| Foreword | p. xv |
| Preface | p. xvii |
| Introduction | p. 1 |
| United States Competitiveness | p. 1 |
| Product Realization Process | p. 2 |
| Prerequisite for Affordable Automation | p. 3 |
| U.S. Decline in World Market Share | p. 3 |
| The Central Role of Engineering Design for Affordable Automation | p. 5 |
| The Nature of Engineering Design for Affordable Automation | p. 9 |
| The Current State of Engineering Design for Affordable Automation in the United States | p. 10 |
| Engineering design practices in U.S. industry | p. 11 |
| The role of designers in the product realization process | p. 11 |
| Changing the goals and culture of U.S. industry | p. 11 |
| Partnership interactions among U.S. industry, research, and education | p. 12 |
| Engineering curricula and the product realization process | p. 12 |
| Industry efforts in engineering design for affordable automation | p. 12 |
| Responsibility of universities | p. 13 |
| University research in engineering design | p. 13 |
| Superior engineering design as a national priority | p. 13 |
| Achieving Affordable Automation | p. 14 |
| Affordable Automation for Competitive Advantage | p. 15 |
| Corporate Commitment and Action for Affordable Automation | p. 16 |
| Plan for Continuous Improvement | p. 18 |
| Definition of customer needs and product performance requirements | p. 18 |
| Planning for product evolution | p. 19 |
| Planning for design and manufacturing | p. 19 |
| Product design | p. 19 |
| Manufacturing process design | p. 20 |
| Production | p. 20 |
| Difficulties in the design of complex products | p. 20 |
| Contemporary Design Practices for Affordable Automation | p. 21 |
| Traditional practices | p. 21 |
| Modern practices for setting strategy and specification for affordable automation | p. 23 |
| Modern practices for executing designs for affordable automation | p. 27 |
| Understanding, Motivating, and Supporting the Designer for Affordable Automation | p. 32 |
| The design task for affordable automation | p. 32 |
| The designer | p. 34 |
| Part Design and Handling for Affordable Automation | p. 35 |
| Introduction | p. 35 |
| The Role of Affordable Automation in Manufacturing Enterprises | p. 35 |
| Case Study: Flexible Printed Circuit Manufacture | p. 36 |
| Part handling and orientation techniques | p. 37 |
| Criteria for automatic etching and assembly | p. 39 |
| Manufacturing system concept | p. 41 |
| An innovative affordable automation production system | p. 42 |
| Economic analysis | p. 48 |
| Applicability of Design for Affordable Automation to Manual and Semiautomated Processes | p. 49 |
| Probability, Statistics, and Reliability in Design for Affordable Automation | p. 51 |
| Design for reliability | p. 52 |
| Descriptive statistics | p. 55 |
| Concepts for mathematical component design | p. 60 |
| Estimation of variability from tolerances | p. 61 |
| Functions of random variables in design for affordable automation | p. 62 |
| Probabilistic design theory for affordable automation | p. 64 |
| The statistical nature of engineering design variables | p. 68 |
| Part Feeding for Affordable Automation | p. 77 |
| Basic Principles | p. 77 |
| Simplicity | p. 77 |
| Standard materials and components | p. 77 |
| Standardized design of products | p. 77 |
| Liberal tolerences | p. 78 |
| Processible materials | p. 79 |
| Collaboration with manufacturing personnel | p. 80 |
| Avoid secondary operations | p. 80 |
| Design for the expected level of production | p. 80 |
| Utilize special process characteristics | p. 80 |
| Avoid process restrictiveness | p. 80 |
| Basic Principles of Fastener Design for Affordable Automation | p. 81 |
| Advantages of threaded fasteners | p. 81 |
| Screw fasteners | p. 81 |
| Functions of prime fasteners | p. 82 |
| Distinction between product and design specifications | p. 83 |
| Product specifications | p. 85 |
| Designing Fasteners for Affordable Automation | p. 95 |
| Selection of threads | p. 95 |
| Corrosion | p. 96 |
| Washers | p. 97 |
| Joint design | p. 98 |
| Tensile loading | p. 98 |
| Shear loading | p. 99 |
| Bending loading | p. 102 |
| Fatigue loading | p. 103 |
| Vibration | p. 103 |
| Managing Quality of Part Fastening | p. 104 |
| Torque tension versus static tension | p. 104 |
| Torque tension characteristics | p. 106 |
| Flexible Feeding Systems for Affordable Automation | p. 108 |
| Double-belt assembly system | p. 112 |
| Manual arrangements in an automated environment (nonsynchronous system) | p. 113 |
| Automatic stations | p. 114 |
| Component buffers | p. 116 |
| Affordable assembly lines | p. 117 |
| Affordable Cellular Manufacturing for an Unmanned Factory | p. 118 |
| Cellular structure for flexible automated assembly | p. 119 |
| Restrictions in applying flexible assembly systems | p. 120 |
| Design for Affordable Automation | p. 123 |
| Design for Assembly | p. 123 |
| Component Design for Affordable Assembly | p. 125 |
| Automated Process Demands on Product Design | p. 126 |
| Oriented Design Alternatives | p. 126 |
| Structuring of product | p. 127 |
| Assembly-oriented design | p. 128 |
| Standardizing of parts | p. 128 |
| Workpiece suitability for automatic handling | p. 131 |
| Design Optimization for Affordable Automatic Assembly | p. 133 |
| Assembly optimization | p. 134 |
| Product rationalization and DFA | p. 134 |
| Product structure | p. 135 |
| Basic Design of Components | p. 136 |
| Design strategy | p. 138 |
| The Case of the Simonsen ECG Electrode | p. 139 |
| Considerations | p. 141 |
| Product proposal | p. 142 |
| Production technology proposal | p. 142 |
| Production system proposal (machines and operators) | p. 143 |
| High-Precision Assembly with Inexpensive Machines | p. 145 |
| Active and passive assembly | p. 146 |
| Self-adaptive guided assembly | p. 146 |
| Planning for Automated Assembly and Fabrication | p. 157 |
| Introduction | p. 157 |
| Initial Survey | p. 158 |
| Qualification | p. 159 |
| Selection | p. 164 |
| Engineering | p. 165 |
| Pick-and-place mechanisms | p. 167 |
| Part feeders | p. 168 |
| Equipment modification | p. 169 |
| Product or part redesign | p. 170 |
| Process revisions | p. 170 |
| Computer-Controlled Part Feeding Magazines | p. 171 |
| Case study: System application of magazine loading | p. 171 |
| System planning | p. 173 |
| System design | p. 174 |
| System description | p. 174 |
| Separation and unloading bins | p. 176 |
| Cost | p. 177 |
| Affordable and Adaptable Grippers for Multiple Assembly Functions | p. 177 |
| Case study: Circuit board assembly | p. 179 |
| Planning for Affordable Automation | p. 187 |
| Introduction | p. 187 |
| Economics | p. 187 |
| Part control | p. 187 |
| Explicit and inplicit inspection | p. 187 |
| Mechanisms | p. 187 |
| Direct and global communication | p. 187 |
| Programmable Assembly | p. 188 |
| Group Technology as a Base for Affordable Automation | p. 191 |
| Key definitions for the group technology concept | p. 192 |
| History of affordable automation and group technology | p. 194 |
| Affordable automation in CAD/CAM integration | p. 196 |
| Methods for Developing Part Families for Affordable Automation | p. 196 |
| Part classification and coding | p. 200 |
| Hierarchial code | p. 201 |
| Attribute code | p. 203 |
| Hybrid code | p. 203 |
| Selecting a coding system | p. 204 |
| DCLASS coding system | p. 211 |
| MICLASS coding system | p. 215 |
| Cost Models for Cellular Manufacturing | p. 219 |
| Production costs | p. 220 |
| Tooling costs | p. 224 |
| Economics of Affordable Automation in Group Technology | p. 226 |
| Cost-Saving Strategies | p. 229 |
| Production Loss in Automatic Assembly Machines | p. 229 |
| Downtime in Automatic Assembly Machines | p. 231 |
| Assembly Cost of Defective Parts | p. 234 |
| Cost Savings in Assembly | p. 236 |
| Asynchronous Assembly Systems | p. 240 |
| Assessment of asynchronous machine | p. 241 |
| Productivity of asynchronous machines | p. 244 |
| Error management and fault recovery | p. 245 |
| Capital Equipment Economics of Synchronous and Asynchronous Systems | p. 246 |
| Synchronous indexing machine | p. 248 |
| Volume sensitivity of synchronous and asynchronous machines | p. 250 |
| Robots as Flexible Assembly Systems | p. 251 |
| Criteria for Robotic Assembly | p. 253 |
| Single-station robotic system | p. 254 |
| Multistation robotic system | p. 257 |
| Affordable Control Systems in Manufacturing | p. 261 |
| Today's Business | p. 261 |
| Intense Competition in the United States | p. 263 |
| Establishing an Affordable Automation Program | p. 263 |
| Belt tightening | p. 263 |
| Robust automation | p. 264 |
| Understanding Workstations, Work Cells, and Work Centers | p. 265 |
| Integration of automated assembly and fabrication systems | p. 268 |
| Integration of sensory and control systems with flexible manufacturing systems | p. 268 |
| Classification of Control Processes | p. 270 |
| Open- and closed-loop control systems | p. 270 |
| Sensors and Their Environment | p. 274 |
| Automated Cartesian Workstation | p. 274 |
| Positioning system for cartesian workstation | p. 276 |
| Linear accuracy of cartesian robot | p. 280 |
| Rotary accuracy of cartesian robot | p. 282 |
| Robotic actuators | p. 286 |
| Positioning tables | p. 287 |
| Conversion of Motion for Affordable Automation | p. 288 |
| Rotary-to-rotary motion generation | p. 289 |
| Belt-and-pully system | p. 290 |
| Rotary-to-linear motion generation | p. 290 |
| Pneumatic Actuators | p. 297 |
| Single-acting pneumatic actuator | p. 297 |
| Control of single-acting pneumatic actuator | p. 298 |
| Double-acting pneumatic actuator | p. 300 |
| Hydraulic Actuators | p. 302 |
| Pneumatic-hydraulic feed unit | p. 302 |
| Electrical Actuators | p. 303 |
| Stepper motor with linear motion | p. 305 |
| Application of the stepper motor as linear actuator | p. 306 |
| Rotary Actuation | p. 307 |
| DC Motors | p. 307 |
| AC synchronous motors | p. 310 |
| Stepper motors | p. 312 |
| Pneumatic motors | p. 312 |
| Sliding-vane motors | p. 314 |
| Hydraulic motors | p. 314 |
| Generation and Control of Forces in Hydraulic Motors and Actuators | p. 315 |
| Rapid traverse control circuit | p. 318 |
| Pressure-dependent sequence control | p. 319 |
| Electrohydraulic Devices | p. 321 |
| Electrohydraulic stepping motor | p. 321 |
| Proportional valve | p. 321 |
| Control of electrohydraulic systems | p. 322 |
| Signal Conversion and Transformation | p. 323 |
| Product Coding and Data Acquisition Systems | p. 327 |
| Bar Codes | p. 329 |
| Accuracy of information gathering | p. 328 |
| Increase of employee productivity | p. 328 |
| Accuracy of inventory | p. 329 |
| Cost of bar-code installation | p. 329 |
| Tracking work in progress | p. 330 |
| Tracking transported items | p. 330 |
| Tracking paperwork in process | p. 330 |
| Increased customer satisfaction | p. 331 |
| Bar-Coding Organizations | p. 331 |
| Bar-Coding Systems | p. 331 |
| The bar-code symbol | p. 332 |
| Substrate | p. 333 |
| Printing technology | p. 333 |
| Scanners | p. 335 |
| Light source | p. 335 |
| Code presentation | p. 336 |
| Symbol presentation | p. 336 |
| Integration of decoding intelligence | p. 337 |
| Information Gathering | p. 338 |
| Symbol density | p. 338 |
| Substrate properties | p. 339 |
| Scanner selection | p. 340 |
| Digitizing and Decoding | p. 342 |
| Encoders | p. 342 |
| Glossary of encoder terms | p. 342 |
| Universal types of encoders | p. 344 |
| Absolute encoders | p. 344 |
| Incremental encoders | p. 346 |
| Directional sensing pulse multiplication | p. 349 |
| Interpolation | p. 349 |
| Selecting Encoders for Innovative Affordable Automation | p. 350 |
| User abuse | p. 351 |
| Bearing loads | p. 351 |
| Protective housing | p. 351 |
| Finish | p. 352 |
| Electrical shielding | p. 352 |
| Temperature and other specifications | p. 352 |
| Environmental sealing | p. 352 |
| Examples of Encoders for Affordable Automation | p. 353 |
| Economic and Social Concerns | p. 357 |
| Financial Planning and Control of Manufacturing Operations | p. 357 |
| Developing a Plan | p. 358 |
| Sales budget | p. 358 |
| The production budget | p. 359 |
| The selling administrative budget | p. 360 |
| The capital budget | p. 360 |
| The financial budget | p. 360 |
| Income statement and balance sheet projections | p. 361 |
| Planning for Profit | p. 361 |
| Controlling operations | p. 362 |
| Cost and profit analysis | p. 363 |
| Information Assimilation and Decision Making | p. 363 |
| Break-even analysis | p. 364 |
| Break-even chart and formula | p. 364 |
| Utilization of break-even analysis | p. 365 |
| Incremental analysis | p. 366 |
| Make-or-buy analysis | p. 368 |
| The importance of the basic data | p. 368 |
| Communication | p. 369 |
| The need for timeliness | p. 370 |
| Reporting strategy | p. 372 |
| Responsibility Centers | p. 373 |
| Controllable and uncontrollable costs | p. 374 |
| Construction of the reports | p. 375 |
| Analyzing cost and profit data | p. 375 |
| Communication of business financial status | p. 376 |
| Mathematical Methods for Planning and Control | p. 377 |
| Dealing with uncertainty | p. 377 |
| Capital budget | p. 379 |
| Inventory analysis | p. 381 |
| Linear programming | p. 383 |
| Project management | p. 386 |
| Where Do Sensor and Control Systems Take Us? | p. 392 |
| Index | p. 401 |
| Table of Contents provided by Syndetics. All Rights Reserved. |