DDE 3443

INDUSTRIAL AUTOMATION
CHAPTER 1
INTRODUCTION TO
AUTOMATION

1
 INTRODUCTION

Production system: manufacturing support

systems and facilities.

Mfg Support Facilities

System (Factory
Equipments)

2
 INTRODUCTION… cont.
• Mfg. Support System
- procedures used to manage prod. and to
solve logistics & technical prob.
Facilities
- the equipments in factory and the way
the equipment is organized. It includes
machines, tooling, material handling
equipment, inspection equipment, comp. &
plant layout.

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4
5
 INTRODUCTION… cont.
• Industrial Automation:
• The technology by which a process or
procedure is accomplished without human
assistance.
• A technique that can be used to reduce costs
and/or to improve quality.
• Can increase manufacturing speed, while
reducing cost.

6
 INTRODUCTION…cont.

• Can lead to products having consistent

quality, perhaps even consistently good
quality
• It is implemented using a program of
instructions combined with a control system
that executes the instructions.

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 INTRODUCTION…cont.

• To automate a process, power is required,

both to drive the process itself and to
operate the program and control system.
• Automated processes can be controlled by
human operators, by computers, or by a
combination of the two.

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 Definition 1
• Automation is a technique that can be used to
reduce costs and/or to improve qual­ity. Automation
can increase manufacturing speed, while reducing
cost. Automation can lead to products having
consistent quality, perhaps even consistently good
quality.

Definition 2
• Automation is a technology concerned with
application of mechanical, electronic and
computer-based system to operate and
control system. This technology includes;

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• Automatic assembly machines
• Automation machine tools to process
parts
• Industrial robots
• Automatic materials handling and
storage system
• Automatic inspection system and
quality control
• Feedback control and computer
process control
• Computer system for planning, data
collection and decision making to
support manufacturing activities
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 INTRODUCTION…cont.

• If a human operator is available to monitor

and control a manufacturing process, open
loop control may be acceptable.
• If a manufacturing process is automated, then
it requires closed loop control, also known
as feedback control.
• example of open loop control and closed loop
control.

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Example of open loop control system

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Example of closed loop control

Temperature
instruction

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Example of closed loop control

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 Arguments in favor of Automation

• Automation is the key to shorter work week –

working hours per week reduces and , allowing
more leisure hours and a higher quality of life.
• Automation brings safer working conditions for
workers.
• Automated production results in lower prices and
better products

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 Arguments against Automation

• It result in the subjugation of human being by a

machine – reduces the need for skilled labor
• There will be reduction in the labor force –
resulting un employment.
• Automation will reduce purchasing power-
markets will become saturated with products that
people cannot afford to purchase.

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 SOME CONSIDERATIONS
• What automation and control technology
is available?
• Are employees ready and willing to use
new technology?
• What technology should be used?
• Should the current mfg process be
improve before automation?
• Should the product be improved before
spending millions of ringgit acquiring
equips.

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MANUAL LABOR IN PRODUCTION
SYSTEMS

• Task is too technologically difficult to

automate.
• Short product life cycle.
• Customized product.
• To cope with ups and downs in demand.
• To reduce risk of product failure.

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BASIC ELEMENT OF AN AUTOMATED
SYSTEM
• Consists of 3 basic elements:
1) The actuator (which does the work)
• Controlled by the controller.
• The actuator in a automated
process may in fact be several
actuators, each of which provides
an output that drives another in
the series of actuator.

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BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.

• Some actuators can only be on and

off. Other actuators respond
proportionally with the signal they
receive from a controller
• Actuators can be selected for the
types of inputs they require, either
DC or AC.

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BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
2)The controller (which ‘tells’ the
actuator to do work)
» A controlled system either
may be a simple digital
system or an analog system.
» Digital and analog controllers
are available ‘off the shelf’
so that systems can be
constructed inexpensive and
with little specialized
knowledge required.

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BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.
3) The sensor (which provides
feedback to the controller so that
it knows the actuator is doing work)

• Obviously, controlled automation

requires devices to sense system
output.
• Sensors also can be used so that a
controller can detect and respond
to changing conditions in its
working environment.

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BASIC ELEMENT OF AN AUTOMATED
SYSTEM…cont.

• Switches and transducers are

another name for sensors.
• Switches can detect when a
measured condition exceeds a pre-
set level. Examples, closes when a
work-piece is close enough to work
on.
• Transducers can describe a
measured condition. Examples,
output increased voltage as a work-
piece approaches the working zone.
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 TYPE OF AUTOMATION

• Hard Automation
– Controllers were built for specific
purposes and could not be altered easily.
– Early analog process controllers had to
be rewired to be reprogrammed.

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 TYPE OF AUTOMATION…cont.

– This controllers do what they are

designed and built to do, quickly and
precisely perhaps, but with little
adaptability for change (beyond minor
adjustments).
– Modification of hard automation is
time-consuming and expensive, since
modifications can only be performed
while the equipment sits idle.

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 TYPE OF AUTOMATION…cont.

• Soft Automation
– Modern digital computers are
reprogrammable.
– It is even possible to reprogram them
and test the changes while they work.
– Even if hardware changes are required
to a soft automation system, the lost
time during changeover is less than for
hard automation
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 AUTOMATED MFG. SYSTEM

• Automated Mfg. System can be

classified into three basic types:
Fixed Automation
– A system which the sequence of
processing (or assembly) operations
is fixed by the equipment
configurations.
– Each operations in the sequence is
usually simple.

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AUTOMATED MFG. SYSTEM… cont.

– The features of fixed automation;

• High initial investment for custom-
engineered equipment
• High production rates
• Relatively inflexible in accommodating
product variety.
• Examples, machining transfer lines and
automated assembly machines.

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 AUTOMATED MFG. SYSTEM… cont.

• Programmable Automation
– The production equipment is designed
with the capability to change the
sequence of operations to accommodate
different product configurations.
– The operation sequence is controlled by
a program, which is a set of instruction
coded so that they can be read and
interpreted by the system.

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AUTOMATED MFG. SYSTEM… cont.

– New programs can be prepared and

entered into the equipment to produce
new products.
– The physical setup of the machine must
be changed for each new products.
– This changeover procedures takes time.
– Eg: numerical control (NC) machine
tools, industrial robots and PLC.

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AUTOMATED MFG. SYSTEM… cont.

– The features of programmable

automation;
• High investment in general purpose
equipment.
• Lower production rates than fixed
automation.
• Flexibility to deal with variations and
changes in product configuration.
• Most suitable for batch production.

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AUTOMATED MFG. SYSTEM… cont.

• Flexible Automation
– An extension of programmable
automation.
– Capable of producing a variety of
parts/products with virtually no time
lost for changeovers from one part
style to the next.

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AUTOMATED MFG. SYSTEM… cont.

– The features of flexible automation;

• High investment for custom-
engineered system.
• Continuous production of variable
mixtures of products.
• Medium production rates.
• Flexibility to deal with product design
variations.

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AUTOMATED MFG. SYSTEM… cont.

– Examples, flexible manufacturing

systems for performing machining
operations.
The relative positions of the three
types of automation for different
production volume and product
varieties are shown below.

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Relationship between product variety
& quantity

Low

Medium

100 10000
High
1,000,000

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Relationship of fixed, programmable and
flexible automation

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 REASON FOR AUTOMATING

• To increase labor productivity

• To reduce labor cost
• To improve worker safety
• To improve product quality
• To mitigate the effects of labor
shortages
• To reduce/eliminate routine
manual & clerical tasks.

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REASON FOR AUTOMATING… cont.

• To reduce mfg lead time

• To accomplish processes that cannot
be done manually
• To avoid the high cost of not
automating

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 MANUAL LABOR IN PROD. SYSTEM

There are situations which manual labor is

usually preferred over automation:
• Task is too technologically difficult to
automate.
• Short product life cycle
• Customized product
• To cope with ups and downs in demand
• To reduce risk of product failure

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 PRINCIPLES AND STRATEGIES

American Prod. And Inventory Control

Society(APICS) gives three principles:
• Understand the existing process
• Simplify the process
• Automate the process

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STRATEGIES FOR AUTO./PROD SYSTEM

• Specialization of operation
• Combined operations
• Simultaneous operations
• Integration operations
• Increased flexibility
• Improved material handling and storage
• On-line inspection

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 STRATEGIES FOR AUTO./PROD
SYSTEM… cont.

• Improved material handling and storage

• On-line inspection
• Process control and optimization
• Plant operations control
• Computer-integrated manufacturing

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 AUTOMATION CONTROL

• Usually implies a sequence of mechanical

steps.
• A camshaft is an automation controller
because it mechanically sequences the
steps in the operation of an internal
combustion engine.

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 AUTOMATION CONTROL… cont.

• Manufacturing processes are often

sequenced by special digital computers,
known as programmable logic controller
(PLC).
• PLC can detect and can switch electrical
signals on and off.

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 PROCESS CONTROL

• Usually implies that the product is

produced in a continuous stream.
• Often, it is a liquid that is being
processed.
• Early process control system consisted of
specially-designed analog circuitry that
measured a system’s output ( e.g., the
temperature of liquid leaving a tank),

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 PROCESS CONTROL… cont.

and changed that input ( e.g., changing

the amount of cool liquid mixed in) to
force the output to stay at a preset
value.
• Now, process control is accomplished
using digital computers.

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 MANUFACTURING

Manufacturing – the application of

physical and chemical processes to
alter the geometry, properties and /or
appearance of a given starting
material to make parts/product
- includes the joining of multiple
parts to make assembled products

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 MANUFACTURING… cont.

• Economic viewpoint- the transformation of

material into items of greater value…
• Eg: iron converted into steel, sand
transformed into glass, petroleum
transforms into plastic etc.

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 MANUFACTURING… cont.

Machinery
Tools
Power
Labor

Starting Mfg. Process Complete part

Material

Waste
As a technological process

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 MANUFACTURING… cont.

Mfg. Process

•
•
• Value Added
• Starting material complete
part
• Material in Processing
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 MANUFACTURING… cont.

• Basic activities to convert raw material

into finished products:
i. Processing and assembly operations
ii. Material handling
iii. Inspection and test
iv. Coordination and control

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 Processing and assembly operations

• Processing operation transform a work

material from one state of completion to a
more advanced state that is closer to the
final desired part/product. materials is
fed into the process, energy is apply by
the machinery and tooling to transform
the material into finished products.
• Assembly operations – two or more
components combined to form a new entity
eg: welding, soldering, screws, rivets etc.
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 Material handling & storage

• Moving and storing materials between

processing and/or assembly operations.

Inspection and test

• Both are quality control activities to
determine whether products meet the
design std. and spec.

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 Coordination and control

• includes at process and plant levels

• Process level – manipulating input and
parameters of the process.
• Plants level – labor, maintenance, costing,
shipping, scheduling etc.

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 PRODUCT/PRODUCTION
RELATIONSHIPS

• 4 keys parameters:
i. Quality
ii. Variety
iii. Complexity of assembled
products
iv. Complexity of individual parts.

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 Quantity and variety

Consider: Q= prod. Quantity, P=prod. Variety

: Qj=annual quantity of prod j
: Qf= total quantity of all part

p
Qf = ∑Qj, where P = total no. of diff.
j=1 part, j = 1,2,3,…

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 Product and Part complexity

• Complexity refer to the no.of components

used to produce a product-the mere parts,
the more complex.
• Let, np = the no. of part per product
no = the no. of operation/pros. Steps

The total no. of parts manufactured/year:

npf=total no.of part/yr
p
npf = ∑Qjnpj Qj = annual quantity/yr
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j=1 npj = no. of parts/prod
 Product and Part complexity… cont.

• The total no. of processing operations performed

in the plant:
p npj
nof = ∑Qjnpj ∑nojk
j=1 k=1

Where; nof= total no. ofoperation cycles

nojk= no of processing operation for each part k
npj = no.of parts in product
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 Product and Part complexity… cont.

Conceptualize:
Consider P = no. of product design
Q = quantities
So, the total no. of product produced,
Qf = PQ
the total no. of parts produced,
npf = PQnp
the total no. of mfg operation
performed,
nof = PQnpno 59
 Example

P=100 different product, each product

produced 10,000 unit/yr, each consist of
1000 components, average processing
step=10/component, each processing
step=1min. Determine:
- how many product
- how many part
- how many prod. operation
- how many workers needed
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 Solution

i. Total no. of unit produced, Qf = PQ

100 x 10,000 = 1,000,000
prod./yr
ii. Total no of part produced = npf = PQnp
1.000.000 x 1000 = 1,000,000,000
parts/yr
iii. Prod. operation = nof =PQnpno
iv. Total time = 1,000,000,000 x
1/60=166,666,667 hr
v. Workers=
1666,6666,661/2000=83,333 workers
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 Production rate
• Normally expressed as an hourly rate.
• Also called operation cycle time, Tc.
Tc is defined as the time that one work
unit spends being processed/assembled.
Tc = To + Th + Tth
where Tc = operation cycle time (min/pc)
To = time of actual
processing/assemb.
Th = handling time (min/pc)
Tth= tool handling time(min/pc)
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 Production capacity

• Is defined as the max. rate of o.p that the

production facilities is able to produce
under a given set of assumed operation
cond.( num. of shift/day).
• Let PC = prod. Capacity, n = num. of m/c
Rp = prod. Rate, H = hr/shift, S =num. of
shift/week.
PC = n SH Rp

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 Production capacity… cont.

• If no = num. of distinct operation through which

work units are routed.
PC = n SH Rp / no

• To increase/decrease prod. Capacity:

i. Short term:
 changes of S and H will increase prod. Capacity
ii. Long term
 to increase capacity, change n, increase Rp and
reduce no.

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 MANUFACTURING OPERATION
COSTS
• Mfg costs – fixed and variable costs.
• Fixed costs-remains constant for any level
of prod.
• Variable costs-varies in proportion to the
level of prod.
• Let TC = total annual costs (RM/yr), FC =
fixed annual costs (RM/yr), VC= variable
costs (RM/pc) and Q = annual quantity
produced (pc/yr).

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MANUFACTURING OPERATION
COSTS… cont.

TC = FC + VC(Q)

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 MANUFACTURING OPERATION COSTS…
cont.

• Costs also depend on labor, materials and

overhead.
• Labor costs- paid to workers
• Materials costs- cost of raw materials to
produce product.
• Overhead costs- factory and corporate
o.heat
- factory o.h to operate the factory
- corporate o.h to run the factory
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MANUFACTURING OPERATION
COSTS… cont.

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MANUFACTURING OPERATION
COSTS… cont.

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MANUFACTURING OPERATION COSTS…
cont.

• J.T Black.

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 MANUFACTURING OPERATION COSTS…
cont.

• Overhead rate (burden) to be calculated

and to used in the following year to
allocate overhead costs.
FOHR = FOHC / DLC
Where FOHR = factory overhead
rate
FOHC = annual factory overhead

costs
DLC = annual direct labor costs

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 MANUFACTURING OPERATION
COSTS… cont.

• Corporate overheat rate,

COHR = COHC /DLC
where COHR = annual corporate overhead
rate,
COHC = annual corporate overhead
costs, DLC = annual direct labor costs
DLC = annual direct labor costs

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 MANUFACTURING OPERATION
COSTS… cont.
• Eg:

determine a) FOHR for each plant

b) COHR

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 MANUFACTURING OPERATION COSTS…
cont.

Solution:
a) FOHR1 = 2,000 / 800,000 = 250%
FOHR2 = 1,100,000 / 400,000 = 275%

b) COHR = 72,000 / 1,200,000 = 600%

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