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Networking of Sensors and Control Systems in Manufacturing
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to details of the equipment s operation in an error-free environment. Relationships must be developed between the physical description of the equipment s operation and the functional parameters that will be associated with this operation. The objective is to link together the physical design of the equipment and its functional performance through sensory and control systems in the factory setting. This concept provides insight into an area in which future manufacturing system improvements would be advantageous, and also suggests the magnitude of the cost-benefit payoffs that might be associated with various equipment designs. It also reveals the operational efficiency of such systems. An understanding of the relationships between the equipment characteristics and the performance parameters based on sensors and control systems can be used to select the best equipment for the parameter requirements associated with a given factory configuration. In this way, the manufacturing design team can survey alternative types of available equipment and select the units most appropriate for each potential configuration.
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4.2 The Number of Products in a Flexible System
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The first parameter listed earlier, the number of product categories for which the manufacturing system can be used, represents the key concern in flexible manufacturing. A unit of automated manufacturing equipment is described in terms of the number of product categories for which it can be used with only a software download to distinguish among product types. A completely fixed automated manufacturing system that cannot respond to computer control might be able to accommodate only one product category without a manual setup. On the other hand, a very flexible manufacturing system would be able to accommodate a wide range of product categories with the aid of effective sensors and control systems. This parameter will thus be defined by the breadth of the processes that can be performed by an automated manufacturing equipment unit and the ability of the unit to respond to external control data to shift among these operations. The most effective solution will depend on the factory configuration that is of interest. Thus, OEMs are always concerned with anticipating future types of factories in order to ensure that their equipment will be an optimum match to the intended configuration. This also will ensure that the concept of error-free manufacturing can be implemented with a high degree of spontaneity. A continual tradeoff exists between flexibility and cost. In general, more flexible and smarter manufacturing equipment will cost more. Therefore, the objective in a particular setting will be to achieve just the required amount of flexibility, without any extra capability built into the equipment unit.
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Sensors Tracking the Mean Time between Operator Interventions
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The MTOI value should be matched to the factory configuration in use. In a highly manual operation, it may be acceptable to have an operator intervene frequently. On the other hand, if the objective is to achieve operator-independent manufacturing between manual setups, then the equipment must be designed so that the MTOI is longer than the planned duration between manual setups. The manufacturer of automated equipment with adequate sensors and control systems must try to assess the ways in which factories will be configured and produce equipment that can satisfy manufacturing needs without incurring any extra cost due to needed features.
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Each time an intervention is required, it is desirable to compare the intervention interval with that for which the system was designed. If the intervention time becomes large with respect to the planned mean time between operator interventions, then the efficiency of the automated manufacturing equipment drops rapidly in terms of the fraction of time it is available to manufacture the desired product.
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4.5 Sensors Tracking Yield
In a competitive environment, it is essential that all automated manufacturing equipment emphasize the production of quality product. If the automated manufacturing equipment produces a large quantity of product that must be either discarded or reworked, then the operation of the factory is strongly affected, and costs will increase rapidly. The objective, then, is to determine the product yields required for given configurations and to design automated manufacturing equipment containing sensors and control systems that can achieve these levels of yield. Achieving higher yield levels will, in general, require additional sensing and adaptability features for the equipment. These features will enable the equipment to adjust and monitor itself and, if it gets out of alignment, to discontinue operation.
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