Unit-1 COMPUTER AIDED MANUFACTURING

Definition: Automation

Automation
The word ‘Automation’ is derived from greek words “Auto”(self) and “Matos” (moving). Automation therefore is
the mechanism for systems that “move by itself”. However, apart from this original sense of the word, automated
systems also achieve significantly superior performance than what is possible with manual systems, in terms of
power, precision and speed of operation.
Definition: Automation is a set of technologies that results in operation of machines and systems without significant
human intervention and achieves performance superior to manual operation

Introduction to Automation:
Automation is the technology by which a process or procedure is accomplished without human assistance.
Automation is the use of control systems and information technologies to reduce the need for human work in the
production of goods and services. In the scope of industrialization, automation is a step beyond mechanization.
Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of
work, automation greatly decreases the need for human sensory and mental requirements as well.
“Automation = Automatic Control”
Basic elements of an automated system:
1. Power- to accomplish the process and operate the automated system
2. Program of instructions– to direct the process
3. Control system– to actuate the instructions

What is Automation Control System?

Automation Control System - system that is able to control a process with minimal human assistance or
without manual and have the ability to initiate , adjust, action show or measures the variables in the process and stop
the process in order to obtain the desired output.

The main objective of Automation Control System used in the industry are:
1. to increase productivity
2. to improve quality of the product
3. Control production cost
Types of Automation Systems

Automation systems can be categorized based on the flexibility and level of integration in manufacturing process
operations. Various automation systems can be classified as follows

Fixed Automation:It is used in high volume production with dedicated equipment, which has a fixed set of
operation and designed to be efficient for this set. Continuous flow and Discrete Mass Production systems use this
automation. e.g. Distillation Process, Conveyors, Paint Shops, Transfer lines etc. A process using mechanized
machinery to perform fixed and repetitive operations in order to produce a high volume of similar parts.

Programmable Automation:It is used for a changeable sequence of operation and configuration of the machines
using electronic controls. However, non-trivial programming effort may be needed to reprogram the machine or
sequence of operations. Investment on programmable equipment is less, as production process is not changed
frequently. It is typically used in Batch process where job variety is low and product volume is medium to high, and
sometimes in mass production also. e.g. in Steel Rolling
Mills, Paper Mills etc.

Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is invariably computer controlled.
Human operators give high-level commands in the form of codes entered into computer identifying product and its
location in the sequence and the lower level changes are done automatically. Each production machine receives
settings/instructions from computer. These automatically loads/unloads required tools and carries out their
processing instructions. After processing, products are automatically transferred to next machine. It is typically used
in job shops and batch processes where product varieties are high and job volumes are medium to low. Such systems
typically use Multipurpose CNC machines, Automated Guided Vehicles (AGV) etc.

Integrated Automation: It denotes complete automation of a manufacturing plant, with all processes functioning
under computer control and under coordination through digital information processing. It includes technologies such
as computer-aided design and manufacturing, computer-aided process planning, computer numerical control
machine tools, flexible machining systems, automated storage and retrieval systems, automated material handling
systems such as robots and automated cranes and conveyors, computerized scheduling and production control. It
may also integrate a business system through a common database. In other words, it symbolizes full integration of
process and management operations using information and communication technologies. Typical examples of such
technologies are seen in Advanced Process Automation Systems and Computer Integrated Manufacturing (CIM).
Advantages And Disadvantages of Automation Control In Industry
The main advantages of automation are:
Replacing human operators in tasks that involve hard physical work
Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,nuclear facilities, underwater,
etc.)
Performing tasks that are beyond human capabilities of size, weight, speed, endurance,etc.
Economy improvement: Automation may improve in economy of enterprises, society ormost of humanity. For
example, when an enterprise invests in automation, technology recovers its investment; or when a state or
country increases its income due to automation like Germany or Japan in the 20th Century.Reduces operation
time and work handling time significantly.

The main disadvantages of automation are:

Unemployment rate increases due to machines replacing humans and putting those humans out of their jobs.
Technical Limitation: Current technology is unable to automate all the desired tasks.
Security Threats/Vulnerability: An automated system may have limited level of intelligence, hence it is most
likely susceptible to commit error.
Unpredictable development costs: The research and development cost of automating a process may exceed the cost
saved by the automation itself.
High initial cost: The automation of a new product or plant requires a huge initial investment in
comparison with the unit cost of the product, although the cost of automation is spread in many product
batches of things.
 Strategies of Automation

There are certain fundamental strategies that can be employed to improve productivity in manufacturing operations
technology. These are referred as automation strategies.
1. Specialization of operations: The first strategy involves the use of special purpose equipment designed to perform one
operation with the greatest possible efficiency. This is analogous to the concept of labor specializations, which has been
employed to improve labor productivity.
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. This is accomplished by performing more than one operation at a given
machine, thereby reducing the number of separate machines needed. Since each machine 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.
3. Simultaneous operations: A logical extension of the combined operations strategy is to perform at the same time the
operations that are combined at one workstation. In effect, two or more processing (or assembly) operations are being
performed simultaneously on the same workpart, thus reducing total processing time.
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. 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.
6. Improved material handling and storage systems: 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.
7. On-line 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.
8. Process control and optimization: This includes a wide range of control schemes intended to operate the individual process
and associated equipment more efficiency. By this strategy, the individual process times can be reduced and product quality
improved.
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.
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 firm. CIM involves extensive use of
computer applications, computer data bases, and computer networking in the company