INTRODUCTION

TO
AUTOMATION
 INTRODUCTION
Manufacturing :
• Latin Words : Manus (hand), Factus (make).
• Manufacturing started by hand -> Factories.
• Production System : rely on many separate but interacting
functions.
• Production systems automated & computerized.

• Approaches & Technologies :

- Automation.
- Material Handling Technologies.
- Manufacturing Systems.
- Flexible Manufacturing.
- Computer integrated manufacturing(CAD, CAM).
 INTRODUCTION
Production Systems : • Production system is a collection of :

- People.
- Equipment.
- Procedures to perform manufacturing.

• Production divided into two levels :

(a) Facilities :
- Factory, Equipment, Layout.

(b) Manufacturing support systems :

- Set of procedures used by the company to manage production.
 INTRODUCTION
Facilities :
• Manual Work Systems.
• Worker-Machine Systems.
• Automated Systems :

(a) System in which a process is performed by a machine without

the direct participation of a human worker.
(b) Two Levels :

1.Semi Automated : perform a portion of work cycle

2.Fully Automated : operate for extended period without human
attention.
 FACILITIES
 Facilities consist of factory, production machines & tooling,
material handling & inspection equipments, and computer systems that
control manufacturing operations.
 Facilities also include plant layout, which is the way the equipment is
physically arranged in the factory.
 The equipment is usually organized into manufacturing systems, which
are the logical groupings of equipment and workers that
accomplish the processing and assembly operations on parts and
products made by the factory.
 Manufacturing systems can be individual work cells consisting of a
single production machine and a worker assigned to that machine.
 More complex manufacturing systems consist of collections of machines
and workers, for example, a production line.
 The manufacturing systems come in direct physical contact with
the parts and/or assemblies being made.
 FACILITIES
 Three basic categories of manufacturing systems in terms of
human participation in the processes are
 Manual Work Systems
 Worker-Machine Systems, and
 Automated Systems
 MANUAL WORK SYSTEMS
 A manual work system consists of one or more workers performing one or
more tasks without the aid of powered tools.
 Manual material handling tasks are common activities in manual work systems.
 Production tasks commonly requirethe use of hand tools, such
screwdriversand hammers.
 When using hand tools, a work holder is often employed to grasp the
work part and position it securely for processing.
 Examples of production-related manual tasks involving the use of hand tools
include
 A machinist using a file to round the edges of a rectangular part that has
just been milled
 A quality control inspector using a micrometer to measure the diameter of a
shaft
 A material handling worker using a dolly to move cartons in a warehouse
 A team of assembly workers putting together a piece of machinery using
hand tools
 WORKER-MACHINE SYSTEMS
 In a worker-machine system, a human worker operates powered
equipment, such as a machine tool or other production machine.
 This is one of the most widely used manufacturing systems.
 Worker-machine systems include combinations of one or more workers and
one or more pieces of equipment.
 The workers and machines are combined to take advantage of their relative
strengths and
attributes.
 WORKER-MACHIN SYSTEMS
 Examples of worker-machine systems include the following:
 A machinist operating an engine lathe to fabricate a part for a product
 A fitter and an industrial robot working together in an arc–welding work cell
 A crew of workers operating a rolling mill that converts hot steel slabs into flat
plates
 A production line in which the products are moved by mechanized conveyor and the
workers at some of the stations use power tools to accomplish their processing or
assembly tasks.
 AUTOMATED SYSTEMS
 An automated system is one in which a process is performed by a
machine without the direct participation of a human worker.
 Automation is implemented using a program of instructions combined
with a control system that executes the instructions.
 Power is required to drive the process and to operate the program and
control system.
 There is not always a clear distinction between worker-machine systems
and Automated
systems, because many worker- systems operate with some degree of
machine automation.
 Two levels of automation are
 Semi-automated
 Fully Automated
 MANUFACTURING SUPPORT SYSTEMS :
• To operate the production facilities efficiently :

- Design the processes and Equipments.

- Plan and control production orders.
- Satisfy product quality requirement.

• Support systems do not directly contact the

product, but they plan and control its progress
through the factory.

• Manufacturing support involves a cycle of

information processing activities.
MANUFACTURING SUPPORT SYSTEMS
 A company must organize itself to design the processes and equipment, plan
and control the production orders, and satisfy product quality
requirements to operate the production facilities efficiently.
 People and procedures by which a company manages its production
operations are the functions accomplished by manufacturing support
systems.
 Most of these support systems do not directly contact the product, but
they plan and
control its progress through the factory.
 Manufacturing support involves a sequence of activities.
INTRODUCTION
INTRODUCTION
INTRODUCTION
INTRODUCTION
 INTRODUCTION
Automation in Production Systems :
• Two levels :
1. Automation in Manufacturing Systems.
2. Computerization of the Manufacturing Support
Systems.
In modern production system, two levels overlap.
• Computer Integrated Manufacturing (CIM)
indicates use of computers at 2 levels.
Automated Manufacturing Systems :
• Operates in the factory on the physical product.
• Automated operations : Processing, Assembly,
Inspection, Material Handling.
• Automated: Reduced level of Human
intervention.
 INTRODUCTION
Human & Machines :
• Relative Strength of Humans & Machines.

• HUMANS :

1.Sense unexpected Stimuli.

2.Develop new solutions to problems.
3.Adapt to changes.
4.Cope with abstract problems.
5.Generalize from observations.
6.Learn from experience.
7.Make difficult decisions based on incomplete
data.
 INTRODUCTION
• MACHINES :

1.Perform repetitive tasks.

2.Store large amount of data.
3.Retrieve data from memory.
4.Perform multitasks simultaneously.
5.Apply high forces & power.
6.Perform simple computations quickly.
7.Make routine decisions quickly.
 INTRODUCTION TO AUTOMATION
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.
 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.
 INTRODUCTION TO AUTOMATION
 To automate a process, power is required,
operate the program and control system.
 Automated processes can be controlled by
human operators, by computers, or by a
combination of the two.
 INTRODUCTION TO AUTOMATION
 The terms automation and mechanization are often compared and
sometimes confused.
 Mechanization refers to the use of machinery (usually powered) to
assist or replace human workers in performing physical tasks, but
human workers are still required to accomplish the sensory and logic
elements of the tasks.
 By contrast, automation refers to the use of mechanized equipment
that performs the physical tasks without the need for oversight by a
human worker.
AUTOMATION IN PRODUCTION SYSTEMS
 The automated elements of the production system
can be separated into two categories:
 Automation of the manufacturing systems in
the factory
 Computerization of the manufacturing
support systems

 In modern production systems, the two categories

are closely related, because the
automated manufacturing systems on the
factory floor are themselves usually
implemented by computer systems that are
integrated with the manufacturing support
systems and management information
system operating at the plant and enterprise levels.
AUTOMATED MANUFACTURING SYSTEMS
 Automated manufacturing systems operate in the factory on the physical product.
 They perform operations such as processing, assembly, inspection, and material
handling,
in many 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.
 In some highly automated systems, there is virtually no human participation.
 Examples of automated manufacturing systems include:
 Automated machine tools that process parts
 Transfer lines that perform a series of machining operations
 Automated assembly systems
 Manufacturing systems that use industrial robots to perform processing or
assembly
operations
 Automatic material handling and storage to integrate manufacturing
systems operations
 Automatic inspection systems for quality control
 REASONS FOR AUTOMATING
 Increase labor productivity
 Reduce labor cost
 Lessen the effects of labor shortages
 Reduce or eliminate routine manual and clerical tasks
 Improve worker safety
 Improve product quality
 Reduce manufacturing lead time
 Accomplish processes that cannot be done manually
 Avoid the high cost of not automating
ARGUMENTS IN FAVOUR 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
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 unemployment.
 Automation will reduce purchasing power

markets will become saturated with products

that people cannot afford to purchase.
SOME QUESTIONS TO BE ASKED BEFORE GOING FOR AUTOMATION

 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.
 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.
 BASIC ELEMENT OF AN AUTOMATED
SYSTEM

 Consists of 3 basic elements:

1) The actuator (which does the work)
2) The Controller
3) The Sensor
 BASIC ELEMENT OF AN AUTOMATED
SYSTEM

1) The actuator (which does the work)

 Controlled by the controller.

 The actuator in a automated process may

infact be several actuators, each of which

provides an output that drives another in the
series of actuator.
 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.

 BASIC ELEMENT OF AN AUTOMATED
SYSTEM

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.
 BASIC ELEMENT OF AN AUTOMATED
SYSTEM

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.
 Switches and transducers are another name for sensors.

 Switches can detect when a measured condition

exceeds a preset 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 workpiece
approaches the working zone.
 BASIC ELEMENTS OF AN AUTOMATED
SYSTEM

•Power to Accomplish the Automated Process

•Program of Instructions
•Control System
POWER TO ACCOMPLISH THE AUTOMATED
PROCESS
•Power for the Process.
•Loading and unloading the work unit
•Material transport between operations

•Power for Automation

•Controller unit
•Power to actuate the control signals
•Data acquisition and information processing
 PROGRAM OF INSTRUCTIONS
•Single step work cycle

•Multi step work cycle

•Decision-Making in the Programmed Work Cycle

•Operator interaction
•Different part or product styles processed by the System
•Variations in the starting work units
 CONTROL SYSTEM
The control element of the automated system
executes the program of instructions. The
control system causes the process to
accomplish its defined function. which for our
purpose is to carry out some manufacturing
operation.

Types:

•Closed loop (feedback)

•Open loop
 CONTROL SYSTEM
•Closed Loop Control System

Open Loop Control System

 CONTROL SYSTEM
•Open Loop Control System
Open loop systems are usually appropriate
when the following conditions apply:

1.The actions performed by the control system are

simple,
2.The actuating function is very reliable, and
3.Any reaction forces opposing the actuation are
small enough to have no effect on the actuation.
 CONTROL SYSTEM
•Closed Loop Control System
 CONTROL SYSTEM
•Open and Closed Loop Control System
EXAMPLE OF OPEN LOOP CONTROL SYSTEM
EXAMPLE OF CLOSED LOOP CONTROL
SYSTEM
EXAMPLE OF CLOSED LOOP CONTROL
SYSTEM
AUTOMATION IN PRODUCTION SYSTEMS
 AUTOMATION
 Automation is a technology concerned with application of
complex mechanical, electronic and computer-based systems
to operate and control production systems.

 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.
 AUTOMATION
Automation technology includes
 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
 REASONS FOR AUTOMATION
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or eliminate routine manual and clerical
tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead lime
8. To accomplish. processes that cannot be done
manually
9. To avoid the high cast of not automating
 CLASSIFICATION OF AUTOMATION
Based on hardware and software. Three main
classification are :
1.Fixed (hard) automation – involve hardware only
2.Programmable automation – involve software only
3.Flexible automation – involve hardware and
software
 FIXED AUTOMATION
 Fixed automation refers to the use of custom
engineered (special purpose) equipment to
automate a fixed sequence of processing or assembly
operations.
 Sequence of processing operations is fixed by the

equipment configuration.
 Sequence of simple operations.

 Integration and coordination of many operation in one

equipment.
 This is also called hard automation.

 Example: Machining transfer lines and automated

assembly machines
 FEATURES OF FIXED AUTOMATION
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product variety
 Custom Engineered Equipment
 Used in low and medium production manufacturing.
 Special machine for production process efficiency at
higher number/rate of product.
 An Automatic machine and numerical control machine is an
example of fixed automation because the inner construction
and function can’t be changed.
 PROGRAMMABLE AUTOMATION
• Combination of hardware (machine) and software
(programmable).
• Production equipment is designed with capability to
change sequence of operation to accommodate different
product configurations.
• Operation sequence controlled by PROGRAM.
• An equipments can be easily change their setup
according to the product configuration needs after the
first production is finish.
• More different/variety and unique product can
be produced economically in small amount.
• One set of program to control the whole
operation of product.
 PROGRAMMABLE AUTOMATION
• Example – Production line assembly, Air
condition, screen saver, traffic light, radiator

• Used when rate of production are small and there is

a variation at the product.
Typical cycle for a product :

1. Set up and reprogramming.

2. Batch production of parts.
Examples :
1. NC Machine Tools.
2. Industrial Robots.
3. PLCs.
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
 FLEXIBLE AUTOMATION
• Also known as “Flexible Manufacturing
System(FMS)” and “Computer Integrated
Manufacturing(CIM)”.
• Combination of hardware and software ( same as
programmable) but can easily changed during the
operation without waiting the whole operation
completed.
• It can be programmed for different configuration
product either at the beginning, middle or end of
the production according to the production changes.
• But usually configuration product are limited
compare to the programming automation.
 FLEXIBLE AUTOMATION
 Extension of programmable automation.
 Produce variety of parts with virtually no time lost for
changeovers from one part style to next.
 No production time lost in set up and reconfiguration.
 System can produce various mixes of parts.
 Example : FMS.
 FLEXIBLE AUTOMATION
• Allows combination of certain system.
• In flexible automation, different product can be
made in the same time at the same manufacture
system.
• Flexible Automation System mostly consist of series
of workstation that is connected to the material
operation and storage system, assembly line and
control of operation of work by using a program for
a different work station.
• Example – Automobile assemble line.
 FEATURES OF FLEXIBLE AUTOMATION
 High investment for a custom-engineered system
 Continuous production of variable mixtures of

products
 Medium production rate,

 Flexibility to deal with product design variations

Relationship of fixed, programmable and
flexible automation
 AUTOMATION PRINCIPLES & STRATEGIES
 Automation is not always the right answer for a
given production situation.

 Three approaches for dealing with automation

projects :
 1.The USA Principle.

2.Ten strategies for Automation.

3.Automation Migration Strategy.
 THE USA PRINCIPLE
 It is common Sense approach to automation and
process improvement.

• USA Stands for :

- U : understand the existing process.

- S : simplify the process.
- A : automate the process.
 THE USA PRINCIPLE
U: Understanding the Process :
 • Study current process in detail.

• Find answers :

1. What are inputs?

2. What are outputs?
3. What exactly happens between input & output?
4. What is function of process?
5. How does it add value to the product?
6. What are sequence of operations?
 THE USA PRINCIPLE
 Simplify & Automate :
 • Simplify the Process :

(a) Simplify the existing process.

(b) Generate answers to queries :

1. What is the purpose of each step and
transport?
2. Is this step necessary?
3. Can this step be eliminated?
4. Does this step uses the most appropriate
technology?
5. How can the step be simplified?
6. Can steps be combined?
7. Automate the steps in process.
 TEN STRATEGIES FOR AUTOMATION
1. Specialization of operations : Special purpose
equipment to perform one operation with
greatest possible efficiency.
2. Combined operations : Reducing number of
distinct production machines.
3. Simultaneous Operations : Reducing total
processing time.
4. Integration of operations : Linking several
workstation into a single integrated mechanism.
5. Increased flexibility : To achieve max utilization
of equipment.
6. Improved material handling and storage :
Reducing non-productive time.
7. On-line inspection : Corrections to the process
during manufacturing.
 TEN STRATEGIES FOR AUTOMATION
8. Process control and optimization.
9. Plant operations and control.
10. CIM.
 AUTOMATION MIGRATION STRATEGY
Phase 1 : Manual Production
 single station manned cells operating
independently.
 Advantages: quick to set up, low cost tooling

Phase 2 : Automated Production

 single-station automated cells operating
independently.
 As demand for the product grows, and it
becomes clear that automation can be justified,
then the single stations are automated to reduce
labor and increase production rate.
Phase 3 : Automated integrated production
 Multistation system with serial operations and
automated transfer of work units between
stations (i.e with automated material handling
AUTOMATION MIGRATION STRATEGY
 ADVANCED AUTOMATION FUNCTIONS
 In addition to executing work cycle programs, an
automated system may be capable of executing
advanced functions that are not specific to a
particular work unit. In general these functions
are concerned with enhancing the performance
and safety of the equipment.
Advanced automation functions include the
following:
 •Safety monitoring

 •Maintenance and repair diagnostics and

 •Error detection and recovery

 SAFETY MONITORING
Functions of safety monitoring
 To protect human workers in the vicinity of the

system and
 To protect the equipment associated with system

Possible responses to various hazards might

include one or more of the following:
 Complete stoppage of the automated system.

 Sounding an alarm

 Reducing the operation speed of the process

 Taking corrective actions to recover from the

safety violation
 SAFETY MONITORING
The following list suggests some of the possible
sensors and their application for the safety
monitoring:
 Limit switches.

 Photoelectric sensors

 Temperature sensors

 Heat or smoke detectors

 Pressure sensitive floor pads

 Machine vision system

 SAFETY MONITORING
 Maintenance and Repair Diagnostics refers to the
capabilities of an automated system to assist in
the identification of the source of potential or
actual malfunctions and failures of the system.
Three modes of the operation are typical of a
modern maintenance and repair diagnostics
subsystems:
 Status monitoring

 Failure diagnostics

 Recommendation of repair procedure

 STATUS MONITORING
 Status monitoring serves two important functions
in machine diagnostics:
 Providing information for diagnosing a current

failure and
 Providing data to predict a future malfunction or

failure
 ERROR DETECTION AND RECOVERY
 Error Detection: As indicated by the term, error
detection and recovery consists of two steps:
 Error detection and

 Error recovery.

 In analyzing a given production operation, the

possible errors can be classified into one of three
general categories
 •Random errors

 •Systematic errors and

 •Aberrations
 ERROR RECOVERY
 Error recovery is concerned with applying
necessary corrective action to overcome the error
and bring the system back to normal operation.
1.Make adjustments at the end of current cycle
2.Make adjustments during the current cycle
3.Stop the process to invoke corrective action
4.Stop the process and call for help
 LEVELS OF AUTOMATION
1.Device level
2.Machine level
3.Cell or system level
4.Plant level
5.Enterprise level
Thank you