Chapter 1: Automation Introduction Manufacturing company in various industries is achieving rapid increases in productivity by taking advantages of automation techno.

. One important aspect of automation in manufacturing is the use of machines and robots. The automotive industry was the early adopter of automation, using automated machines for material handling, processing operations, assembly and inspection, painting and part transfer. Other industry also investing in automation such as the electronics industry, with its needs mass customization and the miniaturization of electronic goods. Automation will continue to expand into various industries where they will perform such tasks as packing, palletizing and filling. Production system The collection of people, equipment and procedures organized to accomplish the manufacturing operations of a company. Comprises (consist) of 2 components:
Manufacturing support system Set of procedure used to manage the production & solve technical + logistic problem. Facilities consist of the factory, equipment & ways in which the equipment is organized in the factory.

Subtopic: Industrial Automation Manufacturing System The organizing of facilities and people into manufacturing systems is critical to the efficiency of a manufacturing operation. Manufacturing systems come into direct contact with the product.
Facilities: Factory, Production machines, Tooling Manufacturing systems: A group of equipments and workers who operating them.

Plant Layout

Variables effect production: The degree if automation is a function of the quantity of unit being produced and product variety.
Low Production Medium Production High Production 1< Quantity < 100 units/yrs 100 < Quantity < 10,000 units/yrs 10,000 < Quantity < 1mil units/yrs

Composite View:

Facilities factory system

People and Production systems People are an important part of production system because not all equipment and processes are automated. Direct Labor (blue collar) Workers are generally responsible for operating the facilities, Professional Staff (white collar) Workers are generally responsible for manufacturing support systems.

Chapter 1: Automation Plan Layout Concepts: Workers and equipment moves around the product. Fixed Position Layout

Subtopic: Industrial Automation Types of Automated Manufacturing Systems: Fixed Automation. Programmable Automation. Flexible Automation. Fixed Automation High initial investment for customengineered equipment. High production rate. Relatively inflexible in accommodating product variety.

Common operations/processes are grouped together. Process Layout

Collection of workers and stations are designed specifically for the product being produce. Product Layout

Programmable Automation High investment in general purpose equipment. Lower production rates than fixed automation. Flexibility to deal with variations and changes in product configuration. Most suitable for batch production.

Each manufacturing cell specializes in the production of a given set of similar products. Cellular Layout

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.

Examples of automation in Production System: Automated machine tools that process parts. Transfer line that performs a series of machining operations. Automated assembly systems. Manufacturing systems that use industrial robots to perform processing/assembly operation. Automated material handling & storage system to integrate manufacturing operations. Automatic inspection systems for quality control.

Chapter 1: Automation What is Automation? Uses of control system and Information Technologies in order to reduce the needs of humans work in the production of goods and services. Year Industrial Revolution
Jacquard Loom invented by Joseph Marie Jacquard. Its a mechanical loom that simplifies the process of manufacturing textiles with complex patterns. The loom is controlled by pasteboard cards with punches holes, each row of which corresponds to one row of design. Electrical Generator invented by Michael Faraday. Eugenio Barsanti & Felice Matteuci from Italy patented the first working efficient internal combustion engine. Triode was invented by Lee de Forest. It becomes the key component radio, telephone, radar, and television and computer system. Ford Motor Company implemented an innovative assembly line that reduced the manufacturing time. Under old system, parts were carried to a stationary assembly line; 12.5 man-hours were required for each chassis. Using rope to pull the chassis to past stockpiles of components, Ford cut labor time to 6 man-hours.

Sub-Topic: Introduction of Automation Reason not to use robot

Task is technologically too difficult to automate. Short product life cycle. Customize product one of a kind. Flexibility in coping with changing demand.

Principle of Automation Power source. Control system. Machine programming. Power Source It is to convert to mechanical actions. (E.g. electrical supply to electrical actuator) Control system It is to control, directing and regulating the outputs. Machine Programming Determine the set of actions that is to be accomplished by the system. Types of Control Systems Opened-loop (no feedback given) Closed-loop (feedback given) Control system comprised of:
Input Controller Actuator Process Output Sensors

1801

1831 1854

1906

1913

Advantages/Outcomes of Automation
Tireless Reliable and efficient Suitable for hazardous environment operation. No training required. No emotion issues. Fast delivery higher throughput cost effective. Greater precision, better stability, reduce lead time.

Controller (with feedback)

Read input data, compares with feedback signal, makes decision & give command to actuators.

Actuator
Electromechanical device converts the signal from the controller into physical action.

Process
Physical process which being affected by the actuator actions.

Disadvantage of Automation
Limited power of perception & interpretation. Cannot generalize/beyond give information. Cannot make decision. Costly to design, develop, manufacture, testing, installation, maintenance and manage.

Sensor
The sensor samples the system output & converts this measurement into an electric signal that it passes to the controller.