MANUFACTURING
IN A COMPETITIVE ENVIRONMENT
Automation of Manufacturing Processes
There are several levels of automation, from simple automation of
machines to untended manufacturing cell to-ultimately-the factory of the future.
Automation has been implemented successfully in manufacturing processes, material
handling, inspection, assembly, and packaging. Production quantity and rate are important
factors in determining the economical levels of automation. True automation began with the
numerical control machines, with has the capability of flexibility of operation, lower
cost, and ease of making different parts with lower operator skill. Manufacturing
operations are further optimized, both in quality and cost, by adaptive control
techniques, which continuously monitor the operation and make necessary adjustments in
process parameters.
Great advances have been in material handling, particularly in
implementation of industrial robots and automated guided vehicles. The role of sensors is
crucial in the implementation of these technologies, and a wide variety of sensors based
on various principles have been developed and installed. Other advances include flexible
fixturing and automated assembly techniques that reduce the need for worker intervention
and that lower manufacturing costs. The efficient and economic implementation of these
techniques requires that design for assembly, disassembly, and servicing be recognized as
an important factor in the total design and manufacturing process.
Computer-Integrated Manufacturing Systems
Computers already have had a major impact on all aspects of
manufacturing processes and operations. Integrated manufacturing systems are being
implemented to various degrees to optimize operations, reduce cost, and improve product
quality and productivity. Computer-integrated manufacturing has become the important mean
improving productivity, responding to changing market demand, and better controlling
manufacturing and management functions. With extensive use of computers and rapid
developments in sophisticated software, product designs and their analysis and simulation
are more detailed and thorough.
New developments in manufacturing operations, such as group
technology, cellular manufacturing, and flexible manufacturing systems, are contributing
significantly to improved productivity. Artificial intelligence is likely to open new
opportunities in all aspects of manufacturing engineering. The factory of the future will
extend these developments further, while their benefits and economic justification
continue to be debated at all level of management and the workforce.
Competitive Aspects of Manufacturing
Competitive aspects of production an costs are among
the most significant consideration in manufacturing. Regardless of how well the product
meets design specification and quality standards, it must also meet economic criteria in
order to be competitive in the domestic and global marketplace. The total of product
includes several elements, such as costs of material, tooling, capital, labor, and
overhead. Material costs can be reduced through careful selection so that the least
expensive material can be identified and selected, while maintaining design and service
requirements, functions, and specification for good product quality.
Substitution of materials, modification of designs, and relaxing of
tolerance and surface finish requirements are important methods of cost reduction. Certain
guidelines for designing products for economic production have been established. Although
labor costs are becoming a small percentage of product costs, they can be reduced further
through the use of automated and computer-controlled machinery. Automation requires
significant capital expenditures; however, s well-planned production facility can
significantly improve productivity.
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