Post on 05-Apr-2018
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INTRODUCTION TOAUTOMATION
By: Nurdiana Nordin
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Learning Outcomes
At the end of this lecture, students are able to:
i. Define the term of automation
ii. Explain the reason & advantages ofautomationiii. Brief the automation principle & strategiesiv. Distinguish the categories & type of
automationv. Identify and explain the basic elements of
automated systemvi. List and brief the advance automation
functions
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Lecture Contents
i. Automation history
ii. Definition of Automation
iii. Reason & Advantages of Automation
iv. Automation Principles & Strategies
v. Automation Categories
vi. Elements of Automated System
vii. Advance Automation Functions
viii. Levels of Automation
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Automation History
BasicMechanical
DeviceDevelopment
SteamEngine(1765)
Flying-ballgovernor(1785)
Machineprogramming
(1800)
MovingAssembly
Line (1913)
NumericalControlMachine(1952)
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Automation History
IndustrialRobot (1954)
FlexibleManufacturing
System(1960s)
ProgrammableLogic
Controller(1969)
PersonalComputer
(1978)
Continuousdevelopment(1980s-now)
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Definition of Automation
The process of following a predeterminedsequence of operationwithlittle or no
human labor, using specialized equipment
and devices that perform and controlmanufacturing processes. It is achievedthrough the use of variety devices,sensors, actuators, techniques and
equipment that arecapable of observingthe manufacturing process, makingdecisions concerning the changes thatneed to be made in the operation and
controlling all aspect of it.
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Definition of Automation
is the technology by which a process or
procedure isaccomplished without humanassistance. Its implemented using a
program of instructionscombined with acontrol systemthat executes the
instructions
as a technology concerned with theapplication of mechanical, electronic, andcomputer-based systems to operate and
control production
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Advantages of Automation
IncreaseLabor
Productivity
Increaseproductionrate & labor
productivity
Greateroutput per
hour
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Advantages of Automation
Higher investment, replacemanual operations
Substitute human labor,
reduce per unit cost
Reduce LaborCost
Shortage of labor in
advanced nations Automated operation as
substitute for labor
Mitigate the
Effect ofLabor
Shortages
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Advantages of Automation
Reduce/Eliminateroutine manual
and clerical tasks Routine, boring,
fatiguing task
Possibly irksome
Improve workersafety
Transfer activeparticipation tomonitoring role
OSHAimplementation,provide an impetus
for automation
Improve productquality
Performs greateruniformity andconformity to qualityspecifications ofproducts
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Advantages of Automation
Reducemanufacturing lead
time
Reduce elapsedtime between order& delivery
Reduce work-in-process inventory
Accomplish processthat cannot be done
manually
Certain operationmust be aided withmachine
Precision,miniaturization,complexity
geometry realizesby computercontrol system
High Cost of ManualWork
Hire greaternumber of workers,not productive,company notcompetitive
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Automation Principles &Strategies
o Approaches to deal with automationprojects:
i. The USA Principle
ii. Ten Strategies for Automation &Process Improvement
iii. Automation Migration Strategy
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The USA Principle
- Good first step in any automation project
- U : understand the existing process
- S : simplify the process
- A : automate the process
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The USA Principle:Understanding existing process
Comprehend thecurrent process
Identify the inputs &outputs
Operation chart /flow process chart
Search & analyzethe strength &
weakness
Mathematicalmodels, formulating
algorithm
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The USA Principle:Simplify the process
Involves question to existing process
Make use of 10 strategies for automation
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10 Strategies for Automation &
Process Improvement
Specializationof operations
Combinedoperations
Simultaneousoperations
Integration ofoperations
Increasedflexibility
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10 Strategies for Automation &
Process Improvement (cont..)
Improvedmaterial
handling and
storage
On-lineinspection
ProcessControl and
optimization
Plantoperations
control
Computer-integrated
manufacturing
(CIM)
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The USA Principle:Automate the Process
- Possible forms of automation areaccording to 10 strategies of automation
- Automation migration strategy might beused for a new product / process
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Automation Migration Strategy
Phase 1:ManualProduction
Phase 2:AutomatedProduction
Phase 3:AutomatedIntegratedProduction
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Advantages of
Automation Migration Strategy
Allow
introduction ofnew productin shortest
possible time
Allow automationto be introduced
gradually
Avoid thecommitmentto high levelat beginning
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Categories of Automation
Automation ofthe
manufacturingsystems in the
factory
Computerizationof the
manufacturingsupport systems
ComputerIntegrated
Manufacturing
(CIM)
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Automation & Computerization in
Manufacturing System
Manufacturingsupport system
PotentialComputerization
applications
Facilities:
Factoryequipment
Potential
Automationapplications
CIMProductionsystem
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Manufacturing Industries and
Products
Primary
(exploit naturalresources)
Secondary(Convertprimary
output intoproduct)
Tertiary
(servicesector of theeconomy)
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Types of Secondary Industries
Process Industry(continuousproducts)
ManufacturingIndustry(discreteproducts)
Chemicals,Pharmaceuticals,
Petroleum,Basic Metal, Food,Beverages, ElectricPower Generation
Automobiles,Aircraft, Appliances,
Computers,Machinery, Machine
Components
C i B h
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Continuous vs. BatchProduction
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Production System Facilities
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Types of Plant Layout
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Types of Automated Manufacturing
System
FixedAutomation
ProgrammableAutomation
FlexibleAutomation
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Fixed Automation
- Sequence of processing / assembly operation is fixed by theequipment configuration.
-
Simple operation of each sequence
- Typical features:
i. High initial investment for custom engineered equipment
ii. High production rates, very large quantitiesiii. Relative inflexibility equipment for product variety
f f
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Types of Automated Manufacturing
System
FixedAutomation
ProgrammableAutomation
FlexibleAutomation
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Programmable Automation
Programmable Automation:
- Production equipment is designed for any changes of productconfigurations
-
Operation sequence is controlled by a program- Typical features:
i. High investment in general purpose equipment
ii. Lower production rates than fixed automation
iii. Flexibility to deal with variations and changes in productconfiguration
iv. High suitability for batch production
- Used in low & medium volume production
- Consume time for changeover procedure
T f A d M f i
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Types of Automated Manufacturing
System
FixedAutomation
ProgrammableAutomation
FlexibleAutomation
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Flexible Automation
- An extension of programmable automation
- Capability to produce variety of products with no time lost forchangeover
- Typical features:
i. High investment for a custom-engineered system
ii. Continuous production of variable mixtures of products
iii. Medium production rates
iv. Flexibility to deal with product design variations
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Types of Automation
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Elements of Automated System
An automated system consists of three basic elements:
i. Power to accomplish the process and operate the system
ii. Program of instructions to direct the process
iii. Control system to executes the instructions and drive the process
Program of
instructions
Control system Process
Power
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Advanced Automation Function
- Advance automation function may include:
i. Safety monitoring
ii. Maintenance repair & diagnostics
iii. Error detection & recovery
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Level of Automation
EnterpriseLevel
Plant Level
Cell/SystemLevel
Machine
Level
DeviceLevelLevel 1
Level 2
Level 3
Level 4
Level 5 Corporate Information System
Production System
Manufacturing system-groups ofmachines
Individual machines
Sensors, actuators, hardware elements
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My 2 cents
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Pick battles big enough tomatter, small enough to win.
JonathanKozol