Question

In a manufacturing system, 5 workers pick parts from a raw materials bin. After picking the parts, the workers move towards a cell that is composed of 5 manual turning machines. The workers then load the parts onto the machines and then starts the machining process. Once the workers are satisfied that the machining process is complete they stop the machines and unload the parts inspect the machined parts and when satisfied places the machines parts in a finished parts bin. The workers then load the waiting parts. The same activities are repeated on the manual lathes machines until the raw materials bin is empty.

For the manufacturing system described above:

1- Identify the various levels of automation in this system. Justify your answer.

2- Use the USA principle to identify opportunities for automating the manual system described above

3- Given that demand for the machined parts is very high, discuss a suitable automation migration strategy for this manufacturing system

Answer 1

1. We have several levels of automation

a) cell or system level : when the workers load the part onto the cell of 5 turning machines. The cell wil complete the desired work completely.

b) Device level: The workers inspect the work done

2) In USA method we have majorly three levels

a) Understand the existing process

b) Simplify the process

c) Automate the process

As the given situation can be automated by the strategies of improved material handling and storage, loading and unloading of parts can be automated and machining time in the cell can be set as designed in the final product so that the worker will not have to wait and the product inspection can be automated, on line inspection can be carriedout, computer-integrated manufacturing and combined operations will performed.

3) Automated migration strategy: Here there are three main phases existing those are

a) Manual production: single station manned cells working independently, it is quick setup, low cost tooling.

b) Automated production: As the demand grows automation can be jsutified and single station automated cells will operate independently

c) Automated integrated production : Multi-station system with serial operations and automated transfer of work units between stations.