Introduction

to
Automation
-
 What is Automation ???

Intelligent use of Electronics, Pneumatic

and Mechanical components to control
and operate industrial machines to
minimize or replace human operators for a
special purpose application like high
speed pad printing on pet bottle caps
 Produce
High volumes at
similar quantity

Reduced Practically no or very

cost of less chances of
human error
production Advantages

Reduced set up
time and process
errors
 Automation Process
1 Analysis of problem and conceptualization of idea

2 Application Engineering

3 Design of Automation system

4 Manufacturing of Designed Components

Assembly, integration and synchronization of

5
various electro-mechanical aspects

6 Testing, Validation & Documentation

Trial production, approval

7
Commissioning at customer’s end
Automation process and benefits

Automation
Solution’s
Centre

Input Automation
problem Solution

• Niche Market Segment

• High value business opportunity
• Specialized business hence less competition
• Fulfillment of total solution provider concept
 Automation in our industry
Basic machine adaptable for automation

Component feeding mechanism

Component handling mechanism

Basic Component transportation mechanism

elements of
Automation Component Pretreatment system (optional)

Component Post-treatment system (optional)

Component identification system

Visual quality inspection system (optional)

Pneumatic components for various operations

Control system to integrate above modules to

realize the desired operation
 Vibratory Vibratory
bowl feeders Linear
feeders

Component
Feeding
Mechanisms

Continuous Centrifugal
motion step feeders
feeders
 Mechanical
Pick & Place
system
Vaccum based Pneumatic
Pick & Place Pick & Place
System System

Component
Push In Place
Handling
system Push Out System
Mechanisms (Pneumatic
(Pneumatic & &
Mechanical) Mechanical)

Pull in Place system Pull Out System

(Pneumatic & (Pneumatic &
Mechanical) Mechanical)
Few Examples of Component handling Mechanisms
 Component
Transportation
Mechanisms

Pneumatic Electromechanical Pneumatic Electromechanical

Belt & Chain
rotary Rotary Linear conveying linear conveying
indexing system system Conveyors
indexing system system
 PAC
Programmable
Automation Controller)

PLC
HMI
Programmable
Control Human Machine
Logic
systems
Controller Interface)

Control Panel
(house of all instrumentation)
 Cost Principle - view I
Customer’s view
From your costing
(operational cost + rejections
+ reworks etc.)

Price - Cost = Profit

Decided by the What you
customer deserve
 Cost Principle – view II
From your
costing Our view
(operational cost Your desire or
+ rejections wish to have
+ reworks etc.)

Cost + Profit = Price

Thrust on the
customer
 Business Scenario

Key Points to be kept in mind

Cost
Quality
Productivity
Market Share
Profits

Customer Satisfaction
 How to arrive at preliminary costing ??
• Understanding the application & preparation of first hand lay out
• Selection of Machine and decide the hedged Cost of Machine
• Cost of Feeding Mechanism
• Cost of Handling Mechanism
• Cost of Transportation Mechanism
• Cost of other Pneumatics
• Cost of Mechanicals (in built or bought out items)
• Cost of Electricals, Electronics and system integration
• Cost of Design
• Cost of overheads and risk factor
• Profit Margins
Overall Advantages

• Significant improvement in operations without any added value

• Enriching operators' job

• (number of operations mastered, taking initiatives)

• no longer dependency on individual performance

• Short interval management

• Rate of non-complying products mastered

 Thank you
for your attention !!!!!