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can be linked together via satellite communication links irrespective of the location of each center. Manufacturing centers can be located several hundred feet apart or several thousand miles apart. Adequate sensors and control systems together with effective communication links will provide practical real-time data analysis for further determination. The output of the cell is the product of the module of the flexible manufacturing system. It consists of a finished or semi-finished part as well as data in a computer-readable format that will instruct the next cell how to achieve its output requirement. The data are conveyed through the distributed communication networks. If, for example, a part is required to be surfaced to a specific datum in a particular cell, sensors will be adjusted to read the required acceptable datum during the surfacing process. Once the operation is successfully completed, the part must once again be transferred to another cell for further machining or inspection processes. The next cell is not necessarily physically adjacent; it may be the previous cell, as programmed for the required conversion process. The primary reason for the emphasis on integrating sensors and control systems into every manufacturing operation is the worldwide exponentially increasing demand for error-free production operations. Sensors and control technology can achieve impressive results only if effectively integrated with corporate manufacturing strategy. The following benefits can be achieved: Productivity. Greater output and a lower unit cost. Quality. The product is more uniform and consistent. Production reliability. The intelligent self-correcting sensory and feedback system increases the overall reliability of production. Lead time. Parts can be randomly produced in batches of one or in reasonably high numbers, and the lead time can be reduced by 50 to 75 percent. Expenses. Overall capital expenses are 5 to 10 percent lower. The cost of integrating sensors and feedback control systems into the manufacturing source is less than that of stand-alone sensors and feedback systems. Greater utilization. Integration is the only available technology with which a machine tool can be utilized up to 85 percent of the time and the time spent cutting can also be over 90 percent. In contrast, a part (from stock to finished item) spends only 5 percent of its time on the machine tool, and actual productive work takes only 30 percent of this 5 percent. The time for useful work on
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Active, % Tool positioning and tool changing Machining process Loading and inspection Maintenance Setup Idle time Total 85 25 5 15 20 15
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Idle, %
15 15
TABLE 2.1 Time Utilization of Integrated Manufacturing Center Carrying
Sensory and Control Systems
Active, % Machine tool in wait mode Labor control Support services Machining process Total 15 15
Idle, % 35 35 15
TABLE 2.2 Productivity Losses of Stand-alone Manufacturing Center
Excluding Sensory and Control Systems
stand-alone machines without integrated sensory and control systems is as little as 1 to 1.5 percent of the time available (see Tables 2.1 and 2.2). To achieve the impressive results indicated in Table 2.1, the integrated manufacturing system carrying the sensory and control feedback systems must maintain a high degree of flexibility. If any cell breaks down for any reason, the production planning and control system can reroute and reschedule the production or, in other words, reassign the system environment. This can be achieved only if both the processes and the routing of parts are programmable. The sensory and control systems will provide instantaneous descriptions of the status of parts to the production and planning system. If different processes are rigidly integrated into a special-purpose, highly productive system such as a transfer line for large batch production, then neither modular development nor flexible operation is possible. However, if the cells and their communication links to the outside world are programmable, much useful feedback data may be gained. Data on tool life, measured dimensions of machined surfaces by
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in-process gauging and production control, and fault recovery derived from sensors and control systems can enable the manufacturing system to increase its own productivity, learn its own limits, and inform the part programmers of them. The data may also be very useful to the flexible manufacturing system designers for further analysis. In nonreal-time control systems, the data cannot usually be collected, except by manual methods, which are time-consuming and unreliable.
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