Production ControlCompetenciesCHARACTERISTICS OF DIFFERENT TYPES OF FACILITIESCharacteristics Of Different Types Of FacilitiesPiecework ProductionSlide 6Slide 7Small Batch Production (1-20 Parts/Hr.)Slide 9Slide 10Large Batch Or Continuous Processes (20-200 parts/hr.)Slide 12Slide 13Slide 14Slide 15Slide 16Slide 17Slide 18Quality Assurance Through Automated InspectionQuality Assurance Through Automated InspectionJust-in-Time SchedulingMass Production (over 200 parts/hr)Slide 23Slide 24IT 208 Chapter 21 1Production ControlChapter 21IT 208Chapter 212CompetenciesDescribe the difference between Jigs and FixturesDescribe the difference between CAD/CAMDefine computer integrated manufacturingList essential components of robotics and describe their functionDescribe the disadvantage of Just-in-time schedulingIT 208Chapter 213CHARACTERISTICS OF DIFFERENT TYPES OF FACILITIESThe most important factor in manufacturing is the rate of production, because it determines which manufacturing processes will be the most efficient for any given product. This system is driven by the customers’ demand (Pull system)IT 208Chapter 214Characteristics Of Different Types Of FacilitiesPiecework Production Small Batch Production (1-20 Parts/Hr.)Large Batch Or Continuous Processes (20-200 Parts/Hr.)Mass Production (Over 200 Parts/Hr)IT 208Chapter 215Piecework ProductionDefined as the fabrication of one complete unit at a time.Utilization of equipment is not a great concern since the equipment is not usually shared or tied up continuously for the production run. Piecework facilities are often batch processes in which products are made individually.IT 208Chapter 216Piecework Production1. Jigs and Fixtures a) A fixture is a device that is individually designed to hold a specific workpiece in place. Its specific job is to facilitate setup or to make holding easier. •Ex. - Use a fixture to hold a particular plug at an angle for easier soldering. b) A jig is a fixture that establishes certain critical location dimensions on the workpiece. •Ex. – Using a jig for the holding and drilling precise holes (into a casting) for the shafts of a three dimensional mechanism.c) Work holder is the general term for either a jig or a fixture. A miter box or a bench vise might be a workholder.IT 208Chapter 217Piecework Production2. Inspection is the act of determining whether or not the size, shape, and location of all features of the workpiece are consistent with the drawings or other specifications. Inspections are performed by machinists or operators.IT 208Chapter 218Small Batch Production (1-20 Parts/Hr.)At this rate of production, completed parts begin to take up a significant amount of space before they can be shipped and raw materials are needed at a faster rate than they are with piecework. Boredom becomes a concern and not only affects the quality of the product, but safety is also affected.IT 208Chapter 219Small Batch Production (1-20 Parts/Hr.)Numerical Control is a way of controlling the action of machines by giving them a set of instructions in numerical form. Computerized Numerical Control •Can be programmed to control several production machines•Can store programs and data that would allow it to track the wear of the cutting tools and automatically compensate for that wear. •Machines were designed with a tool carrier so that tools could be changed by computer control.IT 208Chapter 2110Small Batch Production (1-20 Parts/Hr.)Some Problems of CNC•New machines are very expensive and only 5% of the part’s total manufacturing time is it actually on the machine. •Only profitable if it frees up time to supervise more machines or to spend time with the human activities that computers cannot do wellIT 208Chapter 2111Large Batch Or Continuous Processes (20-200 parts/hr.)No longer does one person see the part from start to finish.Scheduling is an important part of this type of manufacturing. Inspect the parts frequently to detect trends in parts not meeting standards and take corrective action before the parts are so far from the specifications that they are scrap.IT 208Chapter 2112Large Batch Or Continuous Processes (20-200 parts/hr.)3. Computer-Aided Drafting/ Computer-Automated Manufacturinga) Computer-Aided Drafting is a method of drafting that uses a computer to draw on the screen as instructed by an operator. The computer acts only as an “electronic drafting board”; it does not do anything on its own.IT 208Chapter 2113Large Batch Or Continuous Processes (20-200 parts/hr.)b) Computer Automated Engineering (CAE) is a system that uses a computer to make design drawings, but additionally is capable of doing engineering analysis of the designed object. •Determine the volume and weight of the part and locate its center of mass. •Do a complete structural analysis of the product. •Determine clearances and allowances between matching parts. •Devise the optimum steps for the manufacture of the product. •Create the commands for the computer controlled machines that make the product. •Keep the inventory records and other documentation for the productIT 208Chapter 2114Large Batch Or Continuous Processes (20-200 parts/hr.)c) Computer-Automated Manufacturing is an approach to organizing a manufacturing plant so that all possible analyses, decisions, and actions are assigned to a master computer. d)Typical Computer Operations in CAM •Control the inventory. •Direct the transportation of raw materials, completed products, and parts at different stages during manufacture. •Create machine maintenance schedules. •Control the automatic inspection •Maintain documentation •Control the actions of robots.IT 208Chapter 2115Large Batch Or Continuous Processes (20-200 parts/hr.)Robotics Robots have five essential components: 1) Manipulator - the part of the machine that actually handles the tool, material, or part.2) Actuators - respond to the signals from the controller, causing the manipulator to perform its assigned function. 3) Sensors - detect the positions of the various components of the arm and hand and feed data back to the controller. 4) Controllers - computers that send control signals to the manipulators and respond to the data fed back to them by the sensors.5) Power supplies - provide the energy that drives the controllers, sensors, manipulators, and actuators.IT 208Chapter 2116Large Batch Or Continuous Processes (20-200 parts/hr.)Use of