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Forward This textbook series is published at a very opportunity time when the discipline of industrial engineering is experiencing a phenomenal growth in China academia and with its increased interests in the utilization of the concepts, methods and tools of industrial engineering in the workplace. Effective utilization of these industrial engineering approaches in the workplace should result in increased productivity, quality of work, satisfaction and profitability to the cooperation. The books in this series should be most suitable to junior and senior undergraduate students and first year graduate students, and to those in industry who need to solve problems on the design, operation and management of industrial systems. Gavriel Salvendy Department of Industrial Engineering, Tsinghua University School of Industrial Engineering, Purdue University April, 2002 Preface The first edition of this hook was published in lW;o under the title Automation, Production Systems, andComputer-A.ided Manufacturing. A revision was published in 1981 with about 200 more pages and a slightly different title:AutomarioR, Production Systems, and Computer Integrated Manufacturing. The additional pages expanded the coverage of topres like industrial robotics, programmable logic controllers, material handling and storage, and quality control. nut much of the hook was very similar to the 191';0lex I. By the time I started work on the current volume (technically the second edition of the 1'187 title, but in fact the third generation nfthc 19XOpublication). it was clear that the book was in need of a thorough rewriting, New technologies had heen developed and existing technologies had advanced. new theories and rnethodoirrgies had emerged in the re"'~lrch ]iterature.and my own understanding of automation and production systems had grown and matured (at least [ think so). Readers of the two previous books will find this new volume to be quite different (rom 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, I! is not an exaggeration to say that the entire text has been rewritten (readers will find very few instances where 1 have used the same wording as in the previous editions). Nearly all of the figures are new. II is essentially a new book. There is a risk in changing the book so much. Both ofthe previous edition, 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 hook. What will these instructors think of the new edition. with all of its new and different lean.res? My hope is that they will tryout the new book and find it to be a significant improvement over the 1987 edition, as wc·U as any othertextbook on the subject Specifically. what are the changes in this new edition?To hegin with, the organization has been substamiallv revised. Following two introductory chapters, the hook is organized into rive 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 Ill. MaQufacturing systems: Seven chapters on a manufacturing systems taxonomy, single st ation ce.Is. group tcchriologv, flexible manufacturing svsterns, manual assembly tines. transfer tines. and automated assembly. Preface xii 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/CA~, process planning, production planning and control, and lean production and agile manufacturing. Other changes in organization lYl;7 book.Include: and coverage in the current edition, compared with the • Expanded coverage of automation fundamentals, numerical group technology, flexible manufacturing systems, material quality control and inspection. inspection technologies, controllers. control programming, handling and storage, programmable logic • 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 engi neering, automatic identification and data collection, lean and agile manufacturing. • Consolidatinn of numerical control into one chapter (the old edition had three chapters). • Consolidation Chapters). of industrial robotics into one chapter • The chapters on control systems have been completely dustry practice and technology. (the old edition • More quantitative problems on more topics: nearly 4(X) problems which is almost a 50% increase over the 1987 edition. • Historical notes describing the development automation technologies. had three revised to reflect current in. in the new edition, and historical background of many of the 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 un. dergraduatc or beginning graduate levels. It has the characteristics of an eugineertng 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. III several chapters, application guidelines are presented to help readers decide whether the particular technology may be appropriate for their operations. Acknowledgments Several people should be mentioned for their contributions to the current edition. I am grateful to the following: Prof. G. Srinivasan of the Iridian Institute of Technology, Madras. India. for his thoughtful reviews of Chapters 15 and 16*; Prof. Kalyan Ghosh, Department of Mathematics and Industrial Engineering at Ecole Polytechnique in Montreal, Quebec, Canada. for his suggestions on topics for this new edition: Prof. Steve Goldman, Department of Philosophy here at Lehigh who reviewed Chapter 27 on lean and agile production. and Marcia Hamm Groover, who was very helpful in solving my computer problems for me (she is my-computes tutor" and my wife).l must also thank several graduate students here at Lehigh (past and present) whodirJ some of the research for the book for me: David Abcr, Jose Basto, Pongsak Dulyapraphant, Murat Erkoc, Peter Heugler, Charalambos Marengos, Brant Matthews, Jianbiao Pan. Hulya Sener, Steve Wang. and Tongquiang Wu. I am also grateful for the help and encouragement provided by several editors at Prentice Hall. namely Marcia Horton, Bill Stenquist, Laura Curless, and Scott Disanno. Finally, I am thankful to all of the instructors who adopted the two previous editions, thus making those books commercially successful so that Prentice Hall would allow me to prepare this new edition xiii About 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 include, full-time employment at Eastman Kodak Company as a \1anufacturing 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 mctuue manufacturing processes, metal cutting UlCcry automation and robotics, production systems, material handling, facilities planning, and work systems. He has received a number uf teaching awards, including the Albert Holzman Outstanding Educator Award from the Institute of Industrial Engineers (lIE). His publications include over 75 technical articles and papers which have appeared in Industrial Engineering, liE Transactions,NAMRC Proceedings,ASME Transactions,IEEE Spectrum, international Journal of Productirm Systems, Encyclopaedia Britannica,5ME 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 nave been translated into French, German, Korean, Spanish. Portuguese, Russian, Japanese, and Chinese. His book Fundamentals oj Modem Manufacturing received the 1996 lIE Joinl Publb"henAward 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 \1anufacturing Research Institute (NAMRI). He is a Fellow of lIE and SME. PREVIOUS BOOKS BY THE AUTHOR AUlQmation, Production Sys'tms, and Computer-Aided Manufacturing, Prentice Hall, 1980. CAD/CAM: Computer-Aided Design and Manufacturing, Prentice Hall, 1984 (co-authored with E. W. Zimmers, Jr.). Industrial Robotics: Technology, Programming, and Applications, McGraw-Hill, 1986 (co-authored with M, Weiss, R. Nagel. and N. Odrey) Automation, Production Systems, and Computer Intqp'ated Manufacturing. Prentice Hall, 1987 Fundamentals Hall, 1996 oj Modem Manufacturing: Materials, Processes, and Systems, Prentice Contents Chapter 1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 Chapter 2 MANUFACTlIRING OPERATIONS 2.1 2,2 2.3 2.4 2.5 PARTI: Chapter 3 40 4 5 Basic Elements of an Automated System Advanced Automation Functions 71 Levels of Automation 76 63 INDUSTRIALCONTROL SYSTEMS 79 Process Industries versus Discrete Manufacturing Industries Continuous versus Discrete Control 82 Computer Process Control 88 Forms of Computer Process Control % 80 SENSORS,ACTUATORS, AND OTHER CONTROL SYSTEMCOMPONENTS 5.1 5.2 5.3 5.4 5.5 Sensors 108 Actuators 111 Analog-to-Digital Conversion 112 Digital-lo-Analog Conversion 115 Input/Output Devices for Discrete Data 61 61 INTRODUCTION TO AUTOMATION 4.1 4.2 4.3 4.4 Chapter 24 Manufacturing Industries and Products 28 Manufacturing Operations 31 Product/Production Relationships 35 Production Concepts and Mathematical Models Costs of Manufacturing Operations 48 AUTOMATION AND CONTROL TECHNOLOGIES 3.1 3.2 3.3 Chapter Production System Facilities 2 Manufacturi~g Support Systems 7 Automation in Production Systems 9 Manual Labor in Production Systems 14 Automation Principles and Strategies 17 Organization of the Book 21 117 107 vi Contents Chapter 6 NUMERICAL CONTROL 120 ('.1 122 h' 6.3 6.4 137 65 14) h.h of Nt" Positioning Systems Chapter 6 APPENDIX: APT WORD Chapter 7 INDUSTRIAL ROBOTICS 8 7.1 7.2 7.3 7.4 7,) and Related Attributes 21H End Effectors Sensors in Robotics 222 Industrial Robot Applications 222 7,6 Rohol Chapter DO 10 11 267 Discrete Process Control 257 Ladder Logic Diagrams 2M Programmable Logic Controller268 Personal Computers Using Soh Logie 275 AND IDENTIFICATION 281 Overview 01 Material Handling Equipment 282 Considerations in Material Handling System Design Tile 10 Principles of Material Handling 288 MATERIAL TRANSPORTSYSTEMS 10.1 10.2 10.3 IDA 10.5 10.6 Chapler 240 INTRODUCTION TO MATERIAL HANDLING 9.1 9.2 9.3 Chapler Robots MATERIAL HANDLING TECHNOLOGIES 9 212 DISCRETECONTROL USING PROGRAMMABLE LOGIC CONTROLLERS AND PERSONALCOMPUTERS H.l S.2 RJ 8,4 Part II: 196 210 7.7 Chapter 179 DEFINITIONS 285 292 Industrial Trucks 293 Automated Guided Vehicle Systems 295 Monorails and Other Rail Guided Vehicles 302 Convevor Svstems 30J Crane; and Hoists 309 Analysis of Material Transport Systems 311 STORAGE SYSTEMS 11.1 StelragcSystemPerformance 329 11,2 Storage Location Strategies 331 11.3 Conventional Storage Methods and Equipment 328 332 vii Contents I1.4A~:::::;::::~,:S~O~:~:i~~; ~:~ 335 11.5 E Chapter 12 AUTOMATIC 344 357 DATA CAPTURE 12.1 Overview of Automatic Identification 12.2 Bar Code Technology 361 12.3 Other ADC Technologies 370 PART III: MANUFACTURING Chapter INTRODUCTION 13 13.1 13.2 13.3 13.4 Chapter 14 Chapter 1S Chapter 16 Chapter 17 397 398 AND CELLULAR MANUFACTURING 420 Part families 422 Parts Classification and Coding 425 Production Flow Analysis 431 Cellular Manufacturing 434 Application Considerations in Group Technology 439 Quantitative Analysis in Cellular Manufacturing 442 SYSTEMS 460 Whati~anF.\1S'! 462 FMS Components 469 FMS Applications and Benefits 480 FMS Planning and Irnplernentation Issues 485 Quantitative Analysis of Flexible Manufacturing Systems MANUALASSEMBLYUNES 17.1 [7.2 17.3 17.4 17.5 17.n 17.7 392 CELLS Single Station Manned Workstations Single Station Automated Cells 399 Applications 404 Analysis of Single Station Cells 409 FLEXIBLE MANUFACTURING 16.1 16.2 16.3 16.4 16.5 375 SYSTEMS Components of a Manufacturing System 376 Classification of Manufacturing Systems 381 Overview of' the Classification Scheme 388 Manufacturing Progress Functions (Learning Curves) GROUP TECHNOLOGY 15.1 15.2 15.3 15.4 15.5 15.6 358 SYSTEMS TO MANUFACTURING SINGLE STATION MANUFACTURING 14.1 14.2 14.3 14.4 Methods Fundamentals of Manual Assernhlv Lines 516 AlternativeA%emblySystcms 523 Design tor Assembly 524 Analysis of Single Model Assembly Lines S2S Line Balancing Algorithms 534 Mixed Mudd Assembly Lines 540 Other Considerations in Assembly Line Design 487 514 552 Contents viii Chapter 18 TRANSFER LINES AND SIMILAR AUTOMATED MANUFACtuRING 18.1 18.2 18.3 18.4 Chapter 19 SYSTEMS 566 Fundamentals of Automated Production lint's 565 Applications of Automated Production Lines 575 Analysis of Transfer Lines with No Internal Storage 579 Analysis of Transfer Lines with Storage Buffers 587 601 AUTOMATEO ASSEMBLY SYSTEMS 19.1 Fundamentals of Automated Assembly Systems 602 19.2 Design for Automated Assembly 606 19.3 Quantitative Analysis ofAsscmbly Systems 610 PART IV: Chapler 20 QUALITY CONTROL SYSTEMS INTRODUCTION 20.1 20.2 20.3 20.4 Chapfer 21 22 23 Process Variability and Process Capability Control Charts 658 Other SPC Tools 667 Implementing Statistical Process Control 655 672 INSPECTION PRINCIPLES AND PRACTICES 22.1 22.2 22.3 22.4 22.5 Chapter 631 63j 638 STATISTICAl PROCESS CONTROL 21.1 21.2 21.3 21.4 Chapter TO QUAUTV ASSUIlANCE Quality Defined 633 Traditional and Modern Quality Control Taguchi Methods in Quality Engineering ISO 9000 648 INSPECTION TECHNOLOGIES 23.1 23.2 23.3 23.4 23.S 23.6 23.7 23.8 681 Inspection Fundamentals 682 Sampling versus lOU'f, Inspection 6B7 Automated Inspection 692 When and Where to Inspect 694 Quantitative Analysis of Inspection 698 Inspection Metrology 712 Contact versus Noncontact Inspection Techniques 717 Conventional Measuring and Gaging Techniques 718 Coordinate Measuring Machines 720 Surface Measurement 736 Machine Vision 738 Other Optical Inspection Techniques 745 Noncontact Nonopticallnspection Technologies 747 711