232
Quality engineering: Repeat operation, part movement, 537 Rotor, 136 robust design, 631-632 Repeatability, in robots, defined, 259 Rough-cut capacity planning Taguchi loss function, 632-636 Repositioning efficiency, 433 (RCCP),764 Taguchimethodsin,631-636 Repositioning time, 400, 411 Route sheet, 532, 737, 742
Quality expectations, 18 Resistance-temperature detector, 134 Routing, 293 Quality function deployment (QFD), Resolution, vision system, 700 and industrial robots, 247
728-733 Retrieval CAPP system, 742-743 customer requirements, methods of Revolving joint, 232 S
capturing, 730-731 RFID, See Radio frequency Safety monitoring, 95-96 defined, 728 identification (RFID) Sampling, 651-653, See also Polling house of quality (example), Right-hand rule, 159 (data sampling)
732-733 Rigid pacing, 424 acceptance, 651 Quality programs, 19,601-644 Riveting, 41 attributes, 651 Quality system, ISO definition of, 637 Rivets, 49 lot, 651 Quantitative metrics,64 Robot accuracy and repeatability, operating characteristic curve, Quantity production, 54 257-259 652-653 Quantization error, 146 accuracy, defined, 258 statistical errors in, 652 Quantization-level spacing, 146 addressable points, 257 variables, 651
828
Sampling rate, 145 Sand blasting, 48-49 Satellite terminals, 770 Scan, 281 Scan time, 281 Scanning, See Polling (data sampling) Scanning laser device, 705-706 SCARA (Selective Compliance
Assembly Robot Arm), body-and-arm assembly, 233,235
Scatter diagrams, 619-620 Schedule change test, 557 Scheduling, 293 Scientific management, 42 Scientific Priniciples of Group
Technology (Mitrofanov), 524 Screening, See 100% manual
inspection Screw,86 Screw conveyors, 307 Screw cutting lather, 41 Second Industrial Revolution, 42 Secondary code, 530 Secondary handling system, 565 Secondary industries, 43 Secondary processes, 738 Segmentation, 701 Segmented in-line configuration,
466-467 automated production lines,
466-467 Selector, 500 Self-guided vehicles (SGVs), 301-302 Semi-automated machine, 22, 377 Sensors, 131-135, 144
active, 132 binary, 132 classification of, 131 external,240-241 industrial robots, 240-241 internal,240 micro sensors, 132 obstacle detection, 304 optical, 241 passive, 132 position, 236 proximity, 241 in robotics, 240-241 sensitivity of, 134 tactile, 134, 240-241 ultrasonic range, 134
Sensoryfeedback,240
Sequencing, 273-274 Sequential control, 113 Sequential function chart (SFCs), 283 Service sector, trend toward, 18 Servomotor, 137 Set point control, 114 Setup cost, 773 Setup time (changeover time), 54 Setup time in batch production, and
workstation requirements, 407-408
SFC, See Shop floor control (SFC) Shaping, 41 Sheet metal punchinglblanking,
power form, 89 Sheet metal stamping, 400 Shelves, 336 Shingo, Shigeo, 793 Shop floor control (SFC) , 24,121,
725,754,765-771 defined,765 factory data collection system, 768 order progress, 767-768 order release, 765-766 order scheduling, 766-767
Shop loading, 767 Shop packet, 765 Shortest processing time, 767 Shot peening, 48-49 Side lighting, 701 Signal conditioning, 144 Simple mechanical devices, 239 Simultaneous operations, 33 Single command cycle, 331 Single direction conveyor, analysis of,
318-319 Single direction conveyors, 309 Single machine cell, 558 Single model assembly lines, 425-426,
See also Line balancing analysis of, 426-433 line balancing problem, 429-433 line efficiency, 426 repositioning losses, 428-429 work content time, 427 workload,427
Single station cell, 376 Single-level interrupt system, 118-119 Single-model production line, 54 Single-station automated cells, 396-401
applications of, 402-403 enablers for unattended cell
operation, 397-398
Index
parts storage subsystem and automatic parts transfer, 398-401
storage capacities greater than one 400-401 '
storage capacity of one part, 399-400
Single-station cells, 389-391 Single-sta!ion manned cells, 395-396
applications of, 402 manually operated station, 395-396 semi-automated station, 396
Single-station manual assembly cell,455
Single-station manufacturing cells, 394-416
analysis of,406-413 applications of, 401-406 CNC machining centers, 403-406 single-station automated cells,
396-401 single-station manned cells,
395-396 Single-station manufacturing
systems: analysis of, 406-413 machine clusters, 410-413 number of workstations required,
406-410 Sintering,48 Six Sigma, 19, 24, 621-631, 802
central concept of, 622 champion, use of term, 625 defined, 621 DMAIC procedure, 624-631, 802
analysis and prioritization, 630 basic data analysis, 628-630 charter, 625 control plan development, 631 current sigma level, measuring,
627-628 customer( s ), identifying, 625-626 data collection, 626-627 generation of alternative
improvements, 630 high-level process map, 626 improvements
implementation, 630 organizing the project team, 625 process analysis, 629 root cause analysis, 629-630 transferring responsibility and
disbanding the team, 631
Index
goals of, 621 six sigma level vs. three sigma
level, 623 Skate-wheel conveyors, 305 Slack time, 767 Slewing mode, 141 Smart card, 360 Smelting, 41 Smith, Adam, 419 Soft logic, PCs using, 285-286 Soft product variety, 52 Software systems development, 751 Sokolovskiy, A., 524 Soldering, 41, 49 Solenoids, 141-142 Solidification processes, 48 Solid-state cameras, 700 SolidWorks, 195 Sortation, 657 South Korea, 18 SPC, See Statistical process
control (SPC) Specialization of labor, 418 Specialization of operations, 33 Speed, industrial robots, 236 Speed of response, industrial
robots, 236 Spinning, 40 Spinning jenny, 41 Spot welding, 244 Spray coating, 245-246 Stability, 678
industrial robots, 236 Stacking operations, and industrial
robots, 242 Standard gripper products, 240 Standard operating procedure
(SOP), 631 Standard operations routine, 805 Standard work-in-process
quantity, 807 Standardized work procedures,
804-807 Standards, 42 Stationary scanners, 366 Statistical process control (SPC), 24,
610-621, See also Control charts
cause-and-effect diagrams, 620 check sheets, 618 control charts, 610-616 defect concentration diagrams,
618-619
defined, 610 histograms, 617 implementing, 620-621 Pareto charts, 617 Pareto's Law, 617-618 scatter diagrams, 619-620
Statistical quality control, 19 Stator,136 Status monitoring, 97 Steady-state optimization, 109-110 Steam engine, 86 Steamboat, 86 Step angles, 140, 180 Stepper motors/stepping motors,
140-141 Stereolithography,720 Stock-keeping-unit (SKU), 332-333 Stock-out cost, 771 Storage buffers:
automated production lines, 472-473
manual assembly lines, 452-453 Storage capacity, 330 Storage cost, 772-773 Storage density, 330-331 Storage location strategies, 332-333 Storage systems, 291, 329-357
automated, 337-343 bulk storage, 334 cantilever racks, 336 carousel, 343-345 drawer storage, 336 drive-through racks, 336 engineering analysis of, 345-352 flow-through racks, 336 function of, 329 performance, 330-332 portable racks, 336 rack systems, 334 shelving and bins, 336 storage location strategies, 332-333
Straight turning, 173 Straightcut NC, 161 Strain gage, 134 Strobe lighting, 701 Structured lighting, 701 Structured text (ST), 285 Stulen,Frank,86,156-157 Stylus instruments, 696-697 Subassembly, 46, 247 Subsidiary data, 759 Successive approximation method, 146 Supervisory control, 123-124
Supplementary code, 530 Supply chain management, 755 Supporting machines, 539 Surface plate, 681, 694
829
Surface processing operations, 48-49 Surface roughness, 696-697 Surface treatments, 48-49 Susskind, Alfred, 156 Switching systems, 267 Synchronous transport systems, 423 System 24 concept, 555 System throughput, 331 Systematic errors, 96, 675 System-initiated event, 116
T Tachometer, 134 Tactile sensors, 134,240-241 Taguchi loss function, 632-636, 728 Taguchi methods, 631-636 Takt time, 804-807 Tape format, 188 Target point, 160 Taylor, Frederick Wand Lilian, 42 Technological processing capability,
plants/companies, 60 Tempering, 41 Template matching, 703 Ten strategies for automation and
process improvement, 32-33 Tertiary industries, 43 Testing, inspection vs., 650-651 Thermal cutting machines, and
numerical control, 176 Thermal transfer, and bar codes
printing, 367 Thermistor, 134 Thermocouple, 134 Thin film deposition, 49 Thomson Ramo Woodridge
(TRW),114 Thread checking software, 692 Threaded fasteners, 49 Three-dimensional vision systems, 698 Thresholding,701-702 Time buckets, 758-759 Time study, 42 Time-driven change, 112-113, 115 Timer, 270 Timer-initiated actions, 115 Tolerance, 162 Tolerance analysis, 719 Tolerance time, 424, 451
, I
830
Top-driven unit, 344 Torque-speed curve, 138 Total productive maintenance
(TPM), 62, 800-801 Touch techniques, 360 Touch-sensitive probes, 694 Touch-trigger probes, 683 Towing tracto['s, 297-298
. Towline, 307 Toyota Motor Company, 714 Toyota Production System, 739,
786-788,790 jidoka, 798-799 kanban, 791-793 rnuda, 788-790, 798 production equipment, 800 reliability, 797-798 standard work-in-process
quantity, 807 standardized work procedures,
804-807 takt time, 805-806 work procedures, 804
Traffic factor, 313 Transducers, 131, 144 Transfer function, 132 Tra1;lsfer lines, 86, 464, 466
analysis of, automated production lines, 478-480
flexible, 561 free,466 historical note, 475 with internal storage buffers,
483-490 blocking, 483 lines with more than two
stages,489 practical guidelines from
equations, 489-490 starving, 483 storage buffer effectiveness,
limits of, 483-484 two-stage transfer line analysis,
484-485 with no internal parts storage,
479-482 cycle time analysis, 479-480 performance measures, 480-482 practical guidelines from
equations, 480-482 palletized, 466
Transfer machine, 464 Transistor, 87
Transport kanban (T-kanban), 791 Triangulation, 706-707 Trolley, 307 Truth tables, 269-270 Tube bending machines, and
numerical control, 176 Turning, 41, 48 Turning modules, 563 Twisting joint, 232 Two-dimensional (2-D) bar codes,
368-370 matrix symbology, 369-370 stacked bar codes, 369
Two-dimensional bar codes, 368-370 Two-dimensional vision systems, 698 Type I error, 648, 652 Type II error, 648, 652
U Ultrasonic inspection methods, 708 Ultrasonic range sensor, 134 Uniform annual cost (UAC), 77 Unit load principle, 294-295 Unit operations, 104 United States, 18 Unitizing equipment, 291 Unit-to-unit noise factors, 632 Universal machining center
(UMC),404 Universal Product Code
(UPC), 363, 370 Unutilized station capacity, increasing
(example),585-586 Up counter, 273-274 Up/down counter, 274 Upstream allowance, 424 U.S. customary system (U.S.C.S.), 678 USA Principle, 31-32 Utility workers, 385, 421
manual assembly lines, 452 Utilization, 69, 70, 331, 580, 800
and workstation requirements, 407,409-410
V Vacuum grippers, 239 VAL language, 87 Value-adding activities, 61 Variable costs, 73 Variable routing, 379-380 Variable-rate launching, 444-445 Variables sampling plan, 651 Variant CAPP system, 742-743
Vehicle guidance technology, 300-302
Vehicle management and safety, 302-303 '
Vehicle safety, 304 Vehicle-based systems, 312-317 Vertical lift conveyors, 307-308 Vertical machining center
Index
(YMC),404 Vibration-based conveyors, 307-308 Vidicon camera, 700 Virtual machine cells, 540 Virtual prototyping, 720 Vision systems, 698, See also
Machine vision Vision-guided robotic (VGR)
system, 704 Visual inspection, 527 Visual management, 802-803 Visual workplace, 802
W Walkie trucks, 297 Wasteful activities, 61 Waterjet cutting, and industrial
robots,247 Watt, James, 86 Watt's steam engine, 41 Wealth of Nations, The (Smith), 419 Weaving, 40 Weaving machines, 86 Welding, 49
arc, 244-245 forge,41 fusion,41 power form, 89 spot, 244
Welding machines, and numerical . control,176
Wheel,86 White collar workers, 20 Whitney, Eli, 42, 419 Wide operating range, 677 Width-modulated bar codes, 362 Wilkinson, John, 41 Williamson, David, 555 Winch,86 Windmills, 87 Windows (Microsoft), 87 Wire brushing, and industrial
robots, 247 Woodworking, 40 Work carriers, 380-381
Index
Work cell, 806 Work center, 67
hourly cost of (example), 78 Work content time, 427 Work cycle, steps in, 92 Work envelope, 236 Work flow principle, 418 Work order status reports, 768 Work orders, 763 Work sequence, 805-806 Work standards, computerized, 724 Work transport systems, 421-423
blocked stations, 421 manual methods of work transport,
421-422 mechanized work transport, 422-423 starving, 421 storage buffers, 421
Work volume, 235
Worker involvement, 61 Worker teams, 621-622
assembly by, 455 Worker-machine systems, 21-22 Workholders, 20, 379 Work-in-process (WIP), 72, 757
inventory costs, 775-778 Workload, 384, 406-407 Workpart transfer system:
automated production lines, 468-472
linear transfer systems, 469-470 rotary indexing mechanisms,
471-472 Workstation terminals, 770 Workstations,377:;-378
assembly, 420-421 flexible manufacturing systems
(FMSs),562-564
assembly, 563-564 load/unload stations, 562-563 machining stations, 563 sheet-metal fabrication, 563
manual assembly lines, 450-451 number of, 383-384 parts delivery, 500-503
Wrist configurations, industrial robots, 234-235
y
831
Yaw, robot wrist assembly, 234-235
Z Zero-order hold, 147-149 Zone control, 302-303 Zoning constraints, manual assembly
lines, 453
