Investigation on the Analysis of Design and Development of Flexible Manufacturing System for Starter Motor Field Coil Manufacturing
Abebaw Mengistu Mekonnen
Addis Ababa Institute of Technology, Addis Ababa University, Addis Ababa, Ethiopia
* Correspondence: Email: [email protected], Tel: +2519 1265 03 22.
Abstract: Flexibility in manufacturing is crucial for enhancing productivity and preserving manufacturer?survival?in the face of continuously evolving client preferences and technology developments. Picking the technology for a manufacturing cell's flexible manufacturing system design is the primary purpose of this research. The main objective of the study is to design a flexible manufacturing system for field coil manufacturing. The author intends to design a flexible manufacturing system?that can produce a coil with in a?two minute. The design process comprises developing a workstation, material handling, control system, process plan, layout and strategies of running to produce coil. The setting up of such a factory would replace the imports and save the nation's foreign cash. Additionally, the study establishes forward links with the manufacturing subsector and produces revenue for the government in the form of payroll taxes and tax revenue. It facilitates the production system and is intelligent, effective, and time- efficient.
Keywords: Flexible Manufacturing System ? Automation ? manufacturing strategy ? Industrial robots ? material handling system
1. Introduction
Flexible Manufacturing System can respond to market fluctuations rapidly and at less cost. According to (Tao et al., 2017), the automotive company must use a flexible manufacturing system in order to accommodate its growth and remain competitive in the market. According to (Kumar and Mishra, 2017), flexibility in the automotive sector enables businesses to embrace technological advancements and provide a wide range of products to meet client demands. A Flexible Manufacturing System (FMS) is managed by a central control system that consists of a number of processing workstations, or CNC machine tools, coupled by automated material handling system that can function as an automated storage and retrieval system (ASRS) (Tayyaba et al., 2014).
The aim is to decide on the technology for the design of an FMS in a manufacturing cell that produces the coil for starting motor in a company of the Ethiopian automotive industry. According to (Boyer, K. 1998), the optimal design of FMS is a complex and influenced by a number of obstacles in the context of the automotive sector. The obstacles that these barriers encounter include technical, operational, financial, and strategic hurdles, among others.
An FMS that can adjust manufacturing system to relevant, unforeseen changes in order volume, mix, and due date (Tao et al., 2017). (Kumar & Mishra, 2017) FMSs offer eight different kinds of flexibilities. Three are most pertinent to this investigation. A machine flexibility, material handling flexibility and operation flexibility.
The productivity gained from lower costs and the quality gained from lower variability are no longer the only important considerations when designing an FMS. The purpose of this study is to decide on the technology for the design of an FMS in a manufacturing cell that produces coil for starter motor in a company of the Ethiopian automotive industry.
2. Materials and Methods
2.1 Materials
A starter motor field coil is an electromagnet material used to generate a magnetic field in an electro-magnetic machine, typically a rotating electrical machine such as a motor or generator. It consists of a coil of wire through which a current flows, which shows in the Fig 1 below. Usually, the windings on a coil are made of enameled metallic copper bar/wire.
2.2 Manufactured Data
The manufactured data for the current study has been taken from Federal Democratic Republic of Ethiopia; Growth and Transformation Plan; 2010/11 -2014/15; Volume I: Main Text, during this period, the industry and service sector is expect to grow at an average annual growth rate of 20%. From these report the overall data for the starter motor field coil manufacturing information is summarize in Chart 1.
3.?Research Methodology
The main framework of the research has based on the aspects that given in Fig. 2 below, which provides a systematic illustration of the methodology.
4. Design of flexible manufacturing cell/system
? ? 4.1 Specifying the Manufacturing Requirements
The system was design for flexible manufacturing system (FMS) in an Ethiopian automotive industry-manufacturing cell that manufactures the coil for starter motor. The best possible design for the FMS is a challenging yet crucial subject. A number of obstacles influences the design process, including financial, operational, technical, and strategic obstacles. The design of FMS is crucial to improve the industry's manufacturing performance. One of the prerequisite in the design of FMS is families of components that give a brief information for the design purpose so here in the Fig 3 below briefly show the families of components based on geometric shape and size:
Most of the time the Ethiopian automotive industry produces the round type of coil for automobile engines but all types can be manufacture by implementing flexible manufacturing system. The capacity and functionality of the FMS system is take very short machining time and it use one tool for a long time due to accurately perform its operation. Since everything in the world is dependent on transportation—the automotive industry for instance that uses coils in its starter motors.
4.2. Development of Process Plan
Since it is manufactured using a particular process, a low-cost, and high-performance field coil could be produce.
The manufacturing process of the field coil of this invention is demonstrated sequentially according to Fig 4 a,b,c. Fig. a is a manufacturing process diagram of a coil 3 used in the first embodiment. As shown in the drawing, a flat copper bar or wire one cut to a required unfolded length has a free end that is not show in Fig. It is brought into contact with the core 2 of the apparatus and constitutes a winding start state (Fig 4 a). The winding core 2 forms two pairs whose cross-sectional shapes and dimensions are equal, and is configure to maintain a predetermined initial interval on the left and right in the drawing. The left and right winding cores 2 each have a clamping mechanism (not shown), hold the free end of the flat wire 1 and can rotate (rotate) at the same speed in the left and right (forward and reverse) and simultaneously generate tension. And a moving mechanism (not shown) that is separated from each other.
Next, since the winding core 2 winds up the free end of the flat wire 1 simultaneously and in the same direction, tension is generate in the winding core 2, and the flat wire 1 is pulled from the center and the free end it is wound in close contact with the core 2.
When the winding is further advanced and three quarters of the rotation is perform, a one-turn coil is complete as shown in Fig. It should be note here that the left and right free ends forming the one-turn coil wound in an arrangement facing each other with the flat wire 1 interposed there between, so that the coil to be formed becomes the field coil 3 in the opposite arrangement.
As shown on the above section 2.2 there were unsatisfied demand in the field coil manufacturing in Ethiopian automotive industry so in order to satisfy this demand this study is the best option, which manufactures one coil with in a two minute. Here is Table 1 below shows the standard time table for machines in the system.
The studied manufacturing cell requires nine operators and seven workstations to produce coils.
The workstations (WS) are:
WS 1 - Row material store
WS 2 – Measuring length and thickness then cut
WS 3 – The first, second, third and fourth bending start
WS 4 – Joining of two bends as the required shape clumping mechanism
WS 5 – Quality checker
WS 6 – Overall inspection
WS 7 – Store final product
Figure 5 below shows the exploded view of the starter motor, in which the coil is the component number 4. The other components are bearings and housing (1), pinion assembly (2), armature (3), brushes (5), and solenoid (6).
4.3 Specifying the type of flexibility requirement
A manufacturing system that is flexible is able to change to accommodate new situations. What kind of situations might those be? Everyone have to lay down the requirements for every type of flexibility that desire, so that is something?have to decide. Trying to say, the system shall be flexible, is pointless. Long-term benefits are the reason for adding flexibility to a system; when it is first delivered, it usually does not make much of a difference, but in the areas where it is constructed flexibly, it makes it easier to respond to requirements changes. Flexibility requirements not only serve specific aims but also generally contribute to a good, resilient system. However, some forms of flexibility are costly to achieve, so only make this request if it is essential.
Due to the Ethiopian automotive industry faced a challenge in the design of FMS for field coil production and results for unsatisfied demand due to these and other reason, design flexible manufacturing system (FMS) is required. Therefore, the liabilities were happen in the manufacturing of coil:
4.4. Determination of the type of FMS to be developed
The type of FMS developed for the system were based on the operation it is progressive, based on machine numbers it is a flexible manufacturing cell, and based on the level of flexibility it is sequential type. The ability of a machine to create new kinds of products or alter the sequence in which tasks are carry out is refer to as machine flexibility/ flexible manufacturing cell. As was previously said, coils are manufacture using a variety of items. The coil used in vehicles is not the same as the coils used in large machinery or other electronics. So, flexible manufacturing cell/machine flexibility is required in order to make any type of coil.
4.5 Specifying the type, then capacity of the material handling system and buffer /storage
Equipment for handling coils enables safe and effective coil upending, transporting, down ending, coil mandrel loading, and coil storage. To guarantee that this is the ideal coil handler for this application, every piece of coil handling equipment manufactured by Ethiopian Manufacturing is specially develop and construct to their requirements.?
Based on the process of production the parts can be automatically transport throughout the FMS via chain conveyors and it used as a temporary buffer/storage system. If it is not available can be use the following transportation ways:
Coil Transporter
Coil transporters facilitate the efficient and secure transportation of coils in the manufacturing setting. These coil transporters made specifically for this case and operate without a hitch in the production area. It provide flat deck coil transporters with bespoke cradles so that may use them for any kind of heavy cargo. It can also install a coil cradle to carry the coil vertically.?? In order to maximize efficiency or repurpose an existing piece of equipment, also design and construct a range of custom coil trailers that may be pair with an existing tugger or used in place of a forklift for coil transport.? To enhance our coil handling procedure, coil transporters and coil trailers come with basic safety measures.
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Coil Shuttles
Coil shuttles are the perfect option for securely moving steel coils between related units without the use of cumbersome truck beds or forklifts. Rail-mounted coil shuttles allow for exact coil positioning in relation to the press or unloading mechanism.? An excellent method of moving coils from one machine to the next without using up more plant resources is via a coil shuttle, shown in Fig 6 below.
Coil Pallet
The Coil Pallet & Coil Cradle is one of the most beneficial pieces of machinery for handling coils. The steel cradle can be customized with a range of surfaces based on the application and is made to fit the requirements of the particular coil it is holding. It is simple to pick up and move using common pieces of equipment thanks to the fork pockets.? As shown in Fig 7 below, this makes it possible to store or stage a variety of coils close to the press where they would be use in an upright posture, and to move coils using a typical forklift.
4.6. Design of control system
For coil production, the role of Central computer is control operation of bending machine, clamping mechanism, loading/unloading and quality & over all inspection process, as shown in Fig 8.
The various control strategies can be studied using Simulation analysis before one can suggest an optimum solution. Simulation used effectively for the design and operation of FMS as a decision support system for real time scheduling. A review of simulation work reveals that many real situations are modeled earlier using high-level programming languages such as FORTRAN, PASCAL TURBO C etc. To name few more such SIMULA, SIMAN, GPSS, SIMSCRIPT have reported by (Amrik et al., 2018).
However, in this study the author use FlexSim software for controlling the overall tool life in bending machine. FlexSim Software is another powerful simulation analysis tool is use for making intelligent decisions in design and operations of manufacturing tooling system (Ashkan et al., 2014). A graphical drag and drop tool used for model development, process optimization, resources and product costing visualization of process dynamics and bottlenecks.
Process description
This FMS study is comprised of seven different workstations each with a local buffer at input and output. The system can manufacture more than five different part types that arrive in the systems as work order. Each work order comprises of a set of different part types. To fabricate each part type three to seven operations are required. Each machine is capable of performing different set of operations.
After loading the raw material/copper bar into roller, the bar is manually connect to cutting machine only for the first time. Then operator starts the process by pressing the push button (PB). As soon as the operator pushes the button, cutting machine starts. After straightening, the bar when it reaches in front of the cutting machine (CM), sensor S1 senses the material type (copper) and it has thickens (standard 0.2mm). If operator selects exact measurement, cutting machine starts to cut the rod into desired size. When a desired amount of material is stacked on C2, sensor S3 is ON. As a result, C2 starts moving and the metals are transfer to the bending machine. When the temperature of those materials reaches over 1200° C, sensor S2 senses it and starts the conveyors transfers the heated pieces to the coolant. The bending machine is started by the sensor S4 and go through it B1, B2, B3 according to the order. When the pieces get desired shape, those sent to the clamping machine by conveyor C3. The clamping machine is start by the sensor S5. Then the finished coils sent to the inspection by conveyor C4. Inspection is start by the sensor S8. At last, the finished coils sent to temporary storage by robot. Push button is provide to stop the process manually if required. The whole system process description is present in Fig 9 above.
4.7 Design layout
The best-fit type of layout for this type of manufacturing is line/progressive type because the machines and handling system are arrange in a line as shown in the Fig 10 below. It works best in a system when the components go in a clear, sequential fashion from one workstation to the next without experiencing any backflows. The operation of this type of system is very similar to transfer line type. Work always flows in unidirectional path.
If in line or progressive type is not available by any cause such as workshop design, operator arrangement or any other reason loop type is applicable which is located in Fig 11 below.
4.8 Developing strategies for running the FMS?
The flexible machine working principle is according to the order the machine is flexible to bend the copper bar either in elliptical, rectangular, circular, oval or round shape.
An Industrial FMS consists of robots, computer-controlled machines, computers, sensors, and other stand-alone systems such as inspection machines as shown in Fig 12 above.
5. Result and discussion
5.1 Introduction
This study thoroughly investigates the design and development of a flexible manufacturing system for the production of field coils for starter motors. It does this by determining the manufacturing requirements, creating a process plan, defining the type of flexibility, deciding on the type of FMS to be created, defining the kind and capacity of material handling, designing the control system, creating a layout, and, at the end, creating a strategy for operating the FMS system.
5.2. Result
The overall outcome or result of the research shows to maximize the production rate, improved product quality, reduced manufacturing cost in addition to this the study can create employment. The investigation generates Birr in millions in terms of tax revenue. The setting up of such a factory could substitute the present imports and save the nation's foreign cash. The study also creates forward linkage with the manufacturing sub sector and generates other income for the Government.
5.2.1 Estimated cost and time for implementation
Within the design and development process, the most crucial factor in preventing misunderstandings and disputes is the estimated cost and time required for the flexible manufacturing system design.
5.3 Discussion
It is difficult and expensive to make the shift from traditional manufacturing systems to flexible manufacturing systems. The lack of an official framework for creating FMSs was the focus (Madson et al., 2020). Finding an appropriate answer is the issue this research examines. This research concurrently optimizes an FMS's performance and implementation costs to identify the ideal set of its numerous components, each with varying affects. FMSs are made of various components.
This study estimates the development of FMS for the production of coil. The demand for coil is meet through import and domestic production. Unsatisfied demand for coil is estimate at around 250000 per year. The principal raw materials required are flat copper bar/wire, which have to be imported. The study consists design of FMS like work station, material handling, control system to produce coil.? The study can create employment. The setting up of such a factory would substitute the present imports and save the nation's foreign cash. Additionally, the study intends to build forward links with the manufacturing subsector and provide revenue for the government in the form of payroll taxes and tax revenue.
5.4 Expected Benefits
Cellular manufacturing has been widely recognized and is increasingly implement as the tool to provide added flexibility. In order to serve more clients, it is able to function using a one-piece flow production approach. One time, (Mr. Kuraishi 2022), the president of Oriental Motors, stated, "filling 100 orders for 100 customers one at a time is better for the sake of long term management efficiency than filling an order for 100 products from just one customer."
Production in cells is focus on the market. The manufacturing base has shifted from a demand surplus to a supply surplus economy because of recent advances in technology and the global economy. This shift indicates that the days of producers being able to sell anything due to scarcity are gone. Almost any product can be create better and cheaper somewhere in today's global market, requiring competitors to compete and quickly distinguish between this and that globe. Only by getting rid of all waste at every stage would this match be achievable.
Flexible machine cells by way of designs were laid-out to minimize shop floor waste. For instance, integration of all, or most, necessary machines completely produce the desired parts within one specific area eliminates the excessive transportation of parts in and out of storage and from machine to machine, which takes time and requires non-value added man - hours. Thus, parts needed to produce the finished goods that made and inspect in a relatively smaller area.
Since all equipment needed to manufacture the desired components from start to finish are arranged in a line type layout, within a confined area, and the machines have been setup to achieve quick changeover or possibly zero setup time (when using dedicated setups) then the time to finish one piece completely is immensely shortened. The result is that the end item assembled and subsequently shipped in a much shorter time than was previously possible. Another benefit of cellular manufacturing is realize with small lot production. Small lot sizes require a low work in process inventory and small finished goods inventory. It is obvious that inventory storage requires installation of racks, pallets, bins, and so forth, all of which cost money. When inventory becomes too large installation of Automated Storage becomes necessary and requires resources to manage the inventory. Consequently, inventory turnover rates are greater with large lot sizes and carry higher interest burden. This is quite the opposite with small lot production since it deals with elimination of waste instead of handling them.
In addition, since fewer parts made with small lot sizes, the number of rejects will also be relatively smaller if the process should go out of control. Because of the nature of the cell, problems are immediately magnify and communicated to appropriate channels for resolution and the cell is at a standstill position until the problem is address. In non-cellular manufacturing, visibility of a quality problem is low and goes unattended for some time which creates recurring problematic situations
With the introduction of robots and other automated mechanism, and integration of equipment within a confined area accessible within few walking steps, the ratio of man/machine decreases. This primarily is the result of one man running more than one automated machine at a time. Finally, since the worker has to operate several machines during his/her shift, multi skilled are develop which results in a team effort and the individuals thus help each other as they can participate in the total system of a factory and feel greater job satisfaction.
6. Summary and conclusions
Flexibility has many different meanings and forms. The ways ends, and applications of these kinds were cover in this dissertation. To comprehend the selection criteria of suitable flexibilities in a production setting, these were apply as the foundation. The study discussed in this paper highlighted a few common issues that Ethiopian automotive industry face in their line of business. It then offered a method for choosing which issues to eliminate by creating adaptable manufacturing cells or systems as needed. The reason the company was chose for this study was that it illustrate the most common problems face by Ethiopian automotive manufacturers, and the author was able to gather the company's overall troubleshooting history.
As clearly observed by the reader, flexibility has both adverse and advantageous effects on the system performance.?? A circumstance that highlights both would be one in which producing families of parts calls for the use of a system. A single product system can produce at a rate that balances the demand rate, but holding additional inventory becomes necessary to keep the production rate in line with demand. However, a system less prone to distortion is one that can generate a wide range of various job types. These and other circumstances highlight how difficult it is to design and analyze modern manufacturing and how thorough knowledge of all available options is necessary.
Designers may use computer software as a means for simulating and evaluating the system design. Technologies for flexible manufacturing enable the creation of new goods or adapt to shifting consumer needs. These characteristics define a system's flexibility space, but the degree of flexibility a system can have is determine by top management's strategic and financial decisions. Adaptability is a crucial component of a system's design since it allows the system to incorporate new processes.
The excessive aspirations of almost two decades ago have given way to an awareness in the 2024s of the necessity for a more focused ambition; although one, that encompasses greater scopes of flexible manufacturing systems. It should be evident that manufacturing defects could only be reject or correct by active management's continuous watchfulness. It is understand that management is aware that flexibility has a cost and is not give away.
After more than ten years of industrial operations and FMS interactions, an attitude has emerged that mostly replaces unconditional loyalty to FMS with judicious assessment of the degree of flexibility needed by an organization to achieve its goals. Manufacturers are going to have to employ low-volume, high-mix manufacturing processes because of the recent changes in global events that have contributed to the formation of a global economy and the shift in the market from one of demand excess to one of supply surplus. Enhanced adaptability can facilitate the production run required to generate reduced expenses, shortened lead times, and validate shortened product life cycles. Therefore, the manufacturing strategy is one of the most crucial topics that needs to be consider an essential component of business. The quantity of parts to be produce should be take into account in the plan. Increased volume should result in decreased flexibility. Lower cost fixed automation systems could be able to get by with higher volume sales of a single model product.
In the event that management must defend flexibility as a preventative measure against machinery that may be used to create other products in the unlikely event that the current product fails, the answer to the question of how much to spend in flexibility in comparison to low cost and market uncertainty can be found with them.
This study's main goal, which was to create an FMS for coil production, was accomplish. FMS was create to aid in the creation of a trustworthy and accurate expert system. It facilitates the production system and is intelligent, effective, and time-efficient. Above all, it is adaptable and simple to adjust to accommodate new developments. It is recommend that FMS be use in all automotive businesses to help with coil production and consequently increase productivity.
In conclusion, this research estimates the development of FMS for the production of coil. The demand for coil met through import and domestic production. The principal raw materials required are flat copper sheet or wire, which have to be imported. The study consists design of FMS like work station, material handling, control system to produce coil.? The investigation can create employment. By replacing the present imports, the construction of such a factory would help the nation save foreign cash. In addition, the study establishes forward links with the manufacturing sub sector and produces revenue for the government in the form of payroll fees and tax profits.
References