Parcial 1

Sensores, procesadores y
actuadores en la automatización
de procesos de fabricación
 Temario – 13 hrs
1.- Introducción a la Automatización de procesos
de fabricación
1.1 Tipos de procesos de fabricación.
1.2 Definición de Automatización de Procesos.
1.3 Tipos de Automatización.
1.4 Economía de los procesos de fabricación.
2.- Sensores y actuadores

2
Manufacturing Defined - Technological
Definition
Application of physical and chemical processes
to alter the geometry, properties, and/or
appearance of a given starting material to
make parts or products
 Manufacturing also includes the joining of
multiple parts to make assembled products
 Accomplished by a combination of machinery,
tools, power, and manual labor.
 Almost always carried out as a sequence of
operations
Manufacturing Defined -
Technological Definition
 Manufacturing Defined -
Economic Definition
Transformation of materials into items of
greater value by means of one or more
processing and/or assembly operations
 Manufacturing adds value to the material
 Examples:
 Converting iron ore to steel adds value
 Transforming sand into glass adds value
 Refining petroleum into plastic adds value
Manufacturing Defined -
Economic Definition
Classification of Industries
1. Primary industries – cultivate and exploit
natural resources
 Examples: agriculture, mining
2. Secondary industries – convert output of
primary industries into products
 Examples: manufacturing, power
generation, construction
3. Tertiary industries – service sector
 Examples: banking, education,
government, legal services, retail trade,
transportation
Manufacturing Industries
ISIC Code
 Food, beverages, tobacco 31
 Textiles, apparel, leather and fur products 32
 Wood and wood products, cork 33
 Paper, printing, publishing, bookbinding 34
 Chemicals, coal, petroleum, & their products 35
 Ceramics, glass, mineral products 36
 Basic metals, e.g., steel, aluminum 37
 Fabricated products, e.g., cars, machines, etc. 38
 Other products, e.g., jewelry, toys 39
More Industry Classifications
 Process industries, e.g., chemicals, petroleum,
basic metals, foods and beverages, power
generation
 Continuous production
 Batch production

 Discrete product (and part) industries, e.g., cars,

aircraft, appliances, machinery, and their
component parts
 Continuous production
 Batch production
 Process Industries and
Discrete Manufacturing Industries
Manufacturing Operations
 There are certain basic activities that
must be carried out in a factory to convert
raw materials into finished products
 For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control
Classification of
manufacturing
processes
 Processing Operations
 Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
4. Material removal processes

 Property-enhancing operations (heat treatments)

 Surface processing operations

 Cleaning and surface treatments
 Coating and thin-film deposition
 Assembly Operations
 Joining processes
 Welding
 Brazing and soldering
 Adhesive bonding
 Mechanical assembly (fastening)
 Threaded fasteners (e.g., bolts and nuts, screws)
 Rivets
 Interference fits (e.g., press fitting, shrink fits)
 Other
 Other Factory Operations
 Material handling and storage
 Inspection and testing
 Coordination and control
 Material Handling
 Material transport
 Vehicles,e.g., forklift trucks, AGVs, monorails
 Conveyors
 Hoists and cranes

 Storage systems
 Unitizing equipment
 Automatic identification and data capture
 Barcodes
 RFID
 Other AIDC
Time Spent in Material Handling
 Inspection and Testing
Inspection – examination of the product and its
components to determine whether they
conform to design specifications

 Inspection for variables - measuring

 Inspection of attributes – gaging

Testing – observing the product (or part, material,

subassembly) during actual operation or under
conditions that might occur during operation
 Coordination and Control
 Regulation of the individual processing and
assembly operations
 Process control
 Quality control

 Management of plant level activities

 Production planning and control
 Quality control
 Production Facilities
 A manufacturing company attempts to organize
its facilities in the most efficient way to serve the
particular mission of the plant
 Certain types of plants are recognized as the
most appropriate way to organize for a given
type of manufacturing
 The most appropriate type depends on:
 Typesof products made
 Production quantity
 Product variety
 Production Quantity
Number of units of a given part or product
produced annually by the plant

 Three quantity ranges:

1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units
 Product Variety
Refers to the number of different product or part
designs or types produced in the plant
 Inverse relationship between production quantity
and product variety in factory operations
 Product variety is more complicated than a
number
 Hard product variety – products differ greatly
 Few common components in an assembly
 Softproduct variety – small differences between
products
 Many common components in an assembly
Product Variety vs.
Production Quantity
 Low Production Quantity
Job shop – makes low quantities of specialized
and customized products
 Also includes production of components for
these products
 Products are typically complex (e.g., specialized
machinery, prototypes, space capsules)
 Equipment is general purpose
 Plant layouts:
 Fixedposition
 Process layout
Fixed-Position Layout
Process Layout
 Medium Production Quantities
1. Batch production – A batch of a given product
is produced, and then the facility is changed
over to produce another product
 Changeover takes time – setup time
 Typical layout – process layout
 Hard product variety
2. Cellular manufacturing – A mixture of
products is made without significant changeover
time between products
 Typical layout – cellular layout
 Soft product variety
Cellular Layout
 High Production
1. Quantity production – Equipment is dedicated to
the manufacture of one product
 Standard machines tooled for high production (e.g.,
stamping presses, molding machines)
 Typical layout – process layout
2. Flow line production – Multiple workstations
arranged in sequence
 Product requires multiple processing or assembly
steps
 Product layout is most common
Product Layout
Relationships between Plant Layout
and Type of Production Facility
 Limitations and Capabilities of a
Manufacturing Plant
Manufacturing capability - the technical and physical
limitations of a manufacturing firm and each of its
plants
 Three dimensions of manufacturing capability:
1. Technological processing capability - the available set
of manufacturing processes
2. Physical size and weight of product
3. Production capacity (plant capacity) - production
quantity that can be made in a given time
 Lean Production
Operating the factory with the minimum possible
resources and yet maximizing the amount of work
accomplished
 Resources include workers, equipment, time,
space, materials
 Also implies completing products in the minimum
possible time and achieving a very high quality
level to completely satisfy the customer
 In short, lean production means doing more with
less, and doing it better
 Lean Production and
Manufacturing Activities
Manufacturing activities can be divided into three
categories:
1. Value-adding activities - contribute value to the
work unit
2. Auxiliary activities - support the value-adding
activities
3. Wasteful activities - do not add value nor do they
support the value adding activities
 If not performed, there would be no adverse effect on
the product
 Programs Associated with
Lean Production
 Just-in-time delivery of parts
 Worker involvement
 Continuous improvement
 Reduced setup times
 Stop the process when something is wrong
 Error prevention
 Total productive maintenance