Automation and Management of Productive Systems

Ingegneria Gestionale Automation and Management of Productive Systems



The course aims to provide students with the methodologies and the main tools used for Planning and programming of production as well as for the use of the main elements of automation of production processes, in close connection with some of the most important enabling technologies of the manufacturing era (Manifattura 4.0).
In particular, the course addresses problems, constraints and solutions to organize activities related to the operational management of the physical flows of interconnected manufacturing companies according to Supply Chain's logic, from market demand forecast, through all phases of the planning / programming process of production and supply management, to reach the operational scheduling of the individual production resources.
The operation of the information flow of the production data is also illustrated, with particular attention to the main archives and information, that the company has to manage in order to rule the production process.
The operational features of the main components and devices, needed to increase the degree of automation of the production systems and integrate their operation as required in the era of 4.0, are then examined. Technical aspects, sizing criteria, integration modes and type of information transmitted to the business information system are highlighted.
The aquired skills are related to: the defintion of product demand forecasts; the setting of a Master Production Schedule (MPS) identifying the information required for its construction; the development of MRP records to determine component requirements and fix order plans; the development of a system for the Capacity Requirements Planning (CRP), the setting and testing of a department task scheduling, the check of production phases progress.
The course allows to acquire further capabilities related to: the characteristics of rigid and flexible automation; actuators, transducers and control units for the automation systems; the main components of automated production systems; the basic principles of PLC programming; the programming of an anthropomorphic robot in self learning and through dedicated software.
Knowledge of configuration, operation, technology and basic information technology for industrial plants is required for the profitable achievement of the course goals.
Part A
Planning process: (12h) exercises (8h)
Introduction to planning processes: paradigm 4.0, enabling technologies, and the process planning role. Time horizons and aggregation levels, planning influence factors, hierarchical approach. Management of the demand uncertainty: subjective and objective models. Numerical series analysis, major models to determine trend, seasonality, and randomness. Evaluation criteria for AVG, MSE, MAD forecast models. Production plan development: the sales plan and the financial plan. Aggregate production planning: product families, technical data, resource profiles, capacity constraints, and definition of production quantities. Policies for the aggregate plan definition: chase and level production. The use of RRP.
Programming process (10h) exercises (6h)
Master production schedule definition. Role of the business planner. Rough Cut Capacity Planning (RCCP). Management of demand-dependent materials (push): Material Requirements Planning (MRP), Net calculation and and time distribution of requirements, explosion of levels, optimization of convenient quantities. MRPII. Planning at infinitive resources (CRP), Policies of resource procurement. Theory of Constraints (TOC).
Control Process (6h) Exercises (3h)
Management of demand-dependent materials (pull): JIT production criteria, Kanban mechanism, Kanban typologies, and quantification of Kanban numbers. Production leveling and assembly sequencing. Integration with push management. Operational scheduling of limited capacity production: major models (analytic and heuristic) and new approaches (fuzzy, neural networks, autonomous agents).
Part B
Introduction to Automation (6h): Automations, their classification and measurement criteria. Differences between mechanization and automation. Automation of continuous and discrete processes. Rigid and flexible automation. Historical development of flexible automation and its main applications.
Automation components (6h) Exercises (4h): Pneumatic, Hydraulic and Electric Actuators. Motion Transmission Systems. Position and speed transducers. CN and PLC control units.
Industrial Robots (6h) Exercises (3h): Classification criteria and application fields. Structure of the mechanical system (arm, wrist and hand). Programming modes. Parameters of technical-economic evaluation.
Numerical control machines (8h): Classification criteria and application fields. Basic configurations and optional devices. Pre-set systems. Measuring machines.
Handling and storage systems (6h): Features of AGV and automated warehouses. Sizing criteria.
Factory integration (4h) Exercises (2h): Evolution from Single to Integrated Systems. Flexible Manufacturing Cell (FMC). Flexible Production Systems (FMS).
Teaching Methods
The course involves theoretical lessons alternating with classroom exercises and business speeches. The exercises are specifically developed according to the enunciated theoretical concepts and aimed at verifying the ability to numerically apply techniques and models presented to cases, expressely simplified. The business speeches are designed and delivered in close connection with the discussed topics to illustrate the company's pragmatic approach to the use of the various techniques. For each level of the planning process, an exercise of at least 3h is proposed.
Verification of learning
The exam consist of the only oral examination during which the knowledge and skills acquired on 6 different topics in Part A and B are verified,
supported by simple numerical written questions derived from the exercises carried out during the course. Oral evaluation is expressed in thirtieths for each question, and then averaged on the 6 questions. A sufficient vote (18) is attributed to the single question when the student shows an elementary but exhaustive knowledge of the subject; the maximum vote is given to the student who is able to expose the system aspects related to the single question posed with full autonomy and technical language properties. The final vote consists of the arithmetic average of the votes of the 6 questions and, in the presence of a high quality of the overall exposure and the ability to create logical links between the various topics covered, the maximum evaluation, with honours is assigned.
Notes of class lessons.
Brandolese A., Pozzetti A., Sianesi A. : Gestione della produzione Industriale. Hoepli, Milano, 1991
Schonberger J.R., Knod E.M., “Gestione della Produzione”, Mc Graw-Hill, 1999
Castagna R, Roversi A. : Sistemi produttivi. ISEDI, Torino, 1990
Chase, Aquilano, Jacobs: Production ad Operations management. McGraw-Hill (in inglese)
Fogarty, Blackstone, Hoffmann : Production & Inventory Control. South-Western Publishing group (in inglese)
Levy G., “MRP e logica di implementazione“, Franco Angeli
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