Automation, Production Systems, and Computer-Integrated Manufacturing

by Mikell Groover

Overview

For advanced undergraduate/graduate-level courses in Automation, Production Systems, and Computer-Integrated Manufacturing.

Provides the most up-to-date coverage of automated production systems

Automation, Production Systems, and Computer-Integrated Manufacturing provides up-to-date coverage of production systems, how they are sometimes automated and computerized, and how they can be mathematically analyzed to obtain performance metrics. The text is designed primarily for engineering students at the advanced undergraduate or beginning graduate levels in industrial, mechanical, and manufacturing engineering. The book is also useful for practicing engineers and managers who wish to learn about automation and production systems technologies in modern manufacturing.

This exploration of the technical and engineering aspects of automated production systems provides the most advanced, comprehensive, and balanced coverage of the subject of any text on the market. 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. The 5th Edition has consolidated and reorganized many of the topics, eliminated material that is no longer relevant, and revised end-of-chapter problems.

Product Details

ISBN-13:	9780134605463
Publisher:	Pearson Education
Publication date:	07/13/2018
Edition description:	New Edition
Pages:	816
Product dimensions:	8.10(w) x 10.10(h) x 1.30(d)

About the Author

About our author

Mikell P. Groover is Professor Emeritus of Industrial and Systems Engineering at Lehigh University, where he taught and did research for 44 years. He received his B.A. in Arts and Science (1961), B.S. in Mechanical Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from Lehigh. His industrial experience includes several years as a manufacturing engineer before embarking on graduate studies.

His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems. He has received a number of teaching awards at Lehigh University, as well as the Albert G. Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001). His publications include over 85 technical articles and books. His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean and Chinese. The 1st edition of Fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996).

Dr. Groover is a member of the Institute of Industrial Engineers (IIE) and the Society of Manufacturing Engineers (SME). He is a Fellow of IIE and SME.

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.

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 About This 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

•Chapter 3 MANUFACTURING METRICS AND ECONOMICS

•3.1 Production Performance Metrics
•3.2 Manufacturing Costs

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
•4.4 Automation and Artificial Intelligence

•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—Digital Conversions
•6.4 Input/Output Devices for Discrete Data

•Chapter 7 COMPUTER NUMERICAL CONTROL

•7.1 Fundamentals of NC Technology
•7.2 Computers and Numerical Control
•7.3 Applications of NC
•7.4 Analysis of Positioning Systems
•7.5 NC Part Programming
•7.6 CNC Trends and Developments
•Appendix 7A: Coding for Manual Part Programming

•Chapter 8 INDUSTRIAL ROBOTICS

•8.1 Robot Anatomy and Related Attributes
•8.2 Robot Control Systems
•8.3 End Effectors
•8.4 Applications of Industrial Robots
•8.5 Economic Justification of Industrial Robots
•8.6 Robot Programming
•8.7 Robot Accuracy and Repeatability

•Chapter 9 DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS

•9.1 Discrete Process Control
•9.2 Ladder Logic Diagrams
•9.3 Programmable Logic Controllers
•9.4 Personal Computers and Programmable Automation Controllers

PART III MATERIAL HANDLING AND IDENTIFICATION

•Chapter 10 MATERIAL TRANSPORT SYSTEMS

•10.1 Overview of Material Handling
•10.2 Material Transport Equipment
•10.3 Analysis of Material Transport Systems

•Chapter 11 STORAGE SYSTEMS

•11.1 Overview to Storage Systems
•11.2 Conventional Storage Methods and Equipment
•11.3 Automated Storage Systems
•11.4 Analysis of Storage Systems

•Chapter 12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE

•12.1 Overview of Automatic Identification Methods
•12.2 Bar Code Technology

PART IV MANUFACTURING SYSTEMS

•Chapter 13 OVERVIEW OF MANUFACTURING SYSTEMS

•13.1 Components of a Manufacturing System
•13.2 Types of Manufacturing Systems

•Chapter 14 SINGLE-STATION MANUFACTURING CELLS

•14.1 Single-Station Manned Cells
•14.2 Single-Station Automated Cells
•14.3 Applications of Single-Station Cells
•14.4 Analysis of Single-Station Cells

•Chapter 15 MULTI-STATION MANUFACTURING SYSTEMS: 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 Workstation Details
•15.5 Other Considerations in Assembly Line Design
•15.6 Alternative Assembly Systems
•Appendix 15A Batch-Model and Mixed-Model Lines

•Chapter 16 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED PRODUCTION LINES

•16.1 Fundamentals of Automated Production Lines
•16.2 Applications of Automated Production Lines
•16.3 Analysis of Transfer Lines
•Appendix 16A Transfer Lines with Internal Storage

•Chapter 17 AUTOMATED ASSEMBLY SYSTEMS

•17.1 Fundamentals of Automated Assembly Systems
•17.2 Analysis of Automated Assembly Systems

•Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING

•18.1 Part Families and Machine Groups
•18.2 Cellular Manufacturing
•18.3 Applications of Group Technology
•18.4 Analysis of Cellular Manufacturing
•Appendix 18A Opitz Parts Classification and Coding System

•Chapter 19 MULTI-STATION MANUFACTURING SYSTEMS: AUTOMATED FOR FLEXIBILITY

•19.1 Manufacturing Flexibility Defined
•19.2 Components of an FM
•19.3 Analysis of Flexible Manufacturing Systems
•19.4 Alternative Approaches to Flexible Manufacturing

PART V QUALITY CONTROL 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 Taguchi Methods in Quality Engineering
•20.7 ISO 9000
•Appendix 20A The Six Sigma DMAIC Procedure

•Chapter 21 INSPECTION PRINCIPLES AND PRACTICES

•21.1 Inspection Fundamentals
•21.2 Sampling versus 100% Inspection
•21.3 Automated Inspection
•21.4 When and Where to Inspect
•21.5 Analysis of Inspection Systems

•Chapter 22 INSPECTION TECHNOLOGIES

•22.1 Inspection Metrology
•22.2 Conventional Measuring and Gaging Techniques
•22.3 Coordinate Measuring Machines
•22.4 Surface Measurement
•22.5 Machine Vision
•22.6 Other Optical Inspection Methods
•22.7 Noncontact Nonoptical Inspection Techniques
•Appendix 22A Geometric Feature Construction

PART VI MANUFACTURING SUPPORT SYSTEMS AND COMPUTER-INTEGRATED MANUFACTURING

•Chapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM

•23.1 Product Design and CAD
•23.2 CAM, CAD/CAM, and CIM

•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 Manufacturing Resource Planning (MRP II)
•25.7 Enterprise Resource Planning (ERP)

•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

Appendix

•Answers to Selected Problems
•

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.

Editorial Reviews

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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