Automation, Production Systems, and Computer-Integrated Manufacturing

MIKELL P. GROOVER is Professor of Industrial and Manufacturing Systems Engineering at Lehigh University, where he also serves as Director of the Manufacturing Technology Laboratory. He holds the following degrees all from Lehigh: B.A. (1961) in Arts and Science, B.S. (1962) in Mechanical Engineering, M.S. (1966) and Ph.D. (1969) in Industrial Engineering. He is a Registered Professional Engineer in Pennsylvania (since 1972). His industrial experience includes full-time employment at Eastman Kodak Company as a Manufacturing Engineer. Since joining Lehigh, he has done consulting, research, and project work for a number of industrial companies including Ingersoll-Rand, Air Products & Chemicals, Bethlehem Steel, and Hershey Foods. His teaching and research areas include manufacturing processes, metal cutting theory, automation and robotics, production systems, material handling, facilities planning, and work systems. He has received a number of teaching awards, including the Albert Holzman Outstanding Educator Award from the Institute of Industrial Engineers (IIE). His publications include over 75 technical articles and papers which have appeared in Industrial Engineering, IIE Transactions, NAMRC Proceedings, ASME Transactions, IEEE Spectrum, International Journal of Production Systems, Encyclopaedia Britannica, SME Technical Papers, and others. Professor Groover's avocation is writing textbooks on topics in manufacturing and automation. His previous books are used throughout the world and have been translated into French, German, Korean, Spanish, Portuguese, Russian, Japanese, and Chinese. His book Fundamentals of Modern Manufacturing received the 1996 IIE Joint Publishers Award and the 1996 M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers. Dr. Groover is a member of the Institute of Industrial Engineers, American Society of Mechanical Engineers (ASME), Society of Manufacturing Engineers (SME), and North American Manufacturing Research Institute (NAMRI). He is a Fellow of IIE and SME.

chapter 1 Introduction

1.1     Production Systems

1.2     Automation in Production Systems

1.3     Manual Labor in Production Systems

1.4     Automation Principles and Strategies

1.5     Organization of the Book

Part I Overview of Manufacturing chapter 2 Manufacturing Operations

2.1     Manufacturing Industries and Products

2.2     Manufacturing Operations

2.3     Production Facilities

2.4     Product/Production Relationships

2.5     Lean Production

chapter 3 Manufacturing Models and Metrics

3.1     Mathematical Models of Production Performance

3.2     Manufacturing Costs

Appendix A3 Averaging Procedures for Production Models

Part II Automation and Control Technologies

chapter 4 Introduction to Automation

4.1     Basic Elements of an Automated System

4.2     Advanced Automation Functions

4.3     Levels of Automation

chapter 5 Industrial Control Systems

5.1     Process Industries Versus Discrete Manufacturing Industries

5.2     Continuous Versus Discrete Control

5.3     Computer Process Control

chapter 6 Hardware Components for Automation and Process Control

6.1     Sensors

6.2     Actuators

6.3     Analog-to-Digital Converters

6.4     Digital-to-Analog Converters

6.5     Input/Output Devices for Discrete Data

chapter 7 Numerical Control

7.1     Fundamentals of NC Technology

7.2    Computer Numerical Control

7.3     Distributed Numerical Control

7.4    Applications of NC

7.5     Engineering Analysis of NC Positioning Systems

7.6     NC Part Programming

Appendix A7    Coding for Manual Part Programming

Appendix B7    Part Programming with APT

chapter 8 Industrial Robotics

8.1     Robot Anatomy and Related Attributes

8.2     Robot Control Systems

8.3     End Effectors

8.4     Sensors in Robotics

8.5     Industrial Robot Applications

8.6     Robot Programming

8.7     Robot Accuracy and Repeatability

chapter 9 Discrete Control Using Programmable Logic Controllers and Personal Computers

9.1     Discrete Process Control

9.2     Ladder Logic Diagrams

9.3     Programmable Logic Controllers

9.4     Personal Computers Using Soft Logic

Part III Material Handling and Identification Technologies chapter 10 Material Transport Systems

10.1   Introduction to Material Handling Equipment

10.2   Material Transport Equipment

10.3   Analysis of Material Transport Systems

chapter 11 Storage Systems

11.1   Storage System Performance and Location Strategies

11.2   Conventional Storage Methods and Equipment

11.3   Automated Storage Systems

11.4   Engineering Analysis of Storage Systems

chapter 12 Automatic Identification and Data Capture

12.1   Overview of Automatic Identification Methods

12.2   Bar Code Technology

12.3   Radio Frequency Identification

12.4   Other AIDC Technologies

Part IV Manufacturing Systems chapter 13 Introduction to Manufacturing Systems

13.1   Components of a Manufacturing System

13.2   Classification of Manufacturing Systems

13.3   Overview of the Classification Scheme

chapter 14 Single-Station Manufacturing Cells 14.1   Single Station Manned Workstations

14.2   Single Station Automated Cells

14.3   Applications of Single Station Cells

14.4   Analysis of Single Station Cells

chapter 15 Manual Assembly Lines 15.1   Fundamentals of Manual Assembly Lines

15.2   Analysis of Single Model Assembly Lines

15.3   Line Balancing Algorithms

15.4   Mixed Model Assembly Lines

15.5   Workstation Considerations

15.6   Other Considerations in Assembly Line Design 15.7   Alternative Assembly Systems

chapter 16 Automated Production Lines 16.1   Fundamentals of Automated Production Lines

16.2   Applications of Automated Production Lines

16.3   Analysis of Transfer Lines

chapter 17 Automated Assembly Systems

17.1   Fundamentals of Automated Assembly Systems

17.2   Quantitative Analysis of Assembly Systems

chapter 18 Cellular Manufacturing

18.1   Part Families

18.2   Parts Classification and Coding

18.3   Production Flow Analysis

18.4   Cellular Manufacturing

18.5   Applications of Group Technology

18.6   Quantitative Analysis in Cellular Manufacturing

chapter 19 Flexible Manufacturing Systems

19.1   What is a Flexible Manufacturing Systems?

19.2   FMS Components

19.3   FMS Applications and Benefits 19.4   FMS Planning and Implementation Issues

19.5   Quantitative Analysis of Flexible Manufacturing Systems

PART V Quality Control in Manufacturing Systems

chapter 20 Quality Programs for Manufacturing

20.1   Quality in Design and Manufacturing

20.2   Traditional and Modern Quality Control

20.3   Process Variability and Process Capability

20.4   Statistical Process Control

20.5   Six Sigma

20.6   The Six Sigma DMAIC Procedure

20.7   Taguchi Methods in Quality Engineering

20.8   ISO 9000

chapter 21 Inspection Principles and Practices

21.1   Inspection Fundamentals

21.2   Sampling vs. 100% Inspection

21.3   Automated Inspection

21.4   When and Where to Inspect

21.5   Quantitative Analysis of Inspection

chapter 22 Inspection Technologies

22.1   Inspection Metrology

22.2   Contact vs. Noncontact Inspection Techniques

22.3   Conventional Measuring and Gaging Techniques

22.4   Coordinate Measuring Machines

22.5   Surface Measurement

22.6   Machine Vision

22.7   Other Optical Inspection Techniques

22.8   Noncontact Nonoptical Inspection Technologies

Part VI Manufacturing Support Systems chapter 23 Product Design and CAD/CAM in the Production System

23.1   Product Design and CAD

23.2   CAD System Hardware

23.3   CAM, CAD/CAM, and CIM

23.4   Quality Function Deployment

chapter 24 Process Planning and Concurrent Engineering

24.1   Process Planning

24.2   Computer-Aided Process Planning

24.3   Concurrent Engineering and Design for Manufacturing

24.4   Advanced Manufacturing Planning

chapter 25 Production Planning and Control Systems

25.1   Aggregate Production Planning and the Master Production Schedule

25.2   Material Requirements Planning

25.3   Capacity Planning

25.4   Shop Floor Control

25.5   Inventory Control

25.6   Extensions of MRP

chapter 26 Just-In-Time and Lean Production 26.1   Lean Production and Waste in Manufacturing

26.2   Just-In-Time Production Systems

26.3   Autonomation

26.4   Worker Involvement