INTRODUCTION TO AUTOMATION

By: Nurdiana Nordin

Learning Outcomes
At the end of this lecture, students are able to:
i. ii.

iii. iv.

v.

vi.

Define the term of automation Explain the reason & advantages of automation Brief the automation principle & strategies Distinguish the categories & type of automation Identify and explain the basic elements of automated system List and brief the advance automation functions

Lecture Contents
i.

ii.
iii. iv. v. vi. vii. viii.

Automation history Definition of Automation Reason & Advantages of Automation Automation Principles & Strategies Automation Categories Elements of Automated System Advance Automation Functions Levels of Automation

Automation History

Basic Mechanical Device Development

Steam Engine (1765)

Flying-ball governor (1785)

Machine programming (1800)

Moving Assembly Line (1913)

Numerical Control Machine (1952)

Automation History

Industrial Robot (1954)

Flexible Manufacturing System (1960s)

Programmable Logic Controller (1969)

Personal Computer (1978)

Continuous development (1980s-now)

Definition of Automation
The process of following a predetermined sequence of operation with little or no human labor, using specialized equipment and devices that perform and control manufacturing processes. It is achieved through the use of variety devices, sensors, actuators, techniques and equipment that are capable of observing the manufacturing process, making decisions concerning the changes that need to be made in the operation and controlling all aspect of it.

Definition of Automation
is the technology by which a process or procedure is accomplished without human assistance. Its implemented using a program of instructions combined with a control system that executes the instructions

as a technology concerned with the application of mechanical, electronic, and computer-based systems to operate and control production

Advantages of Automation
Increase production rate & labor productivity
Increase Labor Productivity

Greater output per hour

Advantages of Automation
Reduce Labor Cost
Mitigate the Effect of Labor Shortages
Higher investment, replace manual operations Substitute human labor, reduce per unit cost

Shortage of labor in advanced nations Automated operation as substitute for labor

Advantages of Automation

Reduce/Eliminate routine manual and clerical tasks

Routine, boring, fatiguing task Possibly irksome

Improve worker safety

Transfer active participation to monitoring role OSHA implementation, provide an impetus for automation

Improve product quality

Performs greater uniformity and conformity to quality specifications of products

Advantages of Automation
Reduce manufacturing lead time Reduce elapsed time between order & delivery Reduce work-inprocess inventory Accomplish process that cannot be done manually Certain operation must be aided with machine Precision, miniaturization, complexity geometry realizes by computer control system High Cost of Manual Work Hire greater number of workers, not productive, company not competitive

Automation Principles & Strategies

o

Approaches to deal with automation projects:

i.

The USA Principle Ten Strategies for Automation & Process Improvement Automation Migration Strategy

ii.

iii.

The USA Principle

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Good first step in any automation project U : understand the existing process S : simplify the process

A : automate the process

The USA Principle:

Understanding existing process
Comprehend the current process

Mathematical models, formulating algorithm

Identify the inputs & outputs

Search & analyze the strength & weakness

Operation chart / flow process chart

The USA Principle:

Simplify the process

Involves question to existing process Make use of 10 strategies for automation

10 Strategies for Automation & Process Improvement

Specialization of operations

Simultaneous operations

Increased flexibility

Combined operations

Integration of operations

10 Strategies for Automation & Process Improvement (cont..)

Improved material handling and storage Computerintegrated manufacturing (CIM)

Process Control and optimization

On-line inspection

Plant operations control

The USA Principle:

Automate the Process
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Possible forms of automation are according to 10 strategies of automation Automation migration strategy might be used for a new product / process

Automation Migration Strategy

Phase 2: Automated Production Phase 1: Manual Production

Phase 3: Automated Integrated Production

Advantages of Automation Migration Strategy

Avoid the commitment to high level at beginning

Allow introduction of new product in shortest possible time

Allow automation to be introduced gradually

Categories of Automation
Automation of the manufacturing systems in the factory

Computer Integrated Manufacturing (CIM)

Computerization of the manufacturing support systems

Automation & Computerization in Manufacturing System

Manufacturing support system

Potential Computerization applications

Production system
Facilities: Factory equipment Potential Automation applications

CIM

Manufacturing Industries and Products

Tertiary (service sector of the economy)

Secondary (Convert primary output into product) Primary (exploit natural resources)

Types of Secondary Industries

Process Industry (continuous products)

Chemicals, Pharmaceuticals, Petroleum, Basic Metal, Food, Beverages, Electric Power Generation

Manufacturing Industry (discrete products)

Automobiles, Aircraft, Appliances, Computers, Machinery, Machine Components

Continuous vs. Batch Production

Production System Facilities

Types of Plant Layout

Types of Automated Manufacturing System

Flexible Automation

Fixed Automation

Programmable Automation

Fixed Automation
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Sequence of processing / assembly operation is fixed by the equipment configuration. Simple operation of each sequence Typical features:
i. ii.

iii.

High initial investment for custom engineered equipment High production rates, very large quantities Relative inflexibility equipment for product variety

Types of Automated Manufacturing System

Flexible Automation

Fixed Automation

Programmable Automation

Programmable Automation
Programmable Automation:
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Production equipment is designed for any changes of product configurations Operation sequence is controlled by a program Typical features:
i. ii. iii. iv.

High investment in general purpose equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration High suitability for batch production

Used in low & medium volume production Consume time for changeover procedure

Types of Automated Manufacturing System

Flexible Automation

Fixed Automation

Programmable Automation

Flexible Automation
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An extension of programmable automation Capability to produce variety of products with no time lost for changeover

Typical features:
i. ii. iii. iv.

High investment for a custom-engineered system Continuous production of variable mixtures of products Medium production rates Flexibility to deal with product design variations

Types of Automation

Elements of Automated System

An automated system consists of three basic elements:
i. ii. iii. Power to accomplish the process and operate the system Program of instructions to direct the process Control system to executes the instructions and drive the process
Power

Program of instructions

Control system

Process

Advanced Automation Function

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Advance automation function may include: i. Safety monitoring

ii. Maintenance repair & diagnostics

iii. Error detection & recovery

Level of Automation
Level 5
Enterprise Level

Corporate Information System

Level 4

Plant Level

Production System

Level 3

Cell/System Level

Manufacturing system-groups of machines

Level 2

Machine Level

Individual machines

Level 1

Device Level

Sensors, actuators, hardware elements

My 2 cents

Pick battles big enough to matter, small enough to win. Jonathan Kozol