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P1: Explain how computers are used in manufacturing systems
P1: Explain how computers are used in manufacturing systems
The manufacturing industry uses computers integrated into machining systems for a range of applications, some examples of this are:
CNC means computer numerical code generated by a computer in order to operate the following machining examples:
3,4,5-axis CNC machines- Computers are used in operating multi-axis CNC machines to accurately and efficiently control the movement of the cutting tools used. 3-axis CNC machines are used for simple manufacturing tasks and operates along the X, Y, Z axes. 4-axis machines add rotation on the X-axis which allows more complicated cuts to be made without repositioning the workpiece. 5-axis CNC machines add rotation to the X and Y axes to gain the ability of cutting more detailed, intricate, complex shapes.
Milling- milling machines rely on computers in multiple ways, for example: CAM (Computer-Aided Manufacturing) software is used to receive designs from CAD software and interpret them into precise movements which allows for components from a range of industries (e.g. automotive, aerospace and medical) to have intricate detailing, high precision and specific parameters.
Turning- in turning, computers use CNC to control the lathe which rotates the whilst using a stationary cutting tool to shape it. The computer's role here is to manage the movement of the tools along th X, Y, Z axes to achieve the desired dimensions and surface finish. Turning is often used to produce cylindrical parts.
Boring- CNC boring machines use computers to control the boring tools which are used to enlarde pre-existing holes in a workpiece with high precision. The computer ensures accurate positioning and movement of the tool allowing for consistent and repeatable results, which increases the reliability of this method. This process is essential in industries that require high precision hole dimensions.
Centre machines- these machines combine operations such as milling, drilling and tapping all into one single automated process. Computers can control these multi-functional machines by coordinating different tools and movements in order to streamline production and reduce the need for multiple set ups which can be time consuming.
Welding fabrications machines- computers control these machines in order to operate the welding process to ensure precise, consistent and efficient welds. The computer manages a multitude of parameters including: welding-speed, torch position and movement in order to produce high-quality welds. These machines are useful for the fabrication of complex assemblies where accuracy and repeatability are critical such as in the aerospace industry.
Automation Systems
Automation Systems
In automation systems, factories increase efficiency by reducing input and human intervention by automating operations. It utilises CPUs and sensors to analyse data. Robots use this analysis to manufacture products whilst keeping the high quality stardards of parts, which reduces manual labour costs and increases the precision of the product therefore increasing final product value. These systems are used to monitor the robots, ensuring they are functioning correctly, and if not an alert can be sent to an engineer who can address the issue, this reduces the overall production efficiency.
Types of automation systems are: hydraulic, electric and pneumatic. (see images to the right)
The sensors that monitor factory operations use electric automation systems to detect parameters. Programmable Logic Controllers (PLC) use code programmed to control machine operations. This reduces human intervention by using engineers to monitor processes rather than operate the machinary which increases efficiency, accuracy and precision by automating complex tasks.
Computers are used in hydraulic systems to coordinate hydraulic operations and integrate automation systems. They are also used to collect and analyse data by using predictive maintenance, monitoring performance to improve processes. This can be used in machinary such as hydraulic pumps, actuators and valves which use automation to provide consistent power to the hydraulic system, control movements and hydraulic flow. The automation of these processes is what creates accuracy and precision in the product
Pneumatic systems can be used to check how accurate and consistent the product is. Having high product precision is crucial in manufacturing as it ensures products are to tolerances and specifacations, slight deviations could affect performance and safety of the product in industries such as automotive, aerospeace or medical.
PLCs are used in these systems to enhance, control, efficiency and integration of automation in manufacturing processes. Computers can manage and navigate operations through PLC systems, doing this also has the advantage of simulateously collecting data and analyse it to increase performance optimisation.
Computer-Aided Planning
Computer-Aided Planning
Computer Aided Planning is a software used by engineers to design and optimise the production process, improving efficiency and overall effectiveness of the product production process. One use of this software is that it helps engineers to allocate resources (e.g. materials, labour, machinary, etc.) to maximise productivity and scheduling. This helps to streamline production ensuring efficiency by analysing data to ensure materials are not out of stock and keeping projects on track, e.g. maufacturing tasks can be completed on time by monitoring this machine and data. Another use of this software is quality control. This involves monitoring and evaluation aspects of production to ensure product standards and requirements are met to maintain consistent quality. This can be done by identifying any defects or variations in order to correct them in the future.
Additive vs. Subtractive Manufacturing
Additive vs. Subtractive Manufacturing
Additive and subtractive manufacturing are often used hand-in-hand due to the different approaches being very useful for different operations or finishes on physical objects. An example of additive manunfacturing is 3D printing, an example of subtractive manufacturing is machines that use CNC code such as multiple axis CNC machines.
Addivitve manufacturing is when material is added onto a surface, e.g. in 3D printing materials such as resin, plastic or metal is deposited layer by layer to make a 3-dimensional object from a digital model (CAD). Two key benefits of additive manufacturing is its ability to produce complex geometry which would otherwise be near impossible to make traditionally, and that it has the potential to reduce waste by only using the exact measurements to manufacture parts. However an issue with this manufacturing type is that it can be time consuming compared to conventional techniques which makes it less suitable for high-volume production.
Subtractive manufacturing involves material being taken away from a solid block or workpiece to create the desired shape using methods such as milling, turning or drilling. This is done by using tools and machinary such as CNC machines to precisely cut away material according to a digtial model. Two key benefits of using this manufacturing method is its ability to have consistently high precision and surface finish which makes it an ideal option for complex parts, and its suitability for working with a range of materials. However one issue with this is that it generates a large amount of waste as excess material is cut away and discarded which can be an inefficient and costly alternative.
Additive maufacturing is useful for producing complex geometries with minimal waste product which makes it a more environmentally manufacturing method, and useful for creating prototypes and low-volume parts however it becomes less effective when the slow-production rate and limited material choices are taken into account. On the other hand, whilst subtractive manufacturing provides high production rate and range of material choice without changing the product, it produces a lot of waste product which makes it less environmentally friendly and a costly alternative.
Robotics
Robotics
Robotics are used in manufacturing to perform repetitive, precise and potentially dangerous tasks with high efficency and accuracy. Robots handle operations such as assembly, welding, painting, etc. which enhances productivity and reducing labour costs, thereby reducing human error and workplace injuries. Advanced robotics with integrated AI are used to monitor operations enabling predictive maintenence.
Systems and Control
Systems and Control
In manufacturing systems machines use mathematical code to program the processes, some examples of these systems are hydraulic, electric and pneumatic.
Electrical systems involve the use of electrical devices to control systems by powering and automating machinary and processes. These systems can interlink robots as they are on a network which allows robotic arms to move and feed back data.
Hydraulic systems use pressurised fluids to control the amount of energy an actuator recieves which allows for precise control of force and movement in tasks like stamping or molding where high power is essential.
Pneumatic systems use compressed air to power and control machinary and is used when tasks need less force than hydraulic systems but still require high speed and precision
PLCs are a key component in the control of automation systems. Signals are sent to machinary such as robotic arms via the CPU. Using PLCs in these systems ensures safety protocols and provides a consistent and adaptable tool in manufacturing.
Computer-Aided Process Planning
Computer-Aided Process Planning
Computers are used in the planning and development stages of a product (CAPP) to increase efficiency and streamline the production process . This approach means more products can be made per hour which means an increase in profit.
Production planning is the process of coordinating aspects of manufaturing to ensure efficient production. It determines scheduling taking into account inventory levels, machinary and labour.
Resource management allocates resources to efficiency and productivity by use of materials, labour and equipment, thereby increasing optimisation of resources. This ensures resources are available and used effectively to meeet production targets and minimise waste.
Data and database management involves organising and effectively storing and maintaining data such as production data, inventory levels and customer information which ensures accuracy, security and accessibility
Automated ordering systems streamline the production process by automaating orders for matterials and supplies which ensures replenishment, a reduction in manual effort and the maintanance of stock levels.
Production and supplier management coordinates activities integrated into production facilities to ensure an efficient supply chain. This includes tracking deliveries and maintaining strong communication with suppliers to meet demands.
Integrated manufacturing systems combine various manufacturing processes into one cohesive, automated system which enhances coordination, reduces production time and improves overall efficiency as different parts seamlessly work together.
M1: Analyse the advantages of using computers in manufacturing
M1: Analyse the advantages of using computers in manufacturing
Advantages of Computers in Manufacturing
Advantages of Computers in Manufacturing
The integration of computers in manufacturing has revolutionised the industry by bringing a range of benefits that enhance efficiency and productivity. One significant benefit is the ability to automate complex processes which allows machinary to run continuously without human intervention. This reduces the need for skilled labour and minimises human error which leads to consistent production quality and an increased output. This means companies can operate machinary 24/7 which optimises the use of expensive equipment and reducing operation costs. Continuous operation and high precision of automated systems ensure that production schedules are met reliably. The reliable production flow enhances the overall productivity and profitability which shows that the integration of computer systems in modern manufacturing is crucial.
Computers also play a crucial role in resource management and waste reduction by using advanced data analysis and simulation tools. This means maufactureres can optimise the use of resources such as materials, time and energy and the precision in resource allocation minimises waste by ensuring only the necessary amount of raw materials is used, therefore reducing the environmental impact of manufacturing processes. Additionally CAD and CAM software allow for the creation of highly accurate product models and prototypes which further reduces the risk of errors and the need for rework which can be costly. This also contributes to a more sustainable manufacturing which benefits both the environment and company.
Finally the use of computers in manufacturing also contributes to better quality control and standardises of quality within products. Quality assurance systems can continuously monitor production processes by quickly identifying and addressing deviations or variations from set standards. By using real-time monitoring this helps to maintain high-quality outputs and reduces the chance of products having defects. Additionally, standardised production processes enabled by computer systems ensure that product parts meet specifications which is essential in industries with high-precision being a critical safety factor. The ability to consistently produce high-quality products enhances customer satisfaction and build the company's reputation for reliability.
Overall Advantages
Overall Advantages
Increased efficiency and productivity- The role of computers in improving manufacturing efficiency is very important as it automates complex operations, which allows for continuous operation, minimises manual human intervention and makes products have a smaller variance and error. the automation of manufacturing streamlines workflow which ensures production can run without interruptions. this reduces downtime (period of time where machines or computers are unavailable) and maximises production output. Maintaining an uninterrupted workflow allows manufacturers to achieve higher production rates whilst consistently producing the same quality products. Also, computer-aided manufacturing ensures that the equipment operates how it should and as efficiently as possible to reduce damage, wear and tear to expand the lifespan of tools and machinery. all of these factors combined create a significant boost in productivity.
Computers significantly enhance manufacturing efficiency by automating complex processes, reducing manual intervention and by allowing the operation to be continuously working. Continuous operation and automation of processes leads to higher production rates, consistent quality and the use of machinery being optimised, thereby increasing the overall productivity. This has been a major drive in the industry in terms of mass production, as machines can operate 24/7 if needed and unlike humans do not fatigue, also the rate at which they can make accurate cuts or mould material into shape is far greater than that of a human labour force. As a result production rates accuracy has gone up massively due to CAM practices.
Improved quality and precision- The use of computer systems in manufacturing ensures high precision and uniformity in product output. Advanced technologies like CAD and CAM allow for the production of parts to be exact to specifications whilst reducing errors and ensuring consistent quality across batches. With the addition of multiple axis machines like 5-axis CNC machines, the ability to produce highly complex parts has massively increased. Due to the machines following a set of geometric instructions, referred to as G-code, the CAM driven machines can produce parts with very little error over and over by following that same toolpath and without human error limiting the precision of the parts. More recently lasers are being used with CAM systems to not only test the accuracy of production to a very small degree of error, but also to produce parts to a level of such small precision it would not be possible to do the same by hand or traditional non CAM methods.
Cost savings- Automation and efficient resource management reduce operational costs. Computers minimise the waste by optimising material use and streamlining production processes. Additionally, the reduction in labour costs and enhanced machinery utilisation contribute to significant cost saving for manufacturers. Some high end machines can produce hundreds of parts if not thousands per day, with very little human input and control, this allows for manufacturers to employ only a few staff as part of a maintenance team or what could be considered low skilled workers on the factory line, as the work is more dependent on machine programmers.
Faster production times - Computers speed up manufacturing processes, allowing for quicker turn around times. This is particularly beneficial in implementing JIT production, where parts are manufactured and shipped shortly after receiving orders. Not only that as they can be controlled by PLC's they can have a much greater control on producing at the correct rates otherwise they would over or underproduce which could cause them to lose profits.
Flexibility and quick adaption- Using computers in manufacturing systems offer greater flexibility in responding to changes and issues. Automated systems can quickly adapt to new designs, production requirements or process improvements. This adaptability ensures that manufacturing operations can promptly address problems and implement solutions, maintaining smooth and efficient production flows. Quite often if people were makes products in traditional ways, they might need retraining or at least some time to learn how to produce the new part, whereas with machines as they are following a new g-code they only need to be reprogrammed and they can straight away start production again in some cases.
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