INDUSTRIAL AUTOMATION

(MEU 07569)
LECTURE 1 -AUTOMATION
CLASS – BMTE 3
I N S T R U C T O R:
E N G . G RAC E K I BW E JA
 AUTOMATION
• Theword automation comes from the Greek word “automatos,” meaning self-
acting
• Automation is the process of following a predetermined sequence of
operations with little or no human labor, using specialized equipment and
devices that perform and control manufacturing processes.
•Achieved through the use of a variety of devices, sensors, actuators,
techniques, and equipment that are capable of observing the manufacturing
process, making decisions concerning the changes that need to be made in the
operation, and controlling all aspects of it
• In industry through automation various production operations are converted
from a manual process, to an automated or mechanized process
Example;
Consider Operating a metal lathe
Manually
The worker collects the stock, already cut to size, from a bin. He then places it in
the lathe chuck, and moves the various hand-wheels on the machine to create a
component; When finished the worker begins the process again to make another
item.
Automated
The worker places long lengths of bar into the feed mechanism of an automatic
lathe. The lathe mechanisms feed the material into the chuck, turn the piece to
the correct shape and size, and cut it off the bar before beginning another item.
Other examples of automation
process
In manufacturing the following tasks can be automated:
• Painting
• Stacking
• Welding
• Polishing
• Labelling
• Assembly
• Automation deals with the application of mechatronics and computers for
production of goods and services.
• Manufacturing automation deals with the production of goods.
It includes:
- Automatic machine tools to process parts.
- Automatic assembly machines.
- Industrial robots.
- Automatic material handling.
- Automated storage and retrieval systems.
- Automatic inspection systems.
- Feedback control systems.
- Computer systems for automatically transforming designs into parts.
- Computer systems for planning and decision making to support
manufacturing.
Consideration to automate a
new or existing facility
Decision to automate a new or existing facility requires the following
considerations to be taken into account:
• Type of product manufactured
• Quantity and the rate of production required
• Particular phase of the manufacturing operation to be automated
• Level of skill in the available workforce
• Reliability and maintenance problems that may be associated with
automated systems
• Economics
Advantages of automation
• Increase in productivity.
• Reduction in production costs.
• Minimization of human fatigue.
• Less floor area required.
• Reduced maintenance requirements.
• Better working conditions for workers.
• Effective control over production process.
• Improvement in quality of products.
• Reduction in accidents and hence safety for workers.
• Uniform components are produced.
Goals of automation
• Integrate
various aspects of manufacturing operations so as to improve the
product quality and uniformity, minimize cycle times and effort, and thus
reduce labor costs.
• Improve productivity by reducing manufacturing costs through better
control of production. Parts are loaded, fed, and unloaded on machines
more efficiently. Machines are used more effectively and production is
organized more efficiently.
•Improve quality by employing more repeatable processes. Reduce human
involvement, boredom, and possibility of human error.
• Reduce workpiece damage caused by manual handling of parts.
• Raise the level of safety for personnel, especially under hazardous
working conditions.
•Economize on floor space in the manufacturing plant by arranging the
machines, material movement, and related equipment more efficiently.
Types of automation
There are three types of automation:
1. Fixed Automation (Hard Automation)
2. Programmable Automation
3. Flexible (Soft automation)
Fixed automation (Hard
automation)
• Fixed automation refers to the use of special purpose equipment to automate a
fixed sequence of processing or assembly operations
• It is typically associated with high production rates and it is relatively difficult
to accommodate changes in the product design
• This is also called hard automation
•For example, GE manufactures approximately 2 billion light bulbs per year and
uses fairly specialized, high-speed automation equipment
• Fixed automation makes sense only when product designs are stable and product
life cycles are long
Advantages
• Maximum efficiency.
• Low unit cost.
• Automated material handling—fast and efficient movement of parts.
• Very little waste in production.
Disadvantages
• Large initial investment.
• Inflexible in accommodating product variety.
Programmable Automation
• In programmable automation, the equipment is designed to accommodate a specific
class of product changes and the processing or assembly operations can be changed by
modifying the control program.
• It is particularly suited to “batch production,” or the manufacture of a product in
medium lot sizes (generally at regular intervals).
•The example of this kind of automation is the CNC lathe that produces a specific
product in a certain product class according to the “input program.”
• In programmable automation, reconfiguring the system for a new product is time
consuming because it involves reprogramming and set up for the machines, and new
fixtures and tools.
•Examples numerically controlled machines, industrial robots, etc.
Advantages
• Flexibility to deal with variations and changes in product.
• Low unit cost for large batches.
Disadvantages
• New product requires long set up time.
• High unit cost relative to fixed automation
Flexible Automation (Soft
Automation)
• In
flexible automation, the equipment is designed to manufacture a variety
of products or parts and very little time is spent on changing from one
product to another.
• Thus, a flexible manufacturing system can be used to manufacture various
combinations of products according to any specified schedule.
• With a flexible automation system, it is possible to quickly incorporate
changes in the product (which may be redesigned in reaction to changing
market conditions and to consumer feedback) or to quickly introduce a
new product line.
•For example, Honda is widely credited with using flexible automation
technology to introduce 113 changes to its line of motorcycle products in the
1970s.
• Flexible automation gives the manufacturer the ability to produce multiple
products cheaply in combination than separately.
Advantages
• Flexibility to deal with product design variations.
•Customized products.
Disadvantages
•Large initial investment.
•High unit cost relative to fixed or programmable automation
Reasons for automation
1. Shortage of labor
2. High cost of labor
3. Increased productivity
4. Competition
5. Safety
6. Reducing manufacturing lead-time
7. Lower costs