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Chapter 1 INTRODUCTION 1

1.1 Production System Facilities 2

1.2 Manufacturing Support Systems 7

1.3 Automation in Production Systems 9

1.4 Manual Labor in Production Systems 14

1.5 Automation Principles and Strategies 17

1.6 Organization of the Book 21

Chapter 2 MANUFACTURING OPERATIONS 24

2.1 Manufacturing Industries and Products 28

2.2 Manufacturing Operations 31

2.3 Product/Production Relationships 35

2.4 Production Concepts and Mathematical Models 40

2.5 Costs of Manufacturing Operations 48

PART Ⅰ: AUTOMATION AND CONTROL TECHNOLOGIES 61

Chapter 3 INTRODUCTION TO AUTOMATION 61

3.1 Basic Elements of an Automated System 63

3.2 Advanced Automation Functions 71

3.3 Levels of Automation 76

Chapter 4 INDUSTRIAL CONTROL SYSTEMS 79

4.1 Process Industries versus Discrete Manufacturing Industries 80

4.2 Continuous versus Discrete Control 82

4.3 Computer Process Control 88

4.4 Forms of Computer Process Control 96

Chapter 5 SENSORS,ACTUATORS,AND OTHER CONTROL SYSTEM COMPONENTS 107

5.1 Sensors 108

5.2 Actuators 111

5.3 Analog-to-Digital Conversion 112

5.4 Digital-to-Analog Conversion 115

5.5 Input/Output Devices for Discrete Data 117

Chapter 6 NUMERICAL CONTROL 120

6.1 Fundamentals of NC Technology 122

6.2 Computer Numerical Control 128

6.3 DNC 134

6.4 Applications of Numerical Control 137

6.5 NC Part Programming 145

6.6 Engineering Analysis of NC Positioning Systems 179

Chapter 6 APPENDIX:APT WORD DEFINITIONS 196

Chapter 7 INDUSTRIAL ROBOTICS 210

7.1 Robot Anatomy and Related Attributes 212

7.2 Robot Control Systems 218

7.3 End Effectors 220

7.4 Sensors in Robotics 222

7.5 Industrial Robot Applications 222

7.6 Robot Programming 230

7.7 Engineering Analysis of Industrial Robots 240

Chapter 8 DISCRETE CONTROL USING PROGRAMMABLE LOGIC CONTROLLERS AND PERSONAL COMPUTERS 257

8.1 Discrete Process Control 257

8.2 Ladder Logic Diagrams 264

8.3 Programmable Logic Controllers 268

8.4 Personal Computers Using Soft Logic 275

Part Ⅱ: MATERIAL HANDLING AND IDENTIFICATION TECHNOLOGIES 281

Chapter 9 INTRODUCTION TO MATERIAL HANDLING 281

9.1 Overview of Material Handling Equipment 282

9.2 Considerations in Material Handling System Design 285

9.3 The 10 Principles of Material Handling 288

Chapter 10 MATERIAL TRANSPORT SYSTEMS 292

10.1 Industrial Trucks 293

10.2 Automated Guided Vehicle Systems 295

10.3 Monorails and Other Rail Guided Vehicles 302

10.4 Conveyor Systems 303

10.5 Cranes and Hoists 309

10.6 Analysis of Material Transport Systems 311

Chapter 11 STORAGE SYSTEMS 328

11.1 Storage System Performance 329

11.2 Storage Location Strategies 331

11.3 Conventional Storage Methods and Equipment 332

11.4 Automated Storage Systems 335

11.5 Engineering Analysis of Storage Systems 344

Chapter 12 AUTOMATIC DATA CAPTURE 357

12.1 Overview of Automatic Identification Methods 358

12.2 Bar Code Technology 361

12.3 Other ADC Technologies 370

PART Ⅲ：MANUFACTURING SYSTEMS 375

Chapter 13 INRODUCTION TO MANUFACTURING SYSTEMS 375

13.1 Components of a Manufacturing System 376

13.2 Classification of Manufacturing Systems 381

13.3 Overview of the Classification Scheme 388

13.4 Manufacturing Progress Functions (Learning Curves) 392

Chapter 14 SINGLE STATION MANUFACTURING CELLS 397

14.1 Single Station Manned Workstations 398

14.2 Single Station Automated Cells 399

14.3 Applications 404

14.4 Analysis of Single Station Cells 409

Chapter 15 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING 420

15.1 Part Families 422

15.2 Parts Classification and Coding 425

15.3 Production Flow Analysis 431

15.4 Cellular Manufacturing 434

15.5 Application Considerations in Group Technology 439

15.6 Quantitative Analysis in Cellular Manufacturing 442

Chapter 16 FLEXIBLE MANUFACTURING SYSTEMS 460

16.1 What is an FMS? 462

16.2 FMS Components 469

16.3 FMS Applications and Benefits 480

16.4 FMS Planning and Implementation Issues 485

16.5 Quantitative Analysis of Flexible Manufacturing Systems 487

Chapter 17 MANUAL ASSEMBLY LINES 514

17.1 Fundamentals of Manual Assembly Lines 516

17.2 Alternative Assembly Systems 523

17.3 Design for Assembly 524

17.4 Analysis of Single Model Assembly Lines 525

17.5 Line Balancing Algorithms 534

17.6 Mixed Model Assembly Lines 540

17.7 Other Considerations in Assembly Line Design 552

18.1 Fundamentals of Automated Production Lines 565

Chapter 18 TRANSFER LINES AND SIMILAR AUTOMATED MANUFACTURING SYSTEMS 566

18.2 Applications of Automated Production Lines 575

18.3 Analysis of Transfer Lines with No Internal Storage 579

18.4 Analysis of Transfer Lines with Storage Buffers 587

Chapter 19 AUTOMATED ASSEMBLY SYSTEMS 601

19.1 Fundamentals of Automated Assembly Systems 602

19.2 Design for Automated Assembly 606

19.3 Quantitative Analysis of Assembly Systems 610

PART Ⅳ：QUALITY CONTROL SYSTEMS 631

Chapter 20 INTRODUCTION TO QUALITY ASSURANCE 631

20.1 Quality Defined 633

20.2 Traditional and Modern Quality Control 635

20.3 Taguchi Methods in Quality Engineering 638

20.4 ISO 9000 648

Chapter 21 STATISTICAL PROCESS CONTROL 654

21.1 Process Variability and Process Capability 655

21.2 Control Charts 658

21.3 Other SPC Tools 667

21.4 Implementing Statistical Process Control 672

Chapter 22 INSPECTION PRINCIPLES AND PRACTICES 681

22.1 Inspection Fundamentals 682