OPERATIONAL MANAGEMENT

TOPIC: AUTOMATION IN INDIAN INDUSTRY (ABB)

SUBMITTED TO:
MANOJ KUMAR

SUBMITTED BY:
SATINDER SINGH
RR1901 B38
10901687
 ACKNOWLEDGEMENT

I owe my deepest thanks to God, My Teachers &colleagues who have been

supportive of my efforts and emerging in my explorations.

The report “AUTOMATION IN INDIAN INDUSTRY (ABB)” is one of the

learning ventures for me in the field of Business research. So, I hereby wish to
express our gratitude to those who generously helped us to colour the mosaic of
this report work, with the titles of their knowledge and expertise. We take this
opportunity to express my deep sense of gratitude and indebtness to our teacher
“Mr. MANOJ KUMAR” Who supervised our work, for their able guidance,
suggestions and constructive criticism.
AUTOMATION

Automation (ancient Greek: = self dictated), roboticization or industrial automation or

numerical control is the use of control systems such as computers to control industrial
machinery and processes, replacing human operators. In the scope of industrialization, it is a
step beyond mechanization. Whereas mechanization provided human operators with
machinery to assist them with the physical requirements of work, automation greatly reduces
the need for human sensory and mental requirements as well. Processes and systems can also
be (automated). Automation plays an increasingly important role in the global economy and
in daily experience. Engineers strive to combine automated devices with mathematical and
organizational tools to create complex systems for a rapidly expanding range of applications
and human activities. There are still many jobs which are in no immediate danger of
automation. No device has been invented which can match the human eye for accuracy and
precision in many tasks; nor the human ear. Even the admittedly handicapped human is able
to identify and distinguish among far more scents than any automated device. Human pattern
recognition, language recognition, and language production ability is well beyond anything
currently envisioned by automation engineers.

Specialized hardened computers, referred to as programmable logic controllers (PLCs), are

frequently used to synchronize the flow of inputs from (physical) sensors and events with the
flow of outputs to actuators and events. This leads to precisely controlled actions that permit
a tight control of almost any industrial process. (It was these devices that were feared to be
vulnerable to the "Y2K bug", with such potentially dire consequences, since they are now so
ubiquitous throughout the industrial world.)

Human-machine interfaces (HMI) or computer human interfaces (CHI), formerly known as

man-machine interfaces, are usually employed to communicate with PLCs and other
computers, such as entering and monitoring temperatures or pressures for further automated
control or emergency response. Service personnel who monitor and control these interfaces
are often referred to as stationary engineers.

A separate form of automation involving computers is test automation, where computer

controlled automated test equipment is programmed to simulate human testers in manually
testing an application. This is often accomplished by using test automation tools to generate
special scripts (written as computer programs) that direct the automated test equipment in
exactly what to do in order to accomplish the tests.

Another separate field of automation is Home automation. This type of automation emerged
in the early 1990s. This type of automation is concerned with the controls of everything in a
house, from lights and blinds through security and access system to heating, cooling, water
supply and home theatre systems. A whole house system will gather and integrate all of these
separate subsystems into one integrated system that can be managed from a central display
panel, a remote control or even over the Internet from another physical location.

A more common form of automation is more related to office automation is software

automation, where a computer by means of macro recorder software records the sequence of
user actions (mouse and keyboard) as a macro for playback at a later time.

ABB has been undergoing a profound transformation. In 2001, we reorganized ourselves

along customer lines, making our company simpler to do business with. One fundamental
aspect of our business has not changed - our commitment to sustainability.

Four key goals

• To improve our economic performance.

• To extend our environmental management system to all employees and all activities.

• To proceed with the full-scale, worldwide implementation of our social policy.

• To align our core areas of power and automation technologies with common efforts to
help reduce poverty throughout the world.

It is almost a decade since ABB first committed itself to sustainability by signing the
International Chamber of Commerce’s Charter for Sustainable Development. Company
proud to have been a pioneer and aim to maintain our leadership position, devising and
implementing best practices in our own operations. Equally important, we try to stimulate
discussion and debate about how to achieve sustainable development internally in ABB, in
our direct contacts with customers and suppliers and also in a broader arena that includes
governments, non-governmental organizations and international bodies. One such debate is
about greenhouse gases. ABB believe that climate change is a reality, and company see
greenhouse gas abatement as the biggest single environmental challenge facing governments,
industry and society today. In 2001 we signed up with “e-mission 55” an international
business initiative which calls on governments to ratify the Kyoto Protocol without further
delay.

Sustainability and the reshaping of industries

Nearly two years ago we divested our large-scale power generation business, and set out our
vision of the future of the electricity supply business. A shift to sustainable energy sources
would create demand for new, small-scale, distributed power generation technologies, along
with efficiency gains and environmental improvements in the traditional electricity supply.

ABB is already a leading supplier of many of the new alternative technologies, including
micro turbines, cogeneration systems and wind-powered generators. Company is also strong
in power electronics and controls, which are key enabling technologies for distributed power
generation. Company is developing converters and control systems for micro turbines, fuel
cells and photovoltaic applications. Some examples of ABB’s activities in these fields are
described in this report. Another fast-growing part of our business is Industrial IT: a new
integrated systems architecture for industries and utilities. Industrial IT brings many benefits.
Remote control and automation make factory floors safer; consumption of energy and raw
materials is minimized; costs are cut and the finished products are more eco-efficient.

Sustainability in ABB

In 2001, we began a deep transformation of our organization to make it more responsive to

our customers’ needs. While this process was under way, a business downturn and improved
internal processes caused us to reduce the number of employees working in the company.
Our sustainability function, which involves some 600 people worldwide, was unaffected by
the reduction. One of the most significant sustainability developments of the year was the
launch of our new social policy, with an unprecedented campaign of stakeholder engagement.
Company had 45 round-table discussions with stakeholders in 34 countries to gather views on
the policy, as well as suggestions on how to implement it and measure its performance. In
years of hard work ABB has made sustainability part of our business approach. Independent
assessors confirm this: for instance, the Dow Jones Sustainability Index has ranked us at the
top of our industry group for three years running. In most of our product lines, ABB offers
some of the most sustainable solutions available. But this is not enough – our customers have
to buy them. It is pointless for our customers to invest in sustainable products, if the extra
cost makes their businesses uncompetitive. Creating the right climate for sustainability
requires the involvement of more parties than just suppliers and buyers. Governments, for
instance, can create fiscal incentives. Non-governmental organizations of all kinds are
increasingly successful in mobilizing public opinion against unsustainable practices. And
individual consumers choose to buy sustainable products, even if they cost a little more.

The working environment

ABB’s manufacturing and service facilities are run to

exacting standards for health and safety, and environmental
management. We have implemented the ISO 14001 standard
in 531 manufacturing plants - 98 percent of the total.

Ten years after Rio: more talk, more action

A decade ago world leaders, business heads and non-governmental organizations met in Rio
de Janeiro, where they issued the United Nations Declaration on Environment and
Development. In 2002, they will meet again – this time in Johannesburg, where the agenda
includes three of the most important and controversial challenges to sustainability:
globalization, climate change and the widening poverty gap. ABB support global efforts to
promote sustainability, and we will take part in the discussions in Johannesburg.

But Company can do more than talk. In 2001 we started a program called “Access to
Electricity.” Two billion of the world’s poorest people have no electricity supply, and no
access to the benefits, such as clean water and basic sanitation, that electricity can help
provide. Company researchers are examining how ABB’s sustainable, small-scale power
generation technologies might fill this gap. This will be a long-term commitment for ABB,
working internationally with various partners to make real progress in the fight against
poverty. Another of our initiatives in 2001 was to launch a corporate research and
development program focused on sustainability issues.
Introducing the triple bottom line

One of the biggest problems of reporting on sustainability performance has always been the
lack of agreed standards and measurements. This year, company’s Sustainability Report has
been inspired by the Sustainability Reporting Guidelines, first published in mid-2000 by the
Global Reporting Initiative (GRI) - an international multi-stakeholder undertaking. The GRI
guidelines are based on a “triple bottom line” reporting concept – covering environmental,
economic and social performance.

The changing climate

In 2002, Company intend to integrate sustainability into all levels of organization: strategic
plans, management systems and operating processes. This activity will be led and supported
by Group Function – Sustainability Affairs. As a successor to Jan Strömblad, who retired
during 2001, company has brought in Christian Kornevall, who has extensive and diverse
experience in the sustainability area, to spearhead this effort. Of course, Company will
continue to promote sustainability internally, and in discussions with our customers,
suppliers, business and government leaders, and all other stakeholders. ABB believe that the
global business climate is changing. ABB has already shown that a commitment to
sustainability can be good for business. Soon, commitment to sustainability will be a
fundamental requirement for all businesses. And this is a climate for which ABB is very well
prepared.

Main Automation/Electrical Contractor Approach of ABB

Introduction

As the pace of technology development increases and the demand for increased plant
efficiency and improved power consumption drives the design of industrial facilities,
manufacturers and plant operators are turning to automation and electrical product developers
to provide industrial solutions that meet the technical and execution requirements of these
complex facilities.

This approach moves the product developers from their traditional role of vendor/equipment
supplier providing equipment to a customer developed specification to that of an independent
contractor performing the role of an Engineering, Procurement and Construction (EPC)
contractor providing engineered solutions. ABB defines this role as that of a Main
Automation Contractor (MAC) or Main Electrical Contractor (MEC). In making the
transition from “vendor” to “contractor,” the MAC/MEC is required to adopt a more
proactive approach during the execution of the work. This requires close cooperation with the
client organization and other contractors and suppliers to develop best in class solutions,
implement those solutions across the facilities and manage the interfaces with other
participants to ensure effective integration of all components and systems.

This EPC approach is distinguished from the traditional vendor/supplier role in three
significant ways:

• The scope of supply involves services and supply of product(s), with the emphasis on the
ability to provide the services element. The scope of work requires participation of the
MAC/MEC throughout the full project lifecycle, from Front End Engineering and Design
(FEED) to completions and start-up.

• The work requires significant coordination and information exchange between multiple
project participants.

• The MAC/MEC is responsible for coordination of the overall system(s) and manages the
interfaces to facilitate integration.

There are also significant differences from a project execution perspective where these types
of projects involve multiple participants including process designers, construction
contractors, utility providers, regulatory authorities and government agencies.

First, the scope of work is broader than a conventional vendor/supplier scope and is focused
on the overall solution and not the product(s) that provide the solution.

Second, it requires participation in the front end engineering and design (FEED) phase where
the MAC/MEC works closely with the customer and overall plant designer(s) to develop the
system concept and basic operational specifications.

Third, once the project moves into the full execution phase, the MAC/ MEC has the
responsibility, in addition to providing the product solution, to provide coordination and
interface between the major EPC contractors to ensure the concepts and requirements
developed during the FEED phase are implemented effectively and the design standardization
is achieved across the facilities.

Fourth, the MAC/MEC provides the product solution utilizing its products in combination
with third party supplied products, integrates these with the process and utility equipment
provided by the EPC contractor(s) and assists with the installation of the completed system(s)
under the direction of the EPC contractor(s).

Finally, the MAC/MEC has responsibility to work under the direction of the EPC
contractor(s) at the construction site(s) to achieve final commissioning and start-up of the
facilities. As a global leader in the design and supply of Process Automation and Power
Systems for a broad range of industries, ABB has easily made this transition from main
product vendor to overall solutions provider. Leveraging our expertise around the globe,
ABB has developed the “Book of MAC/MEC,” a robust project execution methodology
which combined with extensive product and industry knowledge provides customers with a
level of service not available from the traditional EPC contractors(s).

Automation Technologies division

• Drives, Motors and Power Electronics

• Control Platform and Enterprise Products

• Low-Voltage Products and Instrumentation

• Paper, Minerals, Marine and Turbo charging

• Robotics, Automotive and Manufacturing Products

• Petroleum, Chemical and Consumer industries

Benefits of Automation

• Less energy consumption

• Less raw materials use

• Lower environmental impact

• Lower costs

• Higher efficiency

• Higher productivity
Remote services

With an installed base of more than $100 billion worth of automation products and systems
worldwide, ABB is constantly working on ways to improve the way these systems are
supported. Remote services use existing and cutting edge technologies to support field
engineers, irrespective of location, in ways only dreamed of five years ago. The Internet,
together with advances in communications and encryption techniques, has contributed
enormously to this. Remote service developments are a direct result of clients’ changing
needs. ABB has been told clearly in almost every industry it serves, that it must continue to
improve the return on assets of the systems it delivers. This does not mean customers want
less support, but rather more support at lower costs. Remote services are designed to
maximize knowledge bases in the most cost-effective manner. The result should ensure that
the best knowledge is in the right place, at the right time, to support the clients’ assets. With a
large number of different types of products, this can be a complex undertaking.

Remote service benefits

A well-executed remote service offering can reduce unnecessary maintenance and downtime,
improve production efficiency, track causes of failures, provide root cause data and fault
diagnosis and recommend actions. It can provide predictive notification of impending failures
allowing proactive instead of reactive corrective actions. Finally, it can allow remote
specialists to apply their expertise to any factory in the world 24 hours per day, 7 days per
week. ABB’s Remote Service business provides predictive and diagnostic capabilities
serving all aspects of a plant – automation, equipment performance, equipment health,
mechanics, electrification, electronics, and production to provide a complete solution.

Three levels of remote monitoring service are available to align with customer needs:

Remote troubleshooting

Remote troubleshooting provides expert on-demand, diagnostic remote support assistance in

the event of a specific problem or failure. A demand- driven connection to the drive
equipment is initiated to begin the troubleshooting process.
Periodic maintenance

Periodic maintenance provides a managed monitoring service for collection of equipment

health information four times per year. Skilled support specialists provide expert data
analysis based on established equipment benchmarks.

Continuous monitoring

Continuous monitoring provides continuous monitoring of key parameters. It automatically

sends a message to an ABB monitoring center when parameters exceed limits. ABB
specialists analyze the alarm and remotely access the device to further diagnose the issue.
Corrective action recommendations are provided to the customer if required.
The freedom to take what’s needed with wireless input/output pads

Signal cables which cause a nuisance or wear during operation are commonplace in industry
and machine building. With WISA COM, elaborate cabling for signal transmission is no
longer necessary, including with regard to conventional sensors and actuators. For this is
where the wireless WIOP100 I/O pad comes into its own, transmitting the signals from the
connected sensors and actuators by radio communication to the central WDIO100
input/output module.

Actuators and conventional position sensors such as

• cylinder switches

• pressure switches

• temperature monitors

• position switches

• sensors (inductive, capacitive, optical, ultrasound)

can be connected to the WIOP100 (wireless I/O pad). While the wireless I/O pad in a
machine/system is attached as closely as possible to the connected field device, the
WDIO100 input/output module is normally positioned together with the machine controls in
the control cabinet. A pair of antennas establishes the radio connection to the wireless I/O
pad. The connection between the input/output module and the control system (PLC) takes
place by field bus as usual.

Benefits at a glance

• Wireless connection of sensors and actuators to the machine control system.

• Data transmission in the 2.4 GHz band: unaffected by typical sources of interference
in an industrial environment.

• Fast and simple tool change since no data/signal connections need to be disconnected
• Configurable at the push of a button.

• Flexible with regard to upgrades and retrofitting.

• Zero-wear data communication.

• Reliable communication without costly plug-in connections, slip rings or dynamic

cable carriers.
 WIOP100

Wireless I/O pad

Control & Optimization: Where we develop methods/algorithms that generate or

support actions and decisions in industrial enterprises to increase the value of the production
for the client.

Sensors & Microsystems: Where we create technology breakthroughs enabling new

products in the field of sensors and instrumentation.

Software Architecture & Processes: Where we focus on both the software

technology and the software development process in order to deliver the right plug and
produce solutions with substantially increased customer value.

Power Electronics: The focus is on innovative power electronics solutions and new
power semiconductor devices in industrial automation and power systems, as well as the
development of breakthrough technologies in the critical areas of power semiconductor chips
and power modules.

Advanced Industrial Communications: Where we create technology breakthroughs

within the area of industrial communication, by utilizing new wired as well as wireless
technologies in ABB applications/products.

Mechatronics & Robotics Automation: A multi-disciplinary area which focuses

mainly on advanced robotics systems, applied optimization and optimum control of
Mechatronic Systems.
Most of the research regarding simulation and modelling is done within the Control &
Optimization program, and also to some extent in the Mechatronics and Robotics program.
Some of the current activities and accomplishments in this area will be outlined below.

ABB has a long tradition of using dynamic models for control design. Already more than 20
years ago the first adaptive controller was introduced. In those days the focus was on
regulatory control based on empirical (black-box) models. Although regulatory controllers
still remain an important part of our business (albeit less often adaptive nowadays), it is more
and more common that model based solutions today take place higher up in the value chain.

It may be a model predictive controller (ABB has recently released version 3.0 of its MPC
called Optimize Predict & Control) delivering set points to the low level PID controllers.
However, dynamic models are increasingly used for optimization of variables more directly
formulated in economic terms rather than the traditional process terms (flow, pressure etc).
Within the Control and Optimization program there are currently optimization projects in
such diverse application areas as pulp and paper, power plants, pharmaceutical and cement
industry.

Another area where models are important ingredients is asset condition monitoring. To detect
and diagnose malfunctioning equipment ahead of time (preventive maintenance) will be a key
area for the future in all industries since our customers want to maximize the lifetime and
uptime of their assets with minimum amount of maintenance. Here we have in various
projects and products applied a number of different techniques; for example multivariate
statistics, neural networks and Bayesian networks.

Another trend is that model based solutions today more often use physical models derived
from first principles rather than purely empirical models. For that purpose you need
appropriate modelling tools and languages, and therefore we are frequent users of, for
Example: Matlab/Simulink, PROMS and Modelica. On top of PROMS we have developed
our own product called Dynamic Solutions, which provides a user interface based on
Microsoft Visio and access to data via an OPC server. For Dynamic Solutions an extensive
model library for chemical processes has also been developed.

In this progress towards more and more model based control and optimization we see some
challenges ahead:
• To get economy of scale we need to be able to re-use models and, for example optimization
environments. This is easier said than done in a large company such as ABB where many
different modelling tools and solvers are used today. It is probably not realistic to standardize
on only one modelling tool and one optimization solver. However, for several reasons we
seek to keep the numbers to a minimum and provide conversion between them.

• Manage all models and other information around a process object (e.g. a pulp digester). For
a single object there may be everything ranging from simple empirical models to full fledged
nonlinear dynamic models.

• A related problem is to maintain all these models during the life cycle of the plant,
including keeping track of different versions of the same model during its development.

• To tie together all aspects of a plant using some type of model; be it a process diagram,
control configuration and tuning, production optimization or asset management.

For all this we intend to utilize ABB’s new Industrial IT platform with Aspects Objects as the
common user model and information infrastructure. There are already today projects
underway in this direction, e.g. prototype for automatic generation of functional structures
from P & I diagrams or Modelica models.

Within arm’s reach

The IRB 120 robot is the smallest addition to the ABB family of single armed robots. It
is ideally suited to a wide range of tasks, including the handling and assembly of small,
delicate components of up to 3 kg in weight.

The IRB 120 offers all the functionality of other ABB robots but in a much smaller package.
It has a single articulated arm designed to mimic the reach of a human arm. Its numerous
mounting options mean it can be arranged to minimize its footprint within a production line.
Its slim wrist and internally routed cables allow it to be used in tight locations, and the easy
to- clean surfaces make it ideally suited to applications requiring dust-free environments.

The robot is light, weighing in at just 25 kg, and features the best path accuracy and motion
control on the market. Smooth movement and accuracy are achieved using ABB’s new
lightweight (27.5 kg) IRC 5 Compact controller, the latest addition to ABB’s comprehensive
IRC 5 family of robot controllers. The combined weight of the IRB 120, its IRC 5 Compact
controller, floor cables and Flex Pendant is less than 60 kg, providing a truly compact,
lightweight robotic system. ABB has many years of experience in the automation business
and is particularly well equipped to automate production processes. The new compact IRB
120 robot and IRC 5 Compact controller will together extend ABB’s automation solutions to
industries concerned with the assembly and handling of small, complex components and

devices.

ABB and sustainability

Sustainability is a topic that is very much on people’s minds today. A growing world
population with rising demands on their standards of living is increasingly coming into
conflict with the Earth’s limited resources. Just as technologies and processes have over the
years been optimized for greater productivity, present day optimization processes are
increasingly taking environmental impact and limited resources into account. Sustainability
can be achieved through a shift to regenerating resources, and ABB is supporting that trend
through many of its technologies, for example in the domains of solar or wind energy.
Dependence on traditional energy sources can however also be reduced by making more
efficient use of the energy that has already been harnessed. This can take the form of more
intelligent deployment of energy through better control strategies.

CONCLUSION

The technologies are proven and commercialized in India. The unique strengths of Indian
system which makes the technology exports feasible are:

• Low capital investment

• Focus on labour intensive low cost operations

• Superior indigenous engineering skills

• Less energy consumption

• Less raw materials use

• Lower environmental impact

• Lower costs

• Higher efficiency

• Higher productivity

So automation is very important for Indian Industry.