单一工作站制造单元.ppt

1、,Chapter 14: Single Station Manufacturing Cells單一工作站製造單元,Instructor：劉天倫 老師,Introduction,Classification Type I M Type I A Planning issues 規畫議題 How many workstations are required? 需要多少工作站 How many machines can be assigned to one worker? 多少機器可能被分發給一名工人,14.1 Single Station Manned Cells 由人操縱的之單一工作站,Chara

2、cteristics特性 Shortest time to implement最短的時間建置 Least capital investment最小資本投資 Easiest system to operate最容易操作的系統 Lowest cost for low quantity production 對少量生產花最低的成本 Most flexible with regard to changeover 對於切換程序非常具有彈性,14.1 Single Station Manned Cells,Variation examples (from one-on-one)變化例子 n=1, w1 M

3、anipulate heavy forgings操作沉重的鍛爐工作 welder and fitter 焊工和配對者 Assemble large pieces of machinery 裝配大的機器,14.2 Single Station Automated Cells 單一自動化工作站,Reasons原因 Labor cost is reduced人工成本被降低 Least expensive among automated mfg system在自動化的製造系統中最不昂貴 Production rates are higher 生產率可提高 The first step in imple

4、menting a multi-station automated system 實現一個多工作站自動化系統過程中的第一步 Supporting equipment支援設備 A robot loading and unloading in the production machine.機器人在生產過程中裝載和卸載 Parts-feeding devices in a single robot assembly cell零件供給的設備,14.2.1 Enablers for Unattended Cell Operation 無須人照顧的單元作業的可行因子,For single model an

5、d batch model 對于單一模型和批量模型來說 Programmed cycle 程式化的週期 Perform every step Parts storage subsystem 零件貯存子系統 One for starting workparts and one for the completed parts. Automated transfer of workparts 自動化的工件轉移 Periodic attention 週期性的注意 Built-in safeguards 內建保護機制 Detect the condition that is destructive to

6、 machine or parts,14.2.1 Enablers for Unattended Cell Operation,For mixed model (additional enablers)對于混合模型來說 Work identification subsystem 工件辨識子系統 Sensors, bar codes, etc. Program downloading capability 程式下載能力 Quick setup changeover capability 迅速的安裝切換能力,14.2.2 Parts Storage Subsystem and Automated

7、Parts Transfer 零件貯儲存子系統與自動化零件轉送,Unattended time無需在場的時間 np: parts storage capacity 零件儲存量 Operational objectives in designing UT 設計UT在作業上的目標 A fixed time interval 固定的時間間隔 The time between scheduled tool changes 配合排程好的工具更換時間 One complete shift 一個完整的輪班 Overnight operation整夜操作方式,14.2.2 Parts Storage Subs

8、ystem and Automated Parts Transfer,Storage capacity of one part需一個工件的儲存容量 Automatic parts transfer mechanism operating with manual loading/unloading 人工裝/卸的操作方式之自動化零件轉送機構 Example: two-position automatic pallet changer (APC) 二位置的自動化平板互換機構,14.2.2 Parts Storage Subsystem and Automated Parts Transfer,Ove

9、rall cycle time (Tc) No storage (np=0) Tm : machine processing time 機器處理時間 Ts : worker service time 工人服務時間 (loading/unloading) One part storage capacity (np=1) Tr : repositioning time 重新定位的時間 In general, Ts Tm,14.2.2 Parts Storage Subsystem and Automated Parts Transfer,storage greater than one (np 1

10、) 儲存量大於1,14.2.2 Parts Storage Subsystem and Automated Parts Transfer,Industrial robot 工業機器人 Alternative to perform loading/unloading 執行裝/卸的另一選擇 Gripper instead of pallet fixtures 裝取器取代平板夾具 Type I A assembly system IA類型裝配系統 Storage for parts and assembled work unit 需考慮零件與組裝件的貯存 Chapter 19 第19章 自動化裝配系

11、統 再介紹,14.3 Application of Single Station Cells,CNC machining center 電腦數值控制切削加工中心 Designed with features 設計所需特徵 Automatic tool-changing 自動的更換工具 Automatic workpart positioning 自動的工件定位 Automatic pallet changer 自動的平板更換機構 Figure 14.1 (如前圖 14.1),14.3 Application of Single Station Cells,Stamping Press 壓製機,

12、14.3 Application of Single Station Cells,CNC turning center 電腦數值控制車削加工中心,14.3 Application of Single Station Cells,Mill-turn center 銑削車削加工中心 5 axes processing 五軸加工 x-axis z-axis Workparts orientation Rotational tools manipulation (2-axes),14.4 Analysis of Single Station Systems,Number of workstations

13、 required Workload (hr)工作量 The total hours required to complete a given amount of work要求完成規定的工作量的總小時數 Number of stations 工作站的數量 AT: available time on one station 一個工作站的可用時間,14.4 Analysis of Single Station Systems,Affected factors 影響(上述理論值計算)的因素 Setup time in batch production 在成批生產的準備時間 Availability

14、可用性 Utilization 使用情形 Worker efficiency 工人效率 Defect rate 缺陷比率,14.4 Analysis of Single Station Systems,Availability and utilization T: actual clock time Worker efficiency (Ew) Defect rate (q) Q : quantity of good units 良品數量 Qo: original quantity 原先的數量 Revised workload 修正後工作量計算,14.4.2 Machine Clusters

15、機器群,Machine Cluster 機器群 A collection of two or more machines producing identical parts/products and is serviced by one worker.集合兩台或更多機器，生產相同的零件/ 產品，並且被一名工人所服務。 Applying to semi-automated machines 應用於半自動化機器 Type I classification Machine cell 機器組 Consists of one or more machines producing a family of

16、parts/products.由一台或更多機器生產一個零件 / 產品的族群 Type II classification,14.4.2 Machine Clusters,Conditions to organize a machine cluster組織一機器群的條件 Machine cycle is long relative to the workers service.機器工作週期相較於工人服務時間是很長的 Machine cycle time is the same機器工作週期相同 Machines are close enough for the worker機器對工人來說夠近 Th

17、e work rules permit a worker to service more than one machine.工作守則允許一名工人檢修不止一台機器,14.4.2 Machine Clusters,A perfectly balanced machine cluster 一個完全平衡的機器群 n: number of machinesTs: worker service time Tm: machine cycle timeTr: worker repositioning time How to decide n as an integer? 怎樣決定n的整數 Applying Cost factors CL and Cm,14.4.2 Machine Clusters,Case 1: n1 = maximum integer最大的整數 n The worker will have idle time 工人將有閑置時間 Tc = Tm + Ts Cpc(n1): cost per work unit 每個工件單位成