Introduction to Production

Automation

By
Engr. Muhammad Tayyab
Automation : Definitions
– The word automation was used for the first time by
Ford Motor Company in 1945 to describe:-
– A logical development in technical program
where automatic handling between machines
is combined with continuous processing at
machines.
– Another Definition:-
– Technology associated with the application of
mechanical, electrical, and computer-based
systems to operate and control production.
Types of Automation
 Fixed Automation
– High initial investment for general purpose
equipment
– High production rates
– Inflexible in accommodating product variety
 Flexible Automation
– High investment for a custom-engineered
system
– Continuous production of variable mixtures of
products
– Medium Production Rates
– Flexibility to deal with product design variations
Degree of Computerization in Production
Systems

 Computer Aided Design (CAD) denotes the use

of computers to design and analyze the product.
 Computer Aided Manufacturing (CAM) denotes
the use of computers to run machine tools.
 CAD/CAM denotes the integration of CAD and
CAM functions into a combined system in which
engineering and manufacturing use information
from a common product database.
 Computer Integrated Manufacturing (CIM)
denotes the pervasive use of computer systems to
design the products, plan the production, control
the operations, and to perform the various business
functions needed in a manufacturing company.
Automation Classification

 Automation is broadly classified into:-

– Manufacturing Automation
Robots, CNC Machine Tools, CAD/CAM
Systems, PLCs, Automated Inspection
Systems, ASRS, Material Handling Systems,
etc.
– Service Automation
Security Systems, Logistics Support Tools,
Office Automation, Ticketing / Reservation
Systems, Hospital Management Systems, ERP
Systems, etc.
Humans Vs Machines
Relative Strengths of
Humans
• Sense unexpected stimuli
• Develop new solutions to
problems
• Cope with abstract problems
• Adapt to change
• Generalize from observations
• Learn from experience
• Make difficult decisions based
on incomplete information
Relative Strengths of
Machines
• Perform repetitive tasks
consistently
• Store large amounts of data
• Retrieve data from memory
reliably
• Perform multiple tasks at the
same time
• Apply high forces and power
• Perform simple computations
quickly
• Make routine decisions
quickly
Production Automation : Examples

 Automated machine tools that process parts

 Transfer lines that perform a series of
manufacturing operations
 Automated assembly lines / systems
 Manufacturing systems that use industrial robots to
perform processing or assembly operations
 Automated material handling and storage systems
to integrate manufacturing operations
 Automatic inspection systems for quality control
Reasons for Automating

 Increase labor productivity

 Reduce labor cost
 Mitigate 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
 Reduce unit cost
Reasons for Not Automating

 Task is too difficult to automate

 Short product life cycle
 Customized product – one-of-a-kind
 Flexibility in coping with changing demand
How to Succeed With Automation

 Implementation in stages
 Avoiding undue reliance on traditional
process
 Discarding strong functional lines
 Well thought of strategy
 Maximum existing manpower retained
 Automation expert hired
How to Fail with Automation

 Implementing a solution without defining a

problem
 Management too secretive about the plan
 Employees not involved
 Technology leap too long
 Absence of an overall strategy or plan