INDUSTRIAL AUTOMATION
Module - 1 : Introduction
Production System
Definition: A collection of people, equipment, and procedures organized to
accomplish the manufacturing operations of a company.
Facilities.
• The facilities of the production system consist of the factory, the
equipment in the factory, and the way the equipment is organized.
PRODUCTION SYSTEM FACILITIES
Plant Layout:
• Plant layout refers to the physical arrangement
of equipment within the factory.
• A well-designed layout enhances operational
efficiency.
• Considerations include workflow optimization
and space utilization.
Manufacturing Systems
Product variety
BMW X5 BMW X7
MANUFACTURING SUPPORT SYSTEMS
AUTOMATION IN PRODUCTION SYSTEMS
• Some elements of the firm's production system are
likely to be automated, whereas others will be
operated manually or electrically. For our purposes
here, automation can be defined as a technology
concerned with the application of mechanical,
electronic, and computer-based systems to operate
and control production.
• The automated elements of the production system
can be separated into two categories: (1) automation
of the manufacturing systems in the factory and (2)
computerization of the manufacturing support
systems.
Automated
Manufacturing
Systems
• Automated machine tools
• Transfer lines
• Automated assembly systems
• Inspection and material handling
Automated Manufacturing Systems
• Automated manufacturing systems operate in the factory on the physical
product. They perform operations such as processing, assembly, inspection, or
material handling, in some cases accomplishing more than one of these
operations in the same system. They are called automated because they perform
their operations with a reduced level of human participation compared with the
corresponding manual process.
• Examples of automated manufacturing systems include:
• automated machine tools that process parts
• transfer lines that perform a series of machining operations
• automated assembly systems.
Automated manufacturing systems can be classified into three basic types: (1) fixed
automation. (2) programmable automation, and (3) flexible automation.
Fixed Automation
A manufacturing system in which the sequence of processing (or assembly)
operations is fixed by the equipment configuration.
For example, the feeding of a rotating spindle.
Typical features:
§Suited to high production quantities
§High initial investment for custom-engineered equipment
§High production rates
Relatively inflexible in accommodating product variety
Examples of fixed automation include machining transfer lines and
automated assembly machines
Programmable Automation
A manufacturing system designed with the capability to change the
sequence of operations to accommodate different product configurations
Typical features:
§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
§Physical setup and part program must be changed between jobs (batches)
Examples of programmable automation include numerically controlled (NC)
machine tools, industrial robots, and programmable logic controllers.
Flexible Automation
An extension of programmable automation in which the system is capable of
producing a variety of parts (or product) with virtually no time lost for
changeovers from one part style to the next.
Typical features:
§High investment for custom-engineered system
§Continuous production of variable mixes of products
§Medium production rates
§Flexibility to deal with soft product variety
Examples of flexible automation are the flexible manufacturing systems for
performing machining operations
Product Variety and Production Quantity for Three
Automation Types
Computerized Manufacturing Support Systems
Automation of the manufacturing support systems is aimed at reducing the
amount of manual and clerical effort in product design, manufacturing
planning and control, find the business functions of the firm.
Objectives of automating the manufacturing support systems:
§To reduce the amount of manual and clerical effort in product design,
manufacturing planning and control, and the business functions
§Integrates computer-aided design (CAD) and computer-aided
manufacturing (CAM) in CAD/CAM
§CIM includes CAD/CAM and the business functions of the firm
Automation Principles and Strategies
Automation is not always the right answer for a given production situation. A
certain caution and respect must be observed in applying automation
technologies. There are three approaches for dealing with automation
projects:
1.The USA Principle
2.Ten Strategies for Automation and Process Improvement
3.Automation Migration Strategy
U.S.A Principle
The USA Principle is a common sense approach to automation projects. USA stands for
1. Understand the existing process
2. Simplify the process
3. Automate the process.
USA approach is so general that it is applicable to nearly any automation project. Going through each
step of the procedure for an automation project may in fact reveal that simplifying the process is
sufficient and automation is not necessary.
Understand the existing process
The obvious purpose of the first step in the USA approach is to comprehend
the current process in all of its details. What are the inputs? What are the
outputs? What exactly happens to the work unit between input and output?
What is the function of the process? How does it add value to the product?
What are the upstream and downstream operations in the production
sequence, and can they be combined with the process under consideration?
§Input/output analysis
§Value chain analysis
§Charting techniques and mathematical modeling
Simplify the process
• Once the existing process is understood, then the search can begin
for ways to simplify. This often involves a checklist of Questions
about the existing process. What is the purpose of this step or this
transport? Is this step necessary? Can this step be eliminated? Is the
most appropriate technology being used in this step? How can this
step be simplified? Are there unnecessary steps in the process that
might be eliminated without detracting from function?
Automate the process
Once the process has been reduced to its simplest form, then
automation can be considered. The possible forms of automation
include those listed in the ten strategies discussed in the
following section.
§Ten strategies for automation and production systems
§Automation migration strategy
Ten Strategies for Automation and Process Improvement
Following the USA Principle is a good first step in any automation project.
If automation seems a feasible solution to improving productivity, quality,
or other measure of performance, then the following ten strategies provide a
road map to search for these improvements.
1.Specialization of operations: The first strategy involves the use of special-
purpose equipment designed to perform one operation with the greatest
possible efficiency
2.Combined operations: Production occurs as a sequence 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.
3.Simultaneous operations: A logical extension of the combined operations strategy is to simultaneously perform the
operations that are combined at one workstation.
4.Integration of operations: Another strategy is to link several workstations together into a single integrated mechanism, using
automated work handling devices to transfer parts between stations.
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 parts or products.
6.Improved material handling and storage: A great opportunity for reducing nonproductive time exists in the use of automated
material handling and storage systems.
7.On-line inspection: Inspection for quality of work is traditionally performed after the process is completed. This means that
any poor-quality product has already been produced by the time it is inspected.
8.Process control and optimization: This includes a wide range of control schemes intended to operate the individual
processes and associated equipment more efficiently.
9.Plant operations control: It attempts to manage and coordinate the aggregate operations in the plant more efficiently. Its
implementation usually involves a high level of computer networking within the factory.
10.Computer-integrated manufacturing: CIM involves extensive use of computer applications, computer data bases, and
computer networking throughout the enterprise
Automation Migration Strategy
For Introduction of New Products
1.Phase 1 – Manual production
§Single-station manned cells working independently
§Advantages: quick to set up, low-cost tooling
2.Phase 2 – Automated production
§Single-station automated cells operating independently
§As demand grows and automation can be justified
3.Phase 3 – Automated integrated production
§Multi-station system with serial operations and automated transfer of work
units between stations
Automation Migration Strategy
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• Control Systems
• Sensors and Actuators
• Automated Machine Tools
• Industrial Robotics
• Logic Controllers
• Handling Systems
• Storage Systems
• Identification Systems
• Manufacturing Cells
• Assembly Lines
• Flexible Manufacturing Systems
