Automation, Production Systems, and Computer-Integrated Manufacturing

Mikell P. Groover is Professor Emeritus of Industrial and Systems Engineering at Lehigh University, where he taught and did research for 44 years. He received his B.A. in Arts and Science (1961), B.S. in Mechanical Engineering (1962), M.S. in Industrial Engineering (1966), and Ph.D. (1969), all from Lehigh. His industrial experience includes several years as a manufacturing engineer before embarking on graduate studies at Lehigh.  His teaching and research areas include manufacturing processes, production systems, automation, material handling, facilities planning, and work systems. He has received a number of teaching awards at Lehigh University, as well as the Albert G. Holzman Outstanding Educator Award from the Institute of Industrial Engineers (1995) and the SME Education Award from the Society of Manufacturing Engineers (2001). His publications include over 75 technical articles and 12 books (listed below). His books are used throughout the world and have been translated into French, German, Spanish, Portuguese, Russian, Japanese, Korean, and Chinese. The first edition of Fundamentals of Modern Manufacturing received the IIE Joint Publishers Award (1996) and the M. Eugene Merchant Manufacturing Textbook Award from the Society of Manufacturing Engineers (1996).  Dr. Groover is a member of the Institute of Industrial Engineers (IIE) and the Society of Manufacturing Engineers (SME). He is a Fellow of IIE and SME.

• PrefaceAcknowledgmentsNew to This EditionSupport Materials for InstructorsAbout the AuthorChapter1 INTRODUCTION1.1 Production Systems 1.2 Automation in Production Systems 1.3 Manual Labor in Production Systems 1.4 Automation Principles and Strategies 1.5 About This Book PART I OVERVIEW OF MANUFACTURINGChapter2 MANUFACTURING OPERATIONS 2.1 Manufacturing Industries and Products 2.2 Manufacturing Operations 2.3 Production Facilities 2.4 Product/Production RelationshipsChapter3 MANUFACTURING METRICS AND ECONOMICS3.1 Production Performance Metrics3.2 Manufacturing CostsAppendix 3A Averaging Formulas for Equation (3.20) PART II AUTOMATION AND CONTROL TECHNOLOGIESChapter4 INTRODUCTION TO AUTOMATION4.1 Basic Elements of an Automated System 4.2 Advanced Automation Functions 4.3 Levels of Automation Chapter5 INDUSTRIAL CONTROL SYSTEMS5.1 Process Industries versus Discrete Manufacturing Industries 5.2 Continuous versus Discrete Control 5.3 Computer Process Control Chapter6 HARDWARE COMPONENTS FOR AUTOMATION AND PROCESS CONTROL6.1 Sensors 6.2 Actuators 6.3 Analog–Digital Conversions 6.4 Input/Output Devices for Discrete Data Chapter7 COMPUTER NUMERICAL CONTROL 7.1 Fundamentals of NC Technology 7.2 Computers and Numerical Control7.3 Applications of NC 7.4 Analysis of Positioning Systems 7.5 NC Part Programming Appendix 7A: Coding for Manual Part Programming Chapter8 INDUSTRIAL ROBOTICS8.1 Robot Anatomy and Related Attributes 8.2 Robot Control Systems 8.3 End Effectors8.4 Applications of Industrial Robots8.5 Robot Programming8.6 Robot Accuracy and Repeatability Chapter9 DISCRETE CONTROL AND PROGRAMMABLE LOGIC CONTROLLERS9.1 Discrete Process Control 9.2 Ladder Logic Diagrams 9.3 Programmable Logic Controllers 9.4 Personal Computers and Programmable Automation ControllersPART III MATERIAL HANDLING AND IDENTIFICATIONChapter 10 MATERIAL TRANSPORT SYSTEMS10.1Overview of Material Handling 10.2Material Transport Equipment 10.3Analysis of Material Transport SystemsChapter 11 STORAGE SYSTEMS11.1 Introduction to Storage Systems11.2Conventional Storage Methods and Equipment 11.3Automated Storage Systems 11.4Analysis of Storage Systems Chapter12 AUTOMATIC IDENTIFICATION AND DATA CAPTURE12.1Overview of Automatic Identification Methods 12.2Bar Code Technology 12.3Radio Frequency Identification 12.4Other AIDC Technologies PART IV MANUFACTURING SYSTEMSChapter 13 OVERVIEW OF MANUFACTURING SYSTEMS13.1Components of a Manufacturing System 13.2Types of Manufacturing Systems Chapter 14 SINGLE-STATION MANUFACTURING CELLS14.1Single-Station Manned Cells 14.2Single-Station Automated Cells 14.3Applications of Single-Station Cells 14.4Analysis of Single-Station Cells Chapter 15 MANUAL ASSEMBLY LINES 15.1Fundamentals of Manual Assembly Lines 15.2Analysis of Single-Model Assembly Lines15.3Line Balancing Algorithms 15.4Workstation Details 15.5Other Considerations in Assembly Line Design 15.6Alternative Assembly Systems Appendix 15A Batch-Model and Mixed-Model LinesChapter 16 AUTOMATED PRODUCTION LINES 16.1Fundamentals of Automated Production Lines 16.2Applications of Automated Production Lines 16.3Analysis of Transfer Lines Appendix 16A Transfer Lines with Internal StorageChapter 17 AUTOMATED ASSEMBLY SYSTEMS17.1Fundamentals of Automated Assembly Systems 17.2Analysis of Automated Assembly Systems Chapter 18 GROUP TECHNOLOGY AND CELLULAR MANUFACTURING18.1Part Families and Machine Groups18.2Cellular Manufacturing 18.3Applications of Group Technology 18.4Analysis of Cellular Manufacturing Appendix 18A Opitz Parts Classification and Coding SystemChapter 19 FLEXIBLE MANUFACTURING CELLS AND SYSTEMS19.1What is a Flexible Manufacturing System? 19.2FMC/FMS Components19.3FMS Application Considerations 19.4Analysis of Flexible Manufacturing Systems 19.5Alternative Approaches to Flexible Manufacturing PART V QUALITY CONTROL SYSTEMSChapter 20 QUALITY PROGRAMS FOR MANUFACTURING20.1Quality in Design and Manufacturing 20.2Traditional and Modern Quality Control 20.3Process Variability and Process Capability 20.4Statistical Process Control 20.5Six Sigma 20.6Taguchi Methods in Quality Engineering 20.7ISO 9000 Appendix 20A The Six Sigma DMAIC Procedure Chapter 21 INSPECTION PRINCIPLES AND PRACTICES21.1Inspection Fundamentals 21.2Sampling versus 100% Inspection 21.3Automated Inspection 21.4When and Where to Inspect 21.5Analysis of Inspection SystemsChapter 22 INSPECTION TECHNOLOGIES22.1Inspection Metrology 22.2Conventional Measuring and Gaging Techniques22.3Coordinate Measuring Machines 22.4Surface Measurement 22.5Machine Vision 22.6Other Optical Inspection Methods 22.7Noncontact Nonoptical Inspection Techniques Appendix 22A Geometric Feature Construction PART VI MANUFACTURING SUPPORT SYSTEMSChapter 23 PRODUCT DESIGN AND CAD/CAM IN THE PRODUCTION SYSTEM23.1Product Design and CAD 23.2CAM, CAD/CAM, and CIM 23.3Quality Function Deployment Chapter 24 PROCESS PLANNING AND CONCURRENT ENGINEERING24.1Process Planning24.2Computer-Aided Process Planning 24.3Concurrent Engineering and Design for Manufacturing 24.4Advanced Manufacturing Planning Chapter 25 PRODUCTION PLANNING AND CONTROL SYSTEMS25.1 Aggregate Production Planning and the Master Production Schedule 25.2Material Requirements Planning 25.3Capacity Planning25.4Shop Floor Control 25.5Inventory Control 25.6Manufacturing Resource Planning (MRP II)25.7 Enterprise Resource Planning (ERP)Chapter 26 JUST-IN-TIME AND LEAN PRODUCTION26.1Lean Production and Waste in Manufacturing 26.2Just-in-Time Production Systems 26.3Autonomation26.4Worker InvolvementAppendix Answers to Selected Problems