Automation, Production Systems, and Computer-Integrated Manufacturing / Edition 3

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Overview

This book provides the most advanced, comprehensive, and balanced coverage on the market of the technical and engineering aspects of automated production systems. It covers all the major cutting-edge technologies of production automation and material handling, and how these technologies are used to construct modern manufacturing systems. Manufacturing Operations; Industrial Control Systems; Sensors, Actuators, and Other Control System Components; Numerical Control; Industrial Robotics; Discrete Control Using Programmable Logic Controllers and Personal Computers; Material Transport Systems; Storage Systems; Automatic Data Capture; Single Station Manufacturing Cells; Group Technology and Cellular Manufacturing; Flexible Manufacturing Systems; Manual Assembly Lines; Transfer Lines and Similar Automated Manufacturing Systems; Automated Assembly Systems; Statistical Process Control; Inspection Principles and Practices; Inspection Technologies; Product Design and CAD/CAM in the Production System; Process Planning and Concurrent Engineering; Production Planning and Control Systems; and Lean Production and Agile Manufacturing. For anyone interested in Automation, Production Systems, and Computer-Integrated Manufacturing.

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Editorial Reviews

Booknews
A text for advanced engineering students, with sections on automation and control technologies, material handling technologies, manufacturing and quality control systems, and manufacturing support systems. Includes example problems and exercises. This second edition offers expanded coverage of automation fundamentals, numerical control programing, group technology, and flexible manufacturing systems, in addition to many other topics. Material has been completely reorganized. This edition also includes 125 new quantitative problems, and historical notes describing the development and historical background of automation technologies. The author teaches industrial and manufacturing systems engineering at Lehigh University. Annotation c. Book News, Inc., Portland, OR (booknews.com)
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Product Details

  • ISBN-13: 9780132393218
  • Publisher: Prentice Hall
  • Publication date: 8/7/2007
  • Edition description: Older Edition
  • Edition number: 3
  • Pages: 840
  • Sales rank: 426,025
  • Product dimensions: 8.20 (w) x 10.10 (h) x 2.00 (d)

Meet the Author

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.

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Read an Excerpt

PREFACE:

Preface

The first edition of this book was published in 1980 under the title Automation, Production Systems, and Computer-Aided Manufacturing. A revision was published in 1987 with about 200 more pages and a slightly different title: Automation, Production Systems, and Computer Integrated Manufacturing. The additional pages expanded the coverage of topics like industrial robotics, programmable logic controllers, material handling and storage, and quality control. But much of the book was very similar to the 1980 text. By the time I started work on the current volume (technically the second edition of the 1987 title, but in fact the third generation of the 1980 publication), it was clear that the book was in need of a thorough rewriting. New technologies had been developed and existing technologies had advanced, new theories and methodologies had emerged in the research literature, and my own understanding of automation and production systems had grown and matured (at least I think so). Readers of the two previous books will find this new volume to be quite different from its predecessors. Its organization is significantly changed, new topics have been added, and some topics from the previous editions have been discarded or reduced in coverage. It is not an exaggeration to say that the entire text has been rewritten (readers will find very few instances where I have used the same wording as in the previous editions). Nearly all of the figures are new. It is essentially a new book.

There is a risk in changing the book so much. Both of the previous editions have been very successful for Prentice Hall and me. Manyinstructors have adopted the book and have become accustomed to its organization and coverage. Many courses have been developed based on the book. What will these instructors think of the new edition, with all of its new and different features? My hope is that they will try out the new book and find it to be a significant improvement over the 1987 edition, as well as any other textbook on the subject.

Specifically, what are the changes in this new edition? To begin with, the organization has been substantially revised. Following two introductory chapters, the book is organized into five main parts:

  1. Automation and control technologies: Six chapters on automation, industrial computer control, control system components, numerical control, industrial robotics, and programmable logic controllers.
  2. Material handling technologies: Four chapters covering conventional and automated material handling systems (e.g., conveyor systems and automated guided vehicle systems), conventional and automated storage systems, and automatic identification and data capture.
  3. Manufacturing systems: Seven chapters on a manufacturing systems taxonomy, single station cells, group technology, flexible manufacturing systems, manual assembly lines, transfer lines, and automated assembly.
  4. Quality control systems: Four chapters covering quality assurance, statistical process control, inspection principles, and inspection technologies (e.g., coordinate measuring machines and machine vision).
  5. Manufacturing support systems: Four chapters on product design and CAD/CAM, process planning, production planning and control, and lean production and agile manufacturing.

Other changes in organization and coverage in the current edition, compared with the 1987 book, include:

  • Expanded coverage of automation fundamentals, numerical control programming, group technology, flexible manufacturing systems, material handling and storage, quality control and inspection, inspection technologies, programmable logic controllers.
  • New chapters or sections on manufacturing systems, single station manufacturing systems, mixed-model assembly line analysis, quality assurance and statistical process control, Taguchi methods, inspection principles and technologies, concurrent engineering, automatic identification and data collection, lean and agile manufacturing.
  • Consolidation of numerical control into one chapter (the old edition had three chapters).
  • Consolidation of industrial robotics into one chapter (the old edition had three chapters).
  • The chapters on control systems have been completely revised to reflect current industry practice and technology.
  • More quantitative problems on more topics: nearly 400 problems in the new edition, which is almost a 50% increase over the 1987 edition.
  • Historical notes describing the development and historical background of many of the automation technologies.

With all of these changes and new features, the principle objective of the book remains the same. It is a textbook designed primarily for engineering students at the advanced undergraduate or beginning graduate levels. It has the characteristics of an engineering textbook: equations, example problems, diagrams, and end-of-chapter exercises. A Solutions Manual is available from Prentice Hall for instructors who adopt the book.

The book should also be useful for practicing engineers and managers who wish to learn about automation and production systems technologies in modern manufacturing. In several chapters, application guidelines are presented to help readers decide whether the particular technology may be appropriate for their operations.

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Table of Contents

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

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Preface

Preface

The first edition of this book was published in 1980 under the title Automation, Production Systems, and Computer-Aided Manufacturing. A revision was published in 1987 with about 200 more pages and a slightly different title: Automation, Production Systems, and Computer Integrated Manufacturing. The additional pages expanded the coverage of topics like industrial robotics, programmable logic controllers, material handling and storage, and quality control. But much of the book was very similar to the 1980 text. By the time I started work on the current volume (technically the second edition of the 1987 title, but in fact the third generation of the 1980 publication), it was clear that the book was in need of a thorough rewriting. New technologies had been developed and existing technologies had advanced, new theories and methodologies had emerged in the research literature, and my own understanding of automation and production systems had grown and matured (at least I think so). Readers of the two previous books will find this new volume to be quite different from its predecessors. Its organization is significantly changed, new topics have been added, and some topics from the previous editions have been discarded or reduced in coverage. It is not an exaggeration to say that the entire text has been rewritten (readers will find very few instances where I have used the same wording as in the previous editions). Nearly all of the figures are new. It is essentially a new book.

There is a risk in changing the book so much. Both of the previous editions have been very successful for Prentice Hall and me. Many instructors have adopted the book and have become accustomed to its organization and coverage. Many courses have been developed based on the book. What will these instructors think of the new edition, with all of its new and different features? My hope is that they will try out the new book and find it to be a significant improvement over the 1987 edition, as well as any other textbook on the subject. Specifically, what are the changes in this new edition? To begin with, the organization has been substantially revised. Following two introductory chapters, the book is organized into five main parts:

I. Automation and control technologies: Six chapters on automation, industrial computer control, control system components, numerical control, industrial robotics, and programmable logic controllers.

II. Material handling technologies: Four chapters covering conventional and automated material handling systems (e.g., conveyor systems and automated guided vehicle systems), conventional and automated storage systems, and automatic identification and data capture.

III. Manufacturing systems: Seven chapters on a manufacturing systems taxonomy, single station cells, group technology, flexible manufacturing systems, manual assembly lines, transfer lines, and automated assembly.

IV. Quality control systems: Four chapters covering quality assurance, statistical process control, inspection principles, and inspection technologies (e.g., coordinate measuring machines and machine vision).

V. Manufacturing support systems: Four chapters on product design and CAD/CAM, process planning, production planning and control, and lean production and agile manufacturing.

Other changes in organization and coverage in the current edition, compared with the 1987 book, include:

  • Expanded coverage of automation fundamentals, numerical control programming, group technology, flexible manufacturing systems, material handling and storage, quality control and inspection, inspection technologies, programmable logic controllers.
  • New chapters or sections on manufacturing systems, single station manufacturing systems, mixed-model assembly line analysis, quality assurance and statistical process control, Taguchi methods, inspection principles and technologies, concurrent engineering, automatic identification and data collection, lean and agile manufacturing.
  • Consolidation of numerical control into one chapter (the old edition had three chapters).
  • Consolidation of industrial robotics into one chapter (the old edition had three chapters).
  • The chapters on control systems have been completely revised to reflect current industry practice and technology.
  • More quantitative problems on more topics: nearly 400 problems in the new edition, which is almost a 50% increase over the 1987 edition.
  • Historical notes describing the development and historical background of many of the automation technologies.
With all of these changes and new features, the principle objective of the book remains the same. It is a textbook designed primarily for engineering students at the advanced undergraduate or beginning graduate levels. It has the characteristics of an engineering textbook: equations, example problems, diagrams, and end-of-chapter exercises. A Solutions Manual is available from Prentice Hall for instructors who adopt the book.

The book should also be useful for practicing engineers and managers who wish to learn about automation and production systems technologies in modern manufacturing. In several chapters, application guidelines are presented to help readers decide whether the particular technology may be appropriate for their operations.

Read More Show Less

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