5.

1 AUTOMATION

5.1.1 Define

Automation can be defined as the technology used for the application of integrated mechanical,

electronic and computer based systems in the operation and control of production systems.

• Automation of production system means:

(i) Automation of manufacturing facilities, or (ii) Automation of manufacturing support systems, or

(ii) Automation of both the facilities and the manufacturing support systems.

• Automation is not new but has been in use in the industry since quite sometime. The automation
seems to be a feasible solution for improving the productivity, quality and economy.

• Automation is not economically feasible in low scale production. However, as the volume of
production

goes on increasing, automation becomes more and more economically feasible.

5.1.2 Need for Automation

(1) To increase productivity:

⚫ The automation of manufacturing operations usually increases production rate. This means
greater

output per hour of labour input. ⚫ Thus, automation leads to increase in labour productivity.

(2) To reduce cost of production:

Computer Integrated Manufacturing

The automation reduces the labour cost and increases the rate of production, thereby reducing

the

cost of production. (3) To improve product quality:

The automation not only results in higher production rates than manual operations but also (

improves the product quality.

4) To mitigate the effects of labour shortages: In developed countries where there is shortage of
labour, automated operations are used as

substitute for labour.

(5) To reduce production time: ⚫ The automation reduces the time required for manufacturing the
product.

(6) To avoid high cost of not automating: The automation exhibits overall benefits like: improved
product quality, high rate of production higher salaries, better labour relations, better customer
satisfaction and better company image.

• The companies without automation are likely to find themselves in a disadvantageous position as

compared to the companies with automation.

(7) To have better control over manufacturing activities: ⚫ Automation provides better control over
entire manufacturing activity of a company.
(8) To improve worker safety: The automation can completely replace the worker, especially in
hazardous operations like: spray

paintings, welding, chemical processing etc., thereby improving the worker safety.

⚫ The automation has changed the role of worker from active participation to a supervision. (9) To
reduce or eliminate routine manual and clerical tasks:

Automation reduces/eliminates routine manual and clerical tasks which are boring, fatiguing and
isksome, thereby improving the general level of working conditions.

5.1.3 High and Low Cost Automation

High Cost Automation:

High cost automation involves of manufacturing facilities or/and manufacturing support system. If
enuentional machine hv CNC machines, material handling by conveyors and AGV's,

High cost automation demands huge capital investment and only scale industries can altered it If

High Cost Automation:

Example of high cost automation, full automation factory. Low cost automation is the introduction of
simple pneumatic, hydraulic, mechanical and electrical

Low Cost Automation:

devices into the existing production machinery, with a view of improving their productivity.

India is fast developing industrially. The industrial growth, particularly during the last decade has
been considerable. This growth of course is not free from the attendant problems. In a country like
ours, which has mainly an agricultural based economy, the industrial development is very likely to
change the existing conditions. Low cost automation should not be regarded in terms of a specified
maximum capital outlay, but as ad approach to automation using equipment and control devices that
are, in general, both technically and

economically, within the scope of the company concerned. The main aim of low cost automation is
to increase productivity and quality of products and reduce the

cost of production and not reduce labour.

5.1.4 Example of Automation

Some of the examples of automation of process in production systems are as follows: (i) NC and CNC
machines.

(i) Automatic assembly machines. (ii) Automated transfer lines.

(iv) Automatic assembly lines.

(v) Industrial robots.

(vi) Automated material handling systems. (vii) Automated storage systems.

(vii) Automated inspection and quality control systems. (ix) Automated feedback and process control
equipment.

(x) Computer aided production, planning and control. 5.2 ELEMENTS OF AUTOMATION

(1) Power Source:

An automated system is used to operate some process and power is required to drive the process as

well as controls. There are many source of power available, but the most commonly used power is
electricity. The actions performed by automated systems are generally of two types.

(a) Processing.

(b) Transfer and positioning.

In the first case, energy is applied to accomplishe some processing operation on some entity. The

process may involves shaping, moulding or loading and unloading. All these actions need power to
transfer

the entity from one state or condition into more valuable state or condition.

The second type of actions transfer and positioning. In these cases, the product must generally be

moved from one location to another during the series of processing steps.

(2) Program of Instructions:

The actions performed by an automated process are defined by a set of instructions known as
process. The programmed instructions determine the set of actions that is to be done automatically
by the system. The program specifies what automated system should do and how its various
components must function in

order to accomplish the desired results.

(3) Control System:

The control element of the automated system executes the program of instructions.

The controls in an automated system can be: (a) Closed loop.

(b) Open loop.

(a) Closed loop control system: It is also known as a feedback control system. In this system the

output variable is compared with an input parameter and any difference between the two is used to
drive the output into agreement with input.

1. Input parameter: As set point, represents the desired value of output.

2. Output variables: Actual value of parameter. 3. Sensors: A sensor is used to measure the output
variable and close the loop

4.

Between input and output: It performs feedback functions.

5. Controller: The controller compares the output with the input and makes the required adjustment
in the process to reduce the difference between them.

6. Actuator: The adjustment being done with one or more actuators which are the hardware devices
that physically carry out the control actions such as, electric motor, cylinder etc. (b) Open loop
control system: It is without the feedback loop. In this case the controls operates without measuring
the output variables, so no comparison is made between the actual value of the output and desired
input parameters. There is always risk that the actuator will not have intended

effect on the process.

5.3 TYPES OF AUTOMATION

The automation of production systems can be broadly classified into three types, as shown

Reference
input r(t)

u(t)

Process

Controlled output c(t)

in Fig. 5.1

5.4

Controller

u(t) = Actuating signal Fig. 5.1: Types of Automation

5.3.1 Fixed (Hard) Automation

Fixed (Hard) automation is an automaton system in which the sequence of processing operations is
fixed by the production equipment (machines) configuration. Each processing operation in a
sequence is simple.

The fixed automaton can not be changed once it is established and hence, it is inflexible in

accommodating the product variety. The fixed automation is economical when there is a continuous
high demands for the product at the

high volume.

⚫ The initial cost of the automated equipment can be spread over a very large number of units, thus,

making the unit cost attractive compared with the equipment without automation.
The fixed automation is suitable for continuous flow type production systems and mass production

system.

⚫ Features of fixed (hard) automation:

6) High initial investment for custom - engineered equipment. (ii) High production rates

(iii) Highly inflexible in accommodating product variety. (iv) Suitable for continuous flow type
production systems and mass production systems.

(v) No tool set up time, as tooling is fixed.

⚫ Examples of fixed automation: Bottling plants, packaging plants, transfer lines etc. 5.3.2
Programmable Automation

• Programmable automation 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 operations sequences is controlled by a program, which is a set of coded instructions that can
be

read by the equipment.

⚫ New programs can be prepared and entered into the equipment to produce the new products, •
To produce a batch of new product, a new program must be prepared and entered into the
equipment
(machine). The physical setup of the machine (ie. tooling, fixtures, machine settings etc.) must also
be changed, this change over procedure takes time and is called as set up time. Programmable
automation is suitable for batch production systems

Features of programmable automation:

(i) High initial investment in general purpose equipments (ii) Lower production

rates than fixed automation. (i) Flexible in accommodating product variety.

(iv) Most suitable for batch production systems.

(v) Tool setup time varies from batch to batch. Examples of programmable automation: NC machines
tools, industrial robots, programmable logic

controllers etc.

5.3.3 Flexible (Soft) Automation

Flexible (soft) automation, which is an extension of programmable automation is an automation

system capable of producing products of design variations, continuously with virtually little or not
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 produced by flexible
automation system is less than that can be produced by programmable automation system.

⚫ Features of flexible (soft) automation: (i) High initial investment for custom-engineered
equipment.
(ii) Medium production rates.

(iii) Flexible in accommodating product design variations. (iv) Suitable for continuous production of
variable products.

(v) Minimal tool setup time.

5.3.4 Comparison of Types of Automation Systems

Production rates

• Comparison of three types of automation systems is summarized in Table 5.1.

Table 5.1: Comparison of three types of automation systems

Comparison parameters

Fixed (Hard)

Programmable Automation

Flexible (Soft) Automation

Automation

Initial Investment

High initial investment

High
initial investment

High initial investment for custom-engineered

for custom-engineered

for general purpose equipment.

equipment. High.

equipment. Medium,

Low to medium,

Flexible

in accommo- Flexible in accommo- dating product design

dating changes

in

product variety.

variations.

Suitable for continuous flow type production

Suitable for batch production systems.

Suitable for continuous production of variable

system

and mass

products.

production systems.

No tool setup time as tooling is fixed.

Tool setup time varies from batch to batch.

Minimal

tool

setup

time.

Flexibility

High inflexible.

Production system

Tool setup time

Automation
The three types of automation systems can be distinguished in terms of production quantity
(volume) and product variety (flexibility) as shown in Fig. 5.2.

Fixed (Hard) automation

Automation

Programmable automation

Flexible (Soft) automation Fig. 5.2: Production quantity and product variety for different automation
system

5.4 STRATEGIES IN AUTOMATION

strategies that can be employed to improve productivity in

There are certain fundamental manufacturing operations technology. These are referred as
automation strategies.

5.4.1 Simplification

The main strategy is simplification process in automation, with the help of this strategy, we done
reduces wasted time to do routine processes. Improves quality by requiring accurate information at
every

step and save money also, because of significant reduced numbers and associated rework.

5.4.2 Specialization of Operations

The first strategy involves the use of special purpose equipment designed to performed one
operation with the greatest possible efficient. This is analogous to the concept of labour
specializations, which has
been employed to improve labour productivity.

5.4.3 Multiple Operation (Combined Operation)

Production occurs as a sequences of operations. Complex parts may require dozens, or even
hundreds.

of processing steps. The strategy of combined operations involves reducing the number of distinct

production machines or workstations through which the part must be routed. This is accomplished
by

performing more than one operation at a given machine, thereby reducing the number of separate

machines needed. Since, each machines typically involves a setup, setup time can be saved as a

consequence of this strategy. Material handling effort and non-operation time are also reduced.

5.4.4 Integration of Operations

Another strategy is to link several workstations into a single integrated mechanism using automated
work handling devices to transfer parts between stations. In effect, this reduces the number of
separate machines though which the product must be scheduled with more than one workstation,
several parts can be processed simultaneously, thereby increasing the overall output of the system.

5.4.5 Increased Flexibility

This strategy attempts to achieve maximum utilization of equipment for job shop and medium
volume situations by using the same equipment for a variety of products. It involves the use of the
flexible automation concepts. Prime objectives are to reduce setup time and programming time for
the production machine. This normally translates into lower manufacturing lead time and lower
work-in-process. 5.4.6 Automated material Handling Storage System
A great opportunity for reducing non-productive time exists in the use of automated material
handling and storage systems. Typical benefits included reduced work-in-process and shorter
manufacturing lead

Times

The three types of automation systems can be distinguished in terms of production quantity
(volume) and product variety (flexibility) as shown in Fig. 5.2.

Fixed (Hard) automation

Automation

Programmable automation

Flexible (Soft) automation Fig. 5.2: Production quantity and product variety for different automation
system

5.4 STRATEGIES IN AUTOMATION

strategies that can be employed to improve productivity in

There are certain fundamental manufacturing operations technology. These are referred as
automation strategies.

5.4.1 Simplification

The main strategy is simplification process in automation, with the help of this strategy, we done
reduces wasted time to do routine processes. Improves quality by requiring accurate information at
every

step and save money also, because of significant reduced numbers and associated rework.

5.4.2 Specialization of Operations

The first strategy involves the use of special purpose equipment designed to performed one
operation with the greatest possible efficient. This is analogous to the concept of labour
specializations, which has

been employed to improve labour productivity.

5.4.3 Multiple Operation (Combined Operation)

Production occurs as a sequences of operations. Complex parts may require dozens, or even
hundreds.

of processing steps. The strategy of combined operations involves reducing the number of distinct

production machines or workstations through which the part must be routed. This is accomplished
by

performing more than one operation at a given machine, thereby reducing the number of separate

machines needed. Since, each machines typically involves a setup, setup time can be saved as a

consequence of this strategy. Material handling effort and non-operation time are also reduced.

5.4.4 Integration of Operations

Another strategy is to link several workstations into a single integrated mechanism using automated
work handling devices to transfer parts between stations. In effect, this reduces the number of
separate machines though which the product must be scheduled with more than one workstation,
several parts can be processed simultaneously, thereby increasing the overall output of the system.

5.4.5 Increased Flexibility

This strategy attempts to achieve maximum utilization of equipment for job shop and medium
volume situations by using the same equipment for a variety of products. It involves the use of the
flexible automation concepts. Prime objectives are to reduce setup time and programming time for
the production machine. This normally translates into lower manufacturing lead time and lower
work-in-process. 5.4.6 Automated material Handling Storage System

A great opportunity for reducing non-productive time exists in the use of automated material
handling and storage systems. Typical benefits included reduced work-in-process and shorter
manufacturing lead

Times

5.4.7 Online Inspection

Inspection for quality of work is traditionally performed after the process. This means that any poor
quality product has already been produced by the time it is inspected. Incorporating inspection into
the manufacturing process permits corrections to the process as product is being made. This reduces
scrap and brings the overall quality of product closer to the nominal specifications intended by the
designer.

5.4.8 Process Control and Optimization This includes a wide range of control schemes intended to
operate the individual process and

associated equipment more efficient. By this strategy, the individual process times can be reduced
and

product quality improved.

5.4.9 Plant Operations Control

Whereas the previous strategy was concerned with the control of the individual manufacturing
process, this strategy is concerned with control at the plant level of computer networking within the
factory. 5.4.10 Computer Integrated Manufacturing (CIM)

Taking the previous strategy, one step further, the integration of factory operations with engineering

design and many of the other business functions of the film. CIM involves extensive use of computer
applications, computer data bases and computer networking in the company.

5.4.11 Online Monitoring

The system here aims in implementing on online facility for monitoring our automation and the
equipment or production status at any instant of demand. Detection of any error in system or
product immediately show this type of monitoring is best monitoring system to reduce the non-
productive, time and increase efficiency of production, also increase accuracy of the product.

Important Points

1. Automation:

• Automation can be defined as the technology used for the application of integrated mechanical,
electronic and computer based systems in the operation and control of production systems.

⚫ Need of automation:

(1) To increase productivity. (2) To reduce cost of production.

(3) To improve product quality.

(4) To mitigate the effect of labour shortages.

(5) To reduce production time. (6) To avoid high cost of not automating.

(7) To have better control over manufacturing activities.

(8) To improve worker safety.

(9) To reduce or eliminate routine manual and clerical tasks.

Elements of Automation:

Power source.

• Program of instructions. ⚫ Control system.

(a) Open loop control system.

(b) Close loop control system.

4. Type of Automation:

Fixed automation.

⚫ Programmable automation.

• Flexible automation.

5. Strategies in Automation:

• Specialization of operation.

• Multiple operations.

Integration of operations.

Increased flexibility.

Automated material handling. Online inspection.

Process control and optimization. Plant operations control.

Computer integrated manufacturing. Simplification.

Practice Questions

1. Define and need of automation. Short note on high and low cost automation.

3. Explain types of automation.

4.

Explain element of automation.

5. Explain fixed automation

6.

Explain programmable automation

7. Explain flexible automation.

8. 9. Comparison between fixed automation, programmable automation and flexible automation.

Explain different strategies used in automation.