(U20MCO703) - AUTOMATION IN MANUFACTURING SYSTEMS

UNIT III AUTOMATED ASSEMBLY SYSTEMS (9 Hrs)

System configurations, Parts delivery at workstations and applications, quantitative analysis of assembly
systems - Parts Delivery System at Workstations, Multi - Station Assembly Machines, Single Station
Assembly Machines, Partial Automation.

AUTOMATED ASSEMBLY SYSTEMS

 The term automated assembly refers to mechanized and automated devices that perform various assembly
tasks in an assembly line or cell.
 Much progress has been made in the technology of assembly automation in recent years.
 Some of this progress has been motivated by advances in the field of robotics. Industrial robots are
sometimes used as components in automated assembly systems.
 Most automated assembly systems are designed to perform a fixed sequence of assembly steps on a
specific product.

Automated assembly technology should be considered when the following conditions exist:
 High product demand.
 Automated assembly systems should be considered for products made in millions of units (or close to this
range).
 Stable product design:
 In general, any change in the product design means a change in workstation tooling and possibly the
sequence of assembly operations. Such changes can be very costly.
 A limited number of components in the assembly:
 Riley recommends a maximum of around a dozen parts.
 The product is designed for automated assembly:
 The product design factors that allow for automated assembly are explored.
 Automated assembly systems involve a significant capital expense.
 However, the investments are generally less than for the automated transfer lines because
1. Work units produced on automated assembly systems are usually smaller than those made on
transfer lines
2. Assembly operations do not have the large mechanical force and power
 Requirements of processing operations such as machining.
 Accordingly, in comparing an automated assembly system and a transfer line with the same number of
stations, the assembly system would tend to be physically smaller.
 This usually reduces the cost of the system.
 FUNDAMENTALS OF AUTOMATED ASSEMBLY SYSTEMS
 An automated assembly system performs a sequence of automated assembly operations to combine multiple
components into a single entity.
 The single entity can be a final product or a subassembly in a larger product.
 In many cases, the assembled entity consists of a base part to which other components are attached.
 The components are usually joined one at a time, so the assembly is completed progressively.
 A typical automated assembly system consists of the following subsystems:
1. One or more workstations at which the assembly steps are accomplished,
2. Parts feeding devices that deliver the individual components to the workstation(s)
3. A work handling system for the assembled entity.
 In assembly systems with one workstation, the work handling system moves the base part into and out of the station.
 In systems with multiple stations, the handling system transfers the partially assembled base part between stations.

SYSTEM CONFIGURATIONS

 Automated assembly systems can be classified according to physical configuration. The principal configurations,
illustrated in Figure, are (a) in-line assembly machine, (b) dial-type assembly machine, (c) carousel assembly
system, and (d) single-station assembly machine.
 The in-line assembly machine, Figure (a), is a series of automatic workstations located along an in-line transfer
system. It is the assembly version of the machining transfer line.
 Synchronous and asynchronous transfer systems are the common means of transporting base parts from station to
station with the in-line configuration.

Figure: Types of automated assembly systems: (a) in-line, (b) dial-type, (c) carousel, and (d) single
station.
 In the typical application of the dial-type machine, Figure (b), base parts are loaded onto fixtures or
nests attached to the circular dial.

 Components are added and/or joined to the base part at the various workstations located around the
periphery of the dial.

 The dial indexing machine operates with a synchronous or intermittent motion, in which the cycle consists
of the service time plus indexing time.

 Dial-type assembly machines are sometimes designed to use a continuous rather than intermittent motion.

 This is common in beverage bottling and canning plants, but not in mechanical and electronics assembly.

 For synchronous transfer of work between stations, the ideal cycle time equals the operation time at the
slowest station plus the transfer time between stations.

 The production rate, at 100% uptime, is the reciprocal of the ideal cycle time.

 Owing to part jams at the workstations and other malfunctions, the system will always operate at less than
100% uptime.

 As seen in Figure (c), the carousel assembly system represents a hybrid between the circular work flow
of the dial-type assembly machine and the straight work flow of the in-line system.

 The carousel configuration can be operated with continuous, synchronous, or asynchronous transfer
mechanisms to move the work around the carousel.

 Carousels with asynchronous transfer of work are often used in partially automated assembly systems.

 In the single-station assembly machine, Figure (d), assembly operations are performed on a base part
at a single location.
 The typical operating cycle involves the placement of the base part at a stationary position in the
workstation, the addition of components to the base, and finally the removal of the completed assembly
from the station.
 An important application of single-station assembly is the component placement machine, widely used in
the electronics industry to populate components onto printed circuit boards.
 For mechanical assemblies, the single-station cell is sometimes selected as the configuration for robotic
assembly applications.
 Parts are fed into the single station, and the robot adds them to the base part and performs the fastening
operations.
 Compared with the other three system types, the cycle time is longer in a single-station assembly system
because all of the assembly tasks are performed sequentially instead of simultaneously.
 Hence, production rates are inherently slower.
 PARTS DELIVERY AT WORKSTATIONS

 In each of the configurations described earlier, a workstation accomplishes one or both of the following
tasks:
1. A component is delivered to the assembly work head and added to the existing base part in front
of the work head
2. A fastening or joining operation is performed at the station to permanently attach components to
the existing base part.
 In the case of a single-station assembly system, these tasks are carried out multiple times at the single
station. Task (1) requires the parts to be delivered to the assembly work head.

Parts delivery system typically consists of the following hardware:

1. Hopper:
 This is the container into which the components are loaded at the workstation. A separate hopper is used
for each component type.
 The components are usually loaded into the hopper in bulk. This means that the parts are randomly
oriented in the hopper.
2. Parts feeder:

 This is a mechanism that removes the components from the hopper one at a time for delivery to the
assembly work head. The hopper and parts feeder are often combined into one operating mechanism.
3. Selector and/or orientor:

 These elements of the delivery system establish the proper orientation of the components for the assembly
work head.
 A selector is a device that acts as a filter, permitting only parts in the correct orientation to pass through.
 Incorrectly oriented parts are rejected back into the hopper.
 An orientor is a device that allows properly oriented parts to pass through, and reorients parts that are not
properly oriented initially.
 Figure (a) Selector and (b) orientor devices used with parts feeders in automated assembly systems.

4. Feed track:

 The preceding elements of the delivery system are usually separated from the assembly work head by a
certain distance.
 A feed track moves the components from the hopper and parts feeder to the location of the assembly work
head, maintaining proper orientation of the parts during the transfer.

5. Escapement and placement device:

 The escapement removes components from the feed track at time intervals that are consistent with the
cycle time of the assembly work head.
 The placement device physically places the component in the correct location at the workstation for the
assembly operation.
 These elements are sometimes combined into a single operating mechanism.

6. The hardware elements of the parts delivery system are illustrated schematically in Figure. A parts
selector is illustrated in the diagram. Improperly oriented parts are returned to the hopper. In the case of
a parts orientor, improperly oriented parts are reoriented and proceed to the feed track.

Figure Hardware elements of the parts delivery system at an assembly workstation.

APPLICATIONS - Automated assembly systems

 Automated assembly systems are used to produce a wide variety of products and subassemblies.
 Table 1 presents a list of typical products made by automated assembly.
 Table 2 provides a representative list of assembly processes that are performed on automated assembly
machines.
 It should be noted that certain assembly processes are more suitable for automation than others.
 For example, threaded fasteners (screws, bolts, and nuts), although common in manual assembly, are a
challenging assembly method to automate.
 This issue is discussed in Chapter 24, which also provides some guidelines for designing products for
automated assembly.

Table 1 Typical Products Made by Automated Assembly

Alarm clocks Fuel injectors Pumps for household appliances Cigarette lighters
Ball bearings Gearboxes Small electric motors Locks
Ball point pens Lightbulbs Spark plugs Wrist watches

Table 2 Typical Assembly Processes Used in Automated Assembly Systems

Automatic dispensing of adhesive Snap fitting

Insertion of components (electronic assembly) Soldering
Placement of components (electronic assembly) Spot welding
Riveting Stapling
Screw fastening (automatic screwdriver) Stitching

QUANTITATIVE ANALYSIS OF ASSEMBLY SYSTEMS

 Quantitative analysis of assembly systems is a crucial aspect of automated assembly systems, as it enables
the evaluation of system performance, identification of bottlenecks, and optimization of the assembly
process.
 Here are some common quantitative analysis techniques used in automated assembly systems:
(1) Performance Metrics: Measure the following performance metrics to evaluate the assembly system:
 Throughput (pieces per unit time)
 Cycle time (time taken to assemble one unit)
 First Pass Yield (FPY): percentage of units assembled correctly on the first attempt
 Defect Rate: percentage of defective units produced
 Total Productive Maintenance (TPM) efficiency: percentage of available production time spent on actual
production
(2) Statistical Process Control (SPC): Use statistical methods to monitor and control the assembly process.
 Control charts: monitor process variables such as temperature, pressure, and vibration to detect deviations
from normal conditions
 Statistical process control limits: set limits for process variables to detect abnormalities
(3) Simulation Modeling: Use simulation software to model the assembly process and analyze:
 System capacity and bottlenecks
 Production scheduling and sequencing
 Material flow and inventory levels
 Operator utilization and workload
(4) Queueing Theory: Analyze the behavior of queues in the assembly system using queuing theory models,
such as:
 M/M/1 (single-server model): calculate average waiting time, queue length, and throughput
 M/M/c (multi-server model): analyze multiple servers and their impact on system performance
(5) Monte Carlo Simulation: Use random sampling to simulate the assembly process and estimate:
 System performance metrics such as throughput, cycle time, and defect rate
 Sensitivity analysis to evaluate the impact of design changes or process modifications on system
performance
(6) Markov Chain Models: Analyze the transition rates between different states in the assembly process
using Markov chain models, such as:
 Finite State Machine (FSM): model the transition between different states (e.g., machine states, product
states)
(7) Discrete Event Simulation: Model the assembly process as a series of discrete events, such as:
 Machine startup/shutdown events
 Product arrival/departure events
 Quality inspection events
(8) Systems Dynamics Modeling: Use systems dynamics modeling to analyze the interactions between
different components of the assembly system, such as:
 Material flow and inventory levels
 Production scheduling and sequencing
 Machine utilization and availability
 These quantitative analysis techniques can be applied to various types of automated assembly systems,
including:
 Industrial automation systems (e.g., manufacturing cells, production lines)
 Automated material handling systems (e.g., conveyor belts, robotic arms)
 Hybrid systems (e.g., human-robot collaboration)

PARTS DELIVERY SYSTEM AT WORKSTATIONS

 Parts Delivery Systems (PDS) play a crucial role in automation manufacturing systems, particularly in
workstations where assembly and manufacturing operations take place.
 A PDS is a system that transports parts from a centralized storage location to the workstation where they
are needed, ensuring that the assembly process is efficient and reliable.
 Here's an overview of how PDS works in automation manufacturing systems:

Types of Parts Delivery Systems:

 Conveyor-based systems: Use conveyors to transport parts to the workstation, often used for high-volume
production.
 Robot-based systems: Utilize robots to pick and place parts at the workstation, suitable for flexible and
dynamic production environments.
 Automated Guided Vehicle (AGV) systems: Use AGVs to transport parts, which are guided by navigation
systems and can operate in various environments.
 Pneumatic or vacuum-based systems: Employ compressed air or vacuum to transport small parts, often
used in precise assembly operations.
 Cable-based systems: Use cables or tracks to guide parts to the workstation, commonly used in robotic
applications.
Benefits of Parts Delivery Systems:
 Improved productivity: Reduces labor costs and increases efficiency by automating part delivery.
 Increased accuracy: Minimizes errors by ensuring that the correct parts are delivered to the workstation.
 Enhanced flexibility: Allows for easy changes in production volumes, product configurations, or part
types.
 Reduced inventory: Decreases inventory levels by ensuring that only the required parts are delivered to
the workstation.
 Improved product quality: Ensures that parts are delivered in a controlled environment, reducing damage
or contamination.

Challenges:
 System integration: Seamless integration with existing manufacturing systems, such as ERP, MES, and
PLCs.
 Part tracking and identification: Accurate tracking and identification of parts to ensure correct delivery
to the workstation.
 Safety considerations: Ensure safe operation of the PDS, avoiding collisions or interference with other
equipment.
 Maintenance and maintenance access: Design the system for easy maintenance and access to minimize
downtime.
 Scalability and flexibility: Design the system to accommodate changes in production volumes or product
mixes.

MULTI - STATION ASSEMBLY MACHINES

 Multi-station assembly machines are a type of automated assembly system that can significantly improve
production efficiency, quality, and productivity in manufacturing systems.
 A multi-station assembly machine is a type of robotic or mechanical assembly system that can perform
multiple assembly operations at different stations.
 Each station performs a specific task, such as screwing, welding, or inserting parts, to assemble a product.
Characteristics:
 Multiple stations: Each station performs a specific task, allowing for flexible and efficient assembly of
complex products.
 Robotic or mechanical: Can be powered by robots or mechanical arms to perform tasks such as welding,
drilling, or cutting.
 Flexibility: Can assemble a variety of products with minimal changes to the machine.
 High precision: Ensures accurate assembly with minimal human intervention.
 Reliability: Reduces labor costs and improves product quality by minimizing human error.

Applications:
 Automotive industry: Assembles car parts, such as engine components, transmission systems, and body
panels.
 Aerospace industry: Assembles aircraft components, such as aircraft frames, engine components, and
avionics systems.
 Medical devices: Assembles medical devices, such as syringes, catheters, and surgical instruments.
 Consumer electronics: Assembles electronic components, such as printed circuit boards (PCBs), cables,
and enclosures.
 Food processing: Assembles food products, such as snack packaging, bottled beverages, and canned
goods.

Benefits:
 Increased efficiency
 Improved quality
 Reduced labor costs
 Flexibility
 Scalability

Types of Multi-Station Assembly Machines:

 Robotic assembly cells: Use robots to perform assembly tasks at each station.
 Mechanical assembly lines: Use mechanical arms or conveyor belts to transport parts between stations.
 Hybrid systems: Combine robotic and mechanical components to create a hybrid assembly system.

SINGLE STATION ASSEMBLY MACHINES

 Single-station assembly machines are a type of automated assembly system that performs a single
assembly operation at a specific station.
 These machines are designed to automate a specific task, such as screwing, welding, or inserting parts,
and can be used in various industries including automotive, aerospace, medical devices, and consumer
goods.
 A single-station assembly machine is a type of automated assembly system that performs a single
assembly operation at a specific station. The machine is designed to automate a specific task, such as
screwing, welding, or inserting parts, and can be used in various industries.

Characteristics:
 Single Station: Performs a single assembly operation at a specific station.
 Automated: Automated assembly operation using mechanical or robotic arms.
 Flexible: Can assemble various products with minimal changes to the machine.
 High Precision: Ensures accurate assembly with minimal human error.
 Reliable: Reduces labor costs and improves product quality by minimizing human error.

Applications:
 Automotive industry: Assembles car parts, such as engine components, transmission systems,etc.
 Aerospace industry: Assembles aircraft components, such as aircraft frames, engine components.
 Medical devices: Assembles medical devices, such as syringes, catheters, and surgical instruments.
 Consumer goods: Assembles electronic components, such as printed circuit boards (PCBs), cables.
 Food processing: Assembles food products, such as snack packaging, bottled beverages, etc.

Benefits:
 Increased Efficiency: Reduces production time and increases output by automating a single assembly
operation.
 Improved Quality: Ensures precise assembly with minimal human error.
 Reduced Labor Costs: Automates labor-intensive tasks, reducing labor costs and improving productivity.
 Flexibility: Can assemble various products with minimal changes to the machine.
 Scalability: Can be easily scaled up or down depending on production needs.

Types of Single-Station Assembly Machines:

 Mechanical Assembly Machines: Use mechanical arms or conveyors to perform assembly operations.
 Robotic Assembly Machines: Use robotic arms to perform assembly operations.
 Pneumatic Assembly Machines: Use compressed air or vacuum to perform assembly operations.

Challenges and Limitations:

 Initial Investment: High initial investment required for designing and implementing single-station
assembly machines.
 Maintenance and Repair: Requires regular maintenance and repair to ensure optimal performance.
 Space Requirements: Requires significant floor space for the machine and its components.
 Difference between Multi station and Single station Assembly Machines
Multi-Station Assembly Machines Single-Station Assembly Machines
Perform multiple assembly operations at Perform a single assembly operation at a specific
different stations station
Each station performs a specific task, such as Limited to a single task, such as screwing or
screwing, welding, or inserting parts welding
Can assemble complex products with multiple Suitable for assembling simple products with few
components and sub-assemblies components
Require more complex programming and control Require less complex programming and control
systems systems
Often used in high-volume production lines to Often used in low-to-medium volume production
assemble complex products lines to assemble simple products

PARTIAL AUTOMATION

 Many assembly lines in industry contain a combination of automated and manual workstations.
 These cases of partially automated production lines occur for two main reasons:
1. Automation is introduced gradually on an existing manual line. Suppose demand for the product made
on a manually operated line increases, so the company decides to increase production and reduce labor
costs by automating some or all of the stations. The simpler operations are automated first, and the
transition toward a fully automated line is accomplished over a long period of time. Until then, the line
operates as a partially automated system.
2. Certain manual operations are too difficult or too costly to automate. Therefore, when the sequence
of workstations is planned for the line, certain stations are designed to be automated while the others
are designed as manual stations.

Types of Partial Automation:

 Semi-Automatic Machines: These machines require human intervention for certain tasks, such as loading
or unloading materials, but perform other tasks automatically.
 Hybrid Machines: These machines combine automated and manual operations, with some tasks
performed automatically and others performed by human workers.
 Supervised Automation: In this type of partial automation, machines are programmed to perform specific
tasks, but human supervision is still required to ensure the process runs smoothly.

Benefits of Partial Automation:

 Increased Efficiency
 Cost Savings
 Improved Quality
 Flexibility
 Training and Development
Challenges of Partial Automation:
 Partial automation often requires significant initial investment in equipment and training.
 Human operators must be trained to work alongside automated systems,
 It require regular maintenance and repair, which
 Human intervention can still introduce errors into the process,

Examples of Partial Automation:

 Assembly Lines: Many assembly lines use partial automation, where machines perform repetitive tasks,
but human workers are needed for quality control and final assembly.
 Welding: Partially automated welding machines require human intervention for positioning and
monitoring, but automate the welding process itself.
 Packaging: Automated packaging machines may require human workers to load or unload products,
but perform tasks such as wrapping, sealing, or labeling automatically.