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A dynamic manufacturing operation.
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Then the data will be fed back to the database and compared with data for the workpiece that are to be machined, and full dimensional data on the workpiece will be accessed. The vision sensor will then scan the workpiece, and its dimensions will be compared with those of the finished part in the parts library. The data will then be fed back to the controller, which will instruct the machine how to start machining, by reference to the database and not to a specific program. When necessary, the workpiece will be transferred to other places for automatic heat treatment or grinding, and later to assembly. In this way, machining without programming and without manual intervention will be practical. Lathes are unlikely to need such a control system, and instead, the database would contain a vast number of programs, the best one being selected
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automatically for the shape of the component to be produced. Of course, these advanced systems in controls and sensors would not be needed to produce all components, nor would they be installed in all flexible manufacturing systems. Lower-level machines would still continue in use for more routine, medium-volume parts. However, in planning for flexible manufacturing systems with computer-integrated manufacturing strategies, managers need to take this sort of development into account. In assembly, a similar sensor and control system could come into use, except that there will be more stages, because of the need to provide the right group of components in suitable positions to be assembled. One handling robot, on a trolley, might be used to supply components to the assembly cell, where some robots and standard units, such as presses and CNC nut runners, would carry out assembly. With the combination of these expert systems and sensors and control systems, flexible manufacturing systems will be able to machine or assemble in batches of one with the efficiency expected in high-volume production runs. Thus, the real aims of flexible manufacturing systems high productivity in small batches, produced within a very short time after the order is placed will be achieved. The other major development is in computer systems for functions from purchasing through delivery. All the systems will be connected together, and will perhaps be incorporated in one computer (which will have voice recognition and voice response), so that for most jobs the keyboard will be unnecessary. Indeed, by the end of this decade, computers with conventional languages and vocal human/ machine interfaces should be available. Anyone will be able to program and make the most complex transactions using normal conversation, so the problem of computer illiteracy will disappear. People will also have access to databases of products, materials, and stock and to expert systems on costing and other relevant subjects. In the case of production control and order processing, this means that, once an order is accepted, the data will be fed to the CAD system, where the designer will produce a new design, modify a design, or merely call up an existing design. Planning will be automatic; from the data generated, the schedule will be produced and components and materials ordered. On arrival, they will be fed through the system to be packed and delivered with hardly any manual intervention. Needless to say, the materials will not wait around in a storeroom, but will come straight off the delivery truck into the system to be processed. Overall, therefore, we are at the beginning of an era which will lead to the end of the factory as we know it. Some machines will be able to carry out simple routine maintenance themselves through advanced sensory and control systems. Very complex robots with a number of sensors will be available to carry out repairs, so that, in theory, operators will be needed only to work with the software in
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