Write short notes on automated flow lines.

Q6. Write short notes on automated flow lines.

Answer:

When several automated machines are linked by a transfer system which moves the parts by using handling machines which are also automated, we have an automated flow line.

After completing an operation on a machine, these mi-finished parts are moved to the next machine in the sequence determined by the process requirements and a flow line is established. The parts at various stages from raw material to ready for fitment or assembly are processed continuously to attain the required shapes or acquire special properties to enable them to perform desired functions. The materials need to be moved, held, rotated, lifted, and positioned for completing different operations. Sometimes, a few of the operations can be done on a single machine with a number of attachments. They are moved further to other machines for performing further operations. 

 

Human intervention may be needed to verify that the operations are taking place according to standards. When these can be achieved with the help of automation and the processes are conducted with self-regulation, we will have automated flow lines established.

The main consideration is to balance times that different machines take to complete the operations assigned to them. It is necessary to design the machines in such a way that, the operation times are the same throughout the sequence in the flow of the martial. In fixed automation or hard automation, where one component is manufactured using several operations and machines, it is possible to achieve this condition. We assume that product life cycles are sufficiently stable to invest heavily on the automated flow lines to achieve reduced cost per unit. The global trends are favoring flexibility in the manufacturing systems. The costs involved in changing the set up of automated flow lines are high. 

 

So, automated flow lines are considered only when the product is required to be made in high volumes over a relatively long period. Designers now incorporate flexibility in the machines which will take care of small changes in dimensions by making adjustments or minor changes in the existing machine or layout. The change in movements needed can be achieved by programming the machines. Provisions for extra pallets or tool holders or conveyors are made in the original design to accommodate anticipated changes.

The logic to be followed is to find out whether the reduction in cost per piece justifies the costs of designing, manufacturing, and setting up automated flow lines. Group Technology and Cellular Manufacturing along with conventional Product and Process Layouts are still resorted to, as they allow flexibility for the production system. As the methodologies of JIT and Lean Manufacturing have become important and relevant in manufacturing, many companies have realized that well designed flow lines suit their purpose well. Flow lines compel engineers to put in place equipment that balance their production rates. It is not possible to think of inventories (Work In Process) in a flow line. 

 

Bottlenecks cannot be permitted. By necessity, every bottleneck gets focused upon and solutions found to ease them. Production managers see every bottleneck as an opportunity to hasten the flow and reduce inventories. However, it is important to note that setting up automated flow lines will not be suitable for many industries.