Use Of Automated Machine Tools In Small And Large Batch Manufacturing - Book Report/Review Example

Use Of Automated Machine Tools In Small And Large Batch Manufacturing Introduction Many sectors and industries are taking advantage of the automated machine tools. There is a long list of advantages of their use that include but are not limited to unmanned production, pallet linkage, multiple machine operation, optimized logistics, and automatic tool provision “According to statistics of the Robotics and Automation Group of the German Engineering Federation (VDMA), more than half the turnover generated in Germany by sales of Assembly and Handling Technology originated outside the car industry for the first time in 2007” (Treppa). The rapid rise in the automation solutions developed by other sectors caused a total decline of sales to 48 per cent in the car industry (Treppa). This paper explains the advantages and limitations of using automated machine tools in the manufacturing of components in both small and large batches, and development in computer aided manufacturing. Advantages of using automated machine tools in small batch manufacturing of components The professionals involved in the production of machinery that fills in and packs the tea-bags have benefited from the automation concepts for many years. An engineering firm located in Meersburch, Germany with the help of Soflex’s management, developed a new line that was realized jointly with Schuler, the company’s partner. One very challenging goal to be achieved by the line was production of different components of the tea packaging machines while keeping the sizes of the batches small. The Head of the Business Unit Automation Machine Tools, Daniel Kost explained the system’s benefits in these words, “The heart of this modern solution is the automated production system (APS), which helps provide the machining centers DMC 60 U dB with work pieces… With the aid of the automation concept, we can keep set-up and clamping times low and maximize machine running times – despite the variety of parts” (Kost cited in Treppa). The German engineering firm used the ATS tool storage unit of Schuler which helped it make 760 different tools accessible to the machining centers out of which, 400 exist in the central linear unit of storage whereas another 120 are located in each of the three machines (Treppa). It is possible to replace each of these tools from one machine to another with no waste of time whereas the unrequired tools remain within the storage unit. This system of tool automation provides the advantage of using just one tool in all the three machines and does not need to be withdrawn from the system until the completion of the service life. As a result of this, the cost of provision as well as of tool is reduced. Limitations in the use of automated machine tools in low batch production One limitation commonly faced by the companies that use the automated machine tools for the production of low batches is the high number of work pieces that vary. This problem was solved by the German engineering firm with the help of ATS tool storage unit of Schuler. Advantages of using automated machine tools in small batch manufacturing of components There are numerous sources of the economies of mass production. The primary cause is to reduce all sorts of nonproductive efforts. In the production of craft, the craftsmen need to collect and assemble all the parts. The same tools are used invariably for different kinds of tasks. In mass production, the tasks become repetitive in nature as the workers use the same tools for performing operations that are nearly identical on a stream of products. Since the tools and components are processed through the assembly line consecutively, they are always at hand whenever needed. The time that is otherwise wasted in the retrieval and preparation of tools and materials is saved with the use of automated machine tools, as a result of which, the product’s manufacturing time is reduced. Another great advantage of the use of automated machine tools is the reduced probability of variation and human error because the tasks are performed by machines rather than humans. The company gets in a position to produce the products in large quantities at a reduced cost because of the reduced costs of labor and increased rate of production. Limitations in the use of automated machine tools in large batch production One limitation of mass production with the help of automated machine tools is inflexibility since the design or production process becomes very difficult to be changed after the implementation of the production line. In addition to that, products that are manufactured on one line of production are very similar and identical. It is difficult to introduce variety for the satisfaction of the different tastes. Nevertheless, variety can be achieved to a certain extent with the application of different decorations and finishes at the production line’s end. For example, although tremendous affordable output was produced by the Ford Model T, yet it could not efficiently respond to the demand for customization, changes in design, and variety. As a result of that, the market share was eventually lost by Ford to the General Motors, that gained the edge from annual changes in models, increased number of accessories, and greater variety of colors (Hounshell). Recent advancements in computer aided manufacturing (CAM) technology “Although the development of computer-aided design (CAD) and computer-aided manufacture (CAM) technology and the benefits of increased productivity became obvious in the automobile and aerospace industries in the 1970s, investigations of this technology's application in the field of dentistry did not begin until the 1980s” (Calamia). The systems have started to become commercially available recently that makes this technology’s potential seem boundless. One of the recent advancements in CAM technologies is performance simulation. The response test to stress and the existence of dynamic relationships among constituents’ system are some of the most common simulation types. Model surfaces in the stress tests are represented by a mesh which distorts when the part is exposed to the stimulated thermal or physical stress. Dynamic tests serve as a substitute for the prototypes of building work. The ease of change the specifications of a part facilitates the achievement of efficiencies that are optimal and dynamic both with respect to the manufacturing of a certain part and the functioning of a parts’ system (“Computer-Aided Design”). Another recent advancement in CAM are the industrial robots. The repetitive tasks that have been performed manually for a long time are nowadays being performed by robots. These robots are controlled by the computers that send the data and receive it such as placement of robotic arms, the number of pieces that are created in a minute, and the duration between different task situations. “Programmers and other computer experts thus replace human workers, who now run the computer system rather than performing the manufacturing tasks” (Johnson and Allen). Areas of development of CAM in the future The possibilities of development for CAM with flexible systems of manufacturing, setups integrating with different systems of data exchange, and CAM integrated systems are unlimited. With the sustained evolution and broadening of technology, flexible systems are able to produce identical products using the CAM software. Presently, systems that are quite elaborate and fast can be run on such platforms as Unix, but they are less widely supported and are expensive. An area of development of CAM in the future is standardization of software to facilitate the sharing of data across different packages. Standards for graphics and data exchange have already been established while Microsoft’s Windows and X Windows System are establishing as the standards of industry for the user interfaces. The CAD voice control software is also being actively explored which is based on the technology of voice recognition (Kucera). Conclusion Concluding, some of the most common drivers of motivation behind the use of automated machine tools by the manufacturing and production companies these days include competitive advantage attained because of lower prices and better quality of products, better relations among labor, and better reputation of the company among the stakeholders. It also enhances the safety of processes and increases the company’s potential for mass customization. Some of the factors that demotivate the manufacturing and production companies to use the automated machine tools include labor resistance, cost incurred in the enhancement of workers’ skills, the amount of initial investment required to integrate the automated machine tools into the system, and management of the changes. Over the passage of time, different ways of increasing the mass production systems’ flexibility have been discovered by the engineers, that have driven the lead times over the new product development down, thus providing the advantage of increased variety and greater customization of products. The CAM software allows performing specific changes required for different products, thus automating the entire process of production. The CAM technologies can control almost all aspects of the manufacturing process except for skilled computer operators. In the recent years, the historical drawbacks of the computer aided machines are being attenuated by the providers of high-end solutions as well as the providers of the niche solutions with respect to the ease of use and manufacturing complexity. Works Cited: Calamia, Advances in computer-aided design and computer-aided manufacture technology. Current Opinion in Cosmetic Dentistry. (1994): 67-73. “Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM).” 2013. Web. 11 Mar. 2013. . Hounshell, David A. From the American System to Mass Production, 1800-1932: The Development of Manufacturing Technology in the United States. Baltimore, Maryland: Johns Hopkins University Press, 1984. Print. Johnson, Sandy, and Allen, John. “What Are the Different Types of Computer-Aided Manufacturing?” 2013. Web. 11 Mar. 2013. . Kucera, David. “COMPUTER-AIDED DESIGN (CAD) AND COMPUTER-AIDED MANUFACTURING (CAM).” 2013. Web. 11 Mar. 2013. . Treppa, Kellie. “Highly productive line developed for small-batch manufacturing: engineering company Teepack invests in Schuler’s innovative automation solution.” 29 Oct. 2008. Web. 11 Mar. 2013. . Read More