Enhancing Manufacturing Flexibility with Fuzzy Logic and PLCs

Posted on Aug 3, 2024 in Design and Engineering

Manufacturing Overview

Definition and Scope

Manufacturing transforms raw materials into finished goods for sale, encompassing both complete and semi-manufacturing processes.

Key Functions

  • Product Design
  • Process Planning
  • Facility Setup and Material Flow
  • Production Operations
  • Production Planning and Control

OEM (Original Equipment Manufacturing)

OEM refers to companies that manufacture products or components for other companies to sell under their brand names.

Operational Strategy in Manufacturing

Operational strategy aligns production capacities with overall corporate strategy. It involves:

  • Strategic Decisions (Long-term): Setting the overall direction and goals for manufacturing operations.
  • Tactical Decisions (Medium-term): Determining how to implement the strategic decisions and allocate resources.
  • Operational Planning and Control (Short-term): Managing day-to-day production activities and ensuring smooth operations.

Production Philosophies

  1. Mass Production: Focuses on cost-efficiency through economies of scale and significant capital investment.
  2. Lean Production: Emphasizes quality, delivery, continuous improvement, and waste reduction through information systems and supply chain optimization.
  3. Agile Manufacturing: Prioritizes flexibility and responsiveness to changing customer demands, leveraging technology for rapid adaptation.
  4. Mass Customization: Combines the efficiency of mass production with the flexibility to offer customized products, often relying on intelligent systems.

Pioneers of Manufacturing

  • Eli Whitney: Introduced standardized parts through interchangeable components.
  • Frederick W. Taylor: Known as the “Father of Scientific Management,” he advocated for employee training, proper job placement, and incentive systems.
  • Frank & Lillian Gilbreth: Pioneered time and motion studies to improve efficiency.
  • Henry Ford: Revolutionized manufacturing with the assembly line and mass production techniques.
  • W. Edward Deming: Championed quality control methods, statistical process control, and employee involvement in decision-making.

Manufacturing Systems

Key Elements

  • Materials and Customers: Understanding customer needs and ensuring a steady flow of materials.
  • People, Plant, Parts, Processes: Optimizing human resources, facilities, components, and production methods.
  • Planning and Control: Establishing production schedules, managing inventory, and monitoring performance.
  • Products and Services: Delivering high-quality goods and services that meet customer expectations.

Market Requirements

  • External: Competitive pricing, delivery flexibility, short lead times, product innovation, and customization options.
  • Internal: High output, operational reliability, adaptability, quality, cost-effectiveness, speed, and dependability.

Production Systems Components

  • Support Systems: Procedures for managing production, materials, personnel, quality, and product lifecycle management (PLM).
  • Facilities: Physical infrastructure, equipment, and team organization.

Classification of Manufacturing Systems

  1. Manual Systems: Rely heavily on human labor.
  2. Worker-Machine Systems: Combine human skills with machine capabilities.
  3. Automated Systems: Utilize machines and technology to perform tasks with minimal human intervention.

Humans vs. Machines in Manufacturing

  • Humans Excel In: Adaptability, problem-solving, creativity, and handling unexpected situations.
  • Machines Excel In: Repetitive tasks, data storage and processing, speed, and consistent precision.

Production Support Systems

  • Business Functions: Integrate manufacturing processes with other business areas like design, planning, and control.
  • Product Design: Utilize software tools for product development and optimization.
  • Manufacturing Planning: Determine production schedules, resource allocation, and process optimization.
  • Production Control: Monitor production progress, track inventory, and make adjustments as needed.

Automation Levels

  • Fixed Automation: High production volume, low flexibility, suitable for fixed sequences of operations.
  • Programmable Automation: Moderate production volume, higher flexibility, allows for changes in operation sequences.
  • Flexible Automation: High production volume, high flexibility, enables the production of various parts or products with minimal changeover time.

SMED (Single Minute Exchange of Die)

A methodology for reducing setup times, aiming to complete changeovers in minutes rather than hours.

Advanced Manufacturing Technologies

  • CIM (Computer Integrated Manufacturing): Integrates computer systems for design, planning, control, and business functions.
  • CAD (Computer-Aided Design): Software for creating and modifying product designs.
  • CAM (Computer-Aided Manufacturing): Software for planning and controlling manufacturing processes.
  • CAD/CAM Integration: Seamlessly connects design and manufacturing processes.

Benefits and Considerations of Automation

Reasons to Automate

  • Increased productivity
  • Reduced costs
  • Mitigation of labor shortages
  • Elimination of repetitive manual tasks
  • Improved employee safety
  • Enhanced product quality
  • Reduced manufacturing lead times
  • Handling complex processes
  • Avoiding the high cost of not automating

When to Consider Alternatives to Automation

  • Tasks difficult to automate
  • Products with short lifecycles
  • Highly customized products
  • Variable demand
  • Need to minimize initial investment risks

USA Principle

A guideline for automation: Understand the process, Simplify it, then Automate it.

Automation Strategies

  • Specialist Operations: Automating specific tasks or workstations.
  • Combined Operations: Integrating multiple operations into a single automated cell.
  • Concurrent Operations: Performing operations simultaneously to reduce cycle time.
  • Operations Integration: Connecting different stages of the manufacturing process.
  • Increased Flexibility: Designing systems for adaptability and product variety.
  • Improved Material Handling and Storage: Automating material movement and storage systems.
  • Online Inspection: Integrating quality checks throughout the production process.
  • Process Control and Optimization: Using data and feedback to optimize process parameters.
  • Control of Plant Operations: Centralized monitoring and control of the entire manufacturing facility.
  • Computer Integrated Manufacturing (CIM): Achieving a fully integrated and automated manufacturing environment.

Phased Automation Implementation

  1. Phase 1: Manual Production Cells: Individual workstations operated independently by human workers.
  2. Phase 2: Automated Production Cells: Single-station cells with automated equipment.
  3. Phase 3: Integrated Production Systems: Multiple automated stations linked together for continuous flow.

Benefits of a Phased Approach

  • Faster introduction of new products
  • Gradual automation as demand increases
  • Reduced risk by avoiding over-automation

Increasing Flexibility in Material Handling

Article: Enhancing Material Handling with PLCs and Fuzzy Logic

This article explores the use of programmable logic controllers (PLCs) combined with fuzzy logic (IFL) to create intelligent material handling systems (IFLPLCs). This approach enhances flexibility and adaptability in factory environments.

By combining the capabilities of PLCs and fuzzy logic, manufacturers can achieve more responsive and efficient material handling processes, leading to improved overall productivity and responsiveness to dynamic production demands.