Part 1+2

Automation
Type of Automation

Computer Integrated Manufacturing

Reasons for Automating

Automation Strategies
 Definition of Automation

 Automation is the technology by which a process

or procedure is performed without human
assistance.

 It is implemented using a program of instructions

combined with a control system that executes the
instructions.
 The beginnings of automation

It was in the context of manufacturing that the

term was originally coined by an engineering
manager at Ford Motor Company in 1946 to describe
the variety of automatic transfer devices and feed
mechanisms that had been installed in Ford's
production plants.
The beginnings of automation
 automatic transfer devices
 and feed mechanisms
THREE COMPONENTS OF AN AUTOMATED
SYSTEM
an automated system consists of three basic
components
AUTOMATION IN PRODUCTION Systems

The automated elements of the production system can be separated into two categories:
(1) automation of the manufacturing systems in the factory.
(2) Computerization of the manufacturing support systems.
 Automated Manufacturing Systems

They perform operations such as processing, assembly, inspection, or material handling

Examples of automated manufacturing
systems
• 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 systems to integrate manufacturing operations
• automatic inspection systems for quality control
 Type of Automation

 Automated systems used in manufacturing can be

classified into three basic types:

(1) fixed automation.

(2) programmable automation.

(3) flexible automation.

Type of Automation

fixed automation

Fixed automation refers to the use of special purpose equipment to automate a fixed
sequence of processing or assembly operations.

Each of the operation in the sequence is usually simple, involving perhaps a plain linear or
rotational motion or an uncomplicated combination of two.

It is relatively difficult to accomodate changes in the product design.

This is called hard automation.

Type of Automation

fixed automation
Advantages:
1. Low unit cost
2. Automated material handling
3. High production rate.
Type of Automation

fixed automation
Disadvantages:
1. High initial Investment
2. Relatively inflexible in accommodating product changes.
Type of Automation

programmable automation
In programmable automation, the production equipment is designed with the capability
to change the sequence of operations to accomodate different product configurations.
The operation sequence is controlled by a program, which is a set of instructions coded.
So that they can be read and interpreted by the system.
New programs can be prepared and entered into the equipment to produce new products.
Type of Automation

programmable automation
Advantages:
1. Flexible to deal with design variations.
2. Suitable for batch production.
Type of Automation

programmable automation
Disadvantages:
1. High investment in general purpose equipment
2. Lower production rate than fixed automation.
Type of Automation

programmable automation
Example:
Numerical controlled machine tools.
Industrial robots.
Programmable logic controller.
Type of Automation

flexible automation
Flexible automation is an extension of programmable automation.
A flexible automation system is capable of producing a variety of parts with
virtually no time lost for changeovers from one part style to the next. There
is no lost production time while reprogramming the system and altering the
physical set up.
Type of Automation

flexible automation
Advantages:
1. Continuous production of variable mixtures of product.
2. Flexible to deal with product design variation.
Type of Automation

flexible automation
Disadvantages:
1. Medium production rate
2. High investment.
3. High ‘unit cost relative to fixed automation.
Type of Automation
Types of facilities and layouts used for different
levels of production quantity and product variety
Type of Automation

Three types of automation relative to

production quantity and product variety
 Computer Integrated Manufacturing

Automation of the manufacturing support systems is

aimed at reducing the amount of manual and
clerical effort in
 product design
 manufacturing planning and control
 the business functions of the firm.
 Computer Integrated Manufacturing

 Nearly all modern manufacturing support systems

are implemented using computer systems.
 Indeed, computer technology is used to
implement automation of the manufacturing
systems in the factory as well
 Computer Integrated Manufacturing

computer integrated manufacturing (CIM) denotes

the pervasive use of computer systems to
 design the products
 plan the production
 control the operations
 perform the various business.
 Computer Integrated Manufacturing

True CIM involves integrating all of these

functions in one system that operates
throughout the enterprise.
Computer Integrated Manufacturing

 computer-aided design (CAD) denotes the use of

computer systems to support the product design
function.
 Computer-aided manufacturing (CAM) denotes
the use of computer systems to perform
functions related to manufacturing engineering.
 CAD/CAM is used to indicate the integration of
the two into one system.
Computer Integrated
Manufacturing
Activities in Manufacturing
information the physical
processing production

product design the processing

production
assembly
planning

material handling

inspection
Computer Integrated
Manufacturing
Activities in Manufacturing

information the physical

processing production

occur in an occur in
Office the Factory
Computer Integrated
Manufacturing
Activities in Manufacturing

The relationship between the physical activities and the information processing
Computer Integrated
Manufacturing Activities in
produc Manufacturing
t
design

Manufacturin
g informatio business
planning n
processing functions

manufacturin
g
control
 Reasons for Automating

1. Increased productivity.
2. High cost of labor.
3. Labor shortages.
4. Safety.
5. High cost of raw materials.
6. Improved product quality.
7. Reduced manufacturing lead time.
8. High cost of not automating.
 Reasons for Automating (1)

Increased productivity
Automation of manufacturing operations help in increasing the
productivity of labor.
This means greater output per hour of labor input.
Higher production rates are achieved with automation than with the
corresponding manual operations.
 Reasons for Automating (2)

High cost of labor.

The high cost of labor is forcing business leaders to
substitute machines for human labor.
Because machines can produce at higher rates of output, the
use of automation results in a lower cost per unit of product.
 Reasons for Automating (3)

Labor shortages.
In many advanced nations there has been a general
shortage of labor.
Labor shortages also stimulate the development of
automation as a substitute for labor.
 Reasons for Automating (4)

Safety.

By automating the operation and transferring the operator

work is made safer.

It has provided an impetus for automation.

 Reasons for Automating (5)

High cost of raw materials.

The high cost of raw materials in manufacturing results in the
need for greater efficiency in using these materials.

The reduction of scrap is one of the benefits of automation.

 Reasons for Automating (6)

Improved product quality.

Automated operations not only produce parts at faster rates

than do their manual counterparts, but they produce parts
with greater consistency and conformity to quality
specifications.
 Reasons for Automating (7)

Reduced manufacturing lead time.

Automation allows the manufacturer to reduce the time
between customer order and product delivery.

This gives the manufacturer a competitive advantage in

promoting good customer service
 Reasons for Automating (8)

High cost of not automating.

The benefits of automation often show up in intangible and
unexpected ways, such as improved quality, higher sales,
better labor relations, and better company image.

Companies that do not automate are likely to find themselves

at a competitive disadvantage with their customers, their
employees, and the general public.
 Automation Strategies

Understand
Simplify
Automate the process
Automation
Strategies

USA Principle
1. Understand the existing process.
2. Simplify the process.
3. Automate the process.
 USA Principle
Automation
Understand the Existing Process
Strategies

1. What are the inputs?

2. What are the outputs?
3. What exactly happens to the work unit between input
and output?
4. What is the function of the process?
5. How does it add value to the product?
6. What are the upstream and downstream operations in
the production sequence, and can they be combined
with the process under consideration?
 Automation Strategies
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10. Computer-integrated manufacturing
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.
Automation
Strategies
2. Combined operations

 reducing the number of

1. production machines

2. workstations

 by performing more than one operation at a given

machine .
Automation
Strategies
3. Simultaneous operations

A logical extension of the combined operations strategy

is to simultaneously perform 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.
Automation
Strategies
4. Integration of operations

link several workstations together into a single integrated

mechanism, using automated work handling devices to
transfer parts between stations.

In effect, this reduces the number of separate machines

through which the product must be scheduled.
Automation
Strategies 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 parts or
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 less work-in-process.
Automation
Strategies 6. Improved material handling and storage

A great opportunity for reducing non productive time

exists in the use of automated material handling and
storage systems.
Automation
Strategies
7. On-line inspection
Inspection for quality of work is traditionally performed
after the process is completed.

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 the product is being
made.
Automation
Strategies
8. Process control and optimization

This includes a wide range of control schemes intended

to operate the individual processes and associated
equipment more efficiently.

By this strategy, the individual process times can be

reduced and product quality improved.
Automation
Strategies
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.

It attempts to manage and coordinate the aggregate

operations in the plant more efficiently.
Automation
Strategies
10. Computer-integrated manufacturing (CIM)

Taking the previous strategy one level higher, we have

the integration of factory operations with engineering
design and the business functions of the firm.
Automation
Strategies
Automation Migration Strategy

Phase 1: Manual production

Phase 2: Automated production

Phase 3: Automated integrated production.

Automation Automation Migration
Strategy
Strategies
Phase 1: Manual production
using single station manned cells operating
independently.
This is used for introduction of the new product for
reasons already mentioned: quick and low cost tooling
to get started.
Automation Automation Migration
Strategy
Strategies
Phase 2: Automated production

using single station automated cells operating independently.

Automation Automation Migration
Strategy
Strategies
Phase 3: Automated integrated production

using a multistation automated system with serial

operations and automated transfer of work units
between stations.
 Automation
Strategies

Automation Migration
Strategy
Phase 1: Manual production
Phase 2: Automated production
Phase 3: Automated integrated production.
Automation
Strategies
Advantages of Automation Migration Strategy

• introduction of the new product in the shortest possible

time.

• It allows automation to be introduced gradually (in planned

phases).

• It avoids the commitment to a high level of automation from

the start.