Concept of Automation
Automation can be defined as the technology used
for the application of integrated mechanical,
electronics and computer based systems in the
operation and control of production systems.
Automation of production system means:
Automation of manufacturing facilities.
Automation of manufacturing support systems. or
Automation of both facilities and the
manufacturing support systems.
Contd…
It is the feasible solution for improving the
productivity, quality and economy.
It is more economical feasible when the volume
of production is going on increasing.
Some of the examples of automation of
processes in production systems are as follows:
NC and CNC machines,
Automatic assembly machines,
Contd…
Automated transfer lines,
Automatic assembly lines,
Industrial robots,
Automated material handling systems,
Automated storage systems,
Automated inspection and quality control systems,
Automated feedback and process control
equipments,
Computer aided production planning and control.
Need for Automation
• Today the automation has become integral part
of the process and manufacturing industries.
• It is needed because of the following
technological, commercial and social reasons:
To increase productivity,
To reduce cost of production,
To improve product quality,
Contd…
To mitigate the effects of labour shortages,
To reduce production time,
To avoid high cost of not automating processes,
To have better control over manufacturing
activities,
To improve worker safety,
To eliminate routine manual and clerical tasks.
Types of Automation
• The automation of production systems can be
broadly classified into three categories:
Graphical Comparison
Fixed (Hard) Automation
It is an automation system in which the sequence
of processing operations is fixed by the
production equipment (machines) configuration.
It can not be changed once it is established and
hence, it is inflexible in accommodating the
product variety.
It is economical when there is continuous high
demands for the product at high volume.
It is suitable for continuous flow type production
systems and mass production systems.
Features of fixed (hard) automation
High initial investment for custom-engineered
equipment;
High production rates;
Highly inflexible in accommodating product
variety;
Suitable for continuous flow type production
systems and mass production systems;
No tool set up time, as tooling is fixed.
Examples: bottling plant, packaging plants,
transfer lines etc.
Programmable Automation
It is an automation system in which the
production equipment (machines) are
designed with a capability to change the
sequence of operations so as to accommodate
the different product configurations.
The operation sequence is controlled by a
program, which is a set of coded instructions
that can be read by the equipment.
Contd…
New programs can be prepared and entered
into the equipment to produce the new
products.
Programmable automation is suitable for
batch production systems.
Features of Programmable Automation
High initial investment in general purpose
equipment;
Lower production rates than fixed automation;
Flexible in accommodating product variety;
Most suitable for batch production systems;
Tool setup time varies from batch to batch.
Example: NC machine tools, industrial robots,
programmable logic controllers, etc.
Flexible (Soft) Automation
• It is an extension of programmable automation. It is
capable of producing products of design variations,
continuously with virtually little or no more time loss for
changeovers from one product to the other.
• There is virtually no production time loss while
reprogramming the system for new configuration of
product. Therefore, the system can produce various
combinations of products continuously instead of
requiring that they be made in batches.
• However, it is important to note that the variety of
products that can be produce by FAS is less than that can
be produced by PAS.
Features of flexible (soft) Automation
High initial investment for custom-engineered
equipment;
Medium production rates;
Flexible in accommodating product design
variations;
Suitable for continuous production of variable
products;
Minimal tool setup time.
Comparison Fixed (Hard) Programmable
Flexible Automation
Parameters Automation Automation
High initial
Initial investment for High initial investment High initial investment
for general purpose for custom-engineered
Investment custom-engineered
equipment. equipment.
equipment.
Production High. Low to medium. Medium.
Rates
Flexible in
Flexible in accommodating
Flexibility Highly inflexible. accommodating changes product design
in product variety. variations.
Suitable for
Production continuous flow type Suitable for continuous
production systems Suitable for batch production of variable
Systems and mass production
production systems.
products.
systems.
Tool Setup No tool setup time as Tool setup time varies Minimal tool setup
Time tooling is fixed. from batch to batch. time.
Advantages and Limitation of
Automation
• Advantages:
increase in productivity
Reduction in labour cost and cost of production
Minimizes the effects of labour shortages
Reduction in inventory
Reduction in scrap and rework
Increase in shop efficiency
Contd…
Better control over manufacturing activities
Increase in sales and profit of company
Improvement in worker safety
Relief to worker from fatigue
Improvement in product quality
Flexibility in variety in product design
Reduction in lead time.
Limitations
High initial cost
High maintenance cost
Expensive break-down time
Worker unemployment
No reward for human skills
Lesser job openings and social imbalance and
unrest.
Industrial Automation
• Automation may be defined as follows:
“It is the process of following a predetermined
sequence of operations with little or no human
labour, using specialized equipment and devices that
perform and control manufacturing processes.”
or
“It is the system in which many or all of the processes
in the production, movement and inspection of parts
and materials are automatically performed or
controlled by self-operating devices.”
Contd…
Or
“It is technology concerned with performing a
process by means of programmed commands
combined with automatic feedback control to
ensure proper execution of the instructions.”
Contd….
Partial automation means replacement of
human activities or involvement by automatic
means only partially.
In full automation, the human involvement
is totally eliminated and the process is entirely
carried out and controlled through automatic
means along with a proper feedback system.
Mechanization
It means that something is done or operated by
machinery and not by hand.
Feedback is not provided and thus one deals with open-
loop systems.
The automatic screw machine with its cam actuated
tools and sequencing represents a high degree of
mechanization.
Automation is a step beyond mechanization, where
human operators are provided with machinery to help
them in their jobs.
Industrial robots are said to be the most visible part of
automation.
Manufacturing Automation
It deals with the production of goods and includes the following:
Industrial robots;
Automatic machine tools to process parts;
Automatic assembly machines;
Automatic material handling
Automated storage and retrieval systems (AS/RS);
Automatic inspection systems;
Feedback control system;
Computer systems for automatically transforming design into
parts;
Computer systems for planning and decision making to support
manufacturing.
Advantages & Limitations of
Automation
Advantages:
Increased productivity.
Reduced overall production cost.
Less floor area required.
Increased overall profits of the manufacturing
concern.
Human fatigue is greatly minimized.
Reduced maintenance requirements.
The workers avail better working conditions.
Contd….
Uniform components are produced.
Effective control over the production process.
Great improvement in the quality and the
reliability of the products.
Human safety is fully ensured.
Limitations:
Initial cost is high.
Labour resistance due to fear of unemployment.
Skilled labour is required which increases the cost.
Applications of Automation
Numerical control.
Automated production lines.
Automated assembly.
Robots in manufacturing
Flexible manufacturing systems (FMS).
Building automation System (BAS).
CAD/CAM and CIM.
Automation in daily life.
Elements of Automation
• The three basic elements of automation are:
1. Source of power………..to perform some
function.
2. Feedback controls……..widely used in modern
automated systems.
Sensors
Analyzers
Actuators
Drives
3. Machine programming
Aims of Automation
To improve product quality
To enhance labour productivity
To reduce labour cost
To check the effect of labour shortages.
To reduce or eliminate routine manual clerical tasks.
To improve work safety.
To reduce manufacturing lead time
To accomplish process that can not be done manually.
To economize on floor space in manufacturing plant by
arranging the machines, material movement and related
equipment more efficiently.
Types of Automation
• The various types of automation are:
Fixed automation (Hard automation).
Programmable automation.
Flexible automation (Soft automation).
Low Cost Automation
• It is a technology that creates some degree of
automation around the existing equipment, tools,
methods, peoples etc., using mostly standard
components available in the market with low
investment, so that payback period is short.
• It is one of the very practical, safe, economical and
rewarding strategies in the present regime of
globaliasation and liberalization to enhance
productivity through quality enhancement and cost
reduction.
Contd…
• Low cost automation system may be adopted for
the following activities:
Loading
Clamping
Forming
Gauging
Feeding
Machining
Welding
Assembling and packing etc.
Contd…
• In low cost automation systems, the various
systems which can be employed are:
Mechanical
Hydraulic
Pneumatic
Electrical & Electronics.
Any of these systems can be used in simple
situations, however, in more difficult practical
applications hybrid systems are used.
Advantages of LCA System
Low investment required.
Better utilization of the material.
Small batch sizes.
Increased labour productivity.
Changes are gradual, smooth and very cost
effective.
Less rejections due to consistency in process.
The hardware components are flexible and
reusable and very adaptable to changes in
product, market conditions etc.
Automation Principle
1. Understand the existing process
– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production
systems
– Automation migration strategy
Automation Strategies
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10.Computer-integrated manufacturing
What are all 10 strategies for automation and
process improvement in CIM?
• This article describes the important points for automation
needed for Computer Integrated Manufacturing System.
• These strategies are used to improve process as well.
• Introduction
Today manufacturing Industries want to automize their
processes to increase their productivity to meet the ever
increasing demand in the market.
• Automation becomes unnecessary after the process has
been simplified. When it is found to be feasible solution
for improved performance, quality and productivity, it is
needed to study about the ten strategies that will give a
road map for any manufacturing organization.
