MAR Module-1

07-Feb-20
Manufacturing Automation & Robotics

PE-6007
Dr. Binay Kumar

Department of Production Engineering
B.I.T Mesra, Ranchi
Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi
Course Objectives
This course enables the students:
Dr. Binay Kumar, Deptt. of Production Engg.,

BIT Mesra, Ranchi 1
07-Feb-20
Course Outcomes
After completion of the course, the learners will be able to:
Syllabus
• MODULE – I: Manufacturing automation, components and types of automation, automation scenario and
factory configuration, role of mechatronics in factory automation.
• MODULE – II: Basic ideas, classification and structure of NC systems, NC-coordinate system,
Constructional features and feedback devices for CNC machine tools, part programming and related
languages, DNC and adaptive control.
• MODULE – III: Electric and servo control in machine tools, stepper motor, PLC, transfer mechanism,
buffer storage and control functions for transfer devices, feeding mechanism definition and concept, flexible
automation.
• MODULE – IV: Computer integrated manufacturing, Flexible manufacturing systems: concept, need,
structure & operation, objectives and benefits.
• MODULE – V: Robot technology: basic elements, classification, physical configuration, basic robot
motions, robot’s specifications, end effector /grippers.
• MODULE – VI: Robot applications: application characteristics and areas such as material handling,
welding, assembly, inspection, processing operation, spray painting etc
• MODULE – VII: Planning and implementation of robotized and FMS projects

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Manufacturing Defined -Technological Definition
• “Application of physical and chemical processes to alter the geometry, properties, and/or
appearance of a given starting material to make parts or products”
• Manufacturing also includes the joining of multiple parts to make assembled products
• Accomplished by a combination of machinery, tools, power, and manual labor.
• Almost always carried out as a sequence of operations
Manufacturing Defined - ECONOMIC Definition

• “Transformation of materials into items of greater value by means of one or more
processing and/or assembly operations”
• Manufacturing adds value to the material
• Examples:
•  Converting iron ore to steel adds value
•  Transforming sand into glass adds value
•  Refining petroleum into plastic adds value

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Process Industries and Discrete Manufacturing Industries
Classification of manufacturing processes

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Automation of manufacturing Processes
Discrete Manufacturing
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Job shop
Batch Production
Variety
Mass Production
Quantity
Automation
Specialization
Skills
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• Mass production
– Automation easily justified
– Objectives: (1) reduce operation cycle time, (2) increase system reliability
– Line is rarely changed - setup time not critical
– Inflexible: not suitable for products with many options or limited production runs
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• Job shop production
– Products produced in small volume
– Automation difficult to justify unless products are too complex to be produced
manually
– Objectives: (1) reduce setup time, (2) reduce processing time, (3) reduce WIP
– Most flexible of production strategies
• Batch production
– Products produced in batches, lots or groups
– Trade-off between job shop and mass production
– Single setup for each batch
– Increase batch size, but increase in waiting time, WIP and inventory result
– Objectives are same as job shop
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Facility layout
Four types of layouts:
Fixed Position: suitable for large products
Process: suitable for job shop
Cellular: suitable when products are similar in batch production and sometimes in job shop
Product flow: suitable for mass production
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Fixed position layout

– Product must remain stationary throughout production sequence
– Machines are brought to the product
– Higher expense due to robustness and accuracy of equipment
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Process layout
– For small, discrete-parts manufacturing
– Machines are grouped into departments according to type of operation
– Advantages: work schedule more flexible
– Disadvantages: WIP is large (cost in inventory and storage space), high material
handling cost, larger batches are made than are required (to justify setup), difficulty in
maintaining control of parts, highest skill level required from operators
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Cell layout
1. In a cell layout, the transformed resources entering the operation move into a cell in which all the
transforming resources it requires in located.
2. After being processed in the cell, the transformed resource may move to a different cell in the operation
or it may be a finished product or service.
3. Each cell may be arranged in either a process or product layout.
4. The cell type layout attempts to bring order to the complex flow seen in a process layout.
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The ground floor plan of a department store showing the sports goods shop-within-a-shop retail ‘cell’
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Product layout
1. In a product layout, the transformed resource flow a long a line of processes that has been prearranged.
2. Flow is clear, predictable and easy to control.
A restaurant complex with all four basic layout types
Line layout cafeteria
Cell layout buffet
Fixed-position layout service

restaurant
buffe
Dese
buffe
Start
rt
er
t
t
Main course buffet Service line
Preparation
Oven
Process layout kitchen
Cool room
Freezer Vegetable prep Grill
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Volume-variety relationship
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Manufacturing Support Systems

To operate the production facilities, a company must organize itself to design the processes and equipment's, plan and
control the production orders, and satisfy the product quality requirements. These functions are accomplished by the
manufacturing support system. Most of these support system does not directly contact the product, but they plan and control
the progress through the factory.
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Manufacturing Support Systems

– Business functions - sales and marketing, order entry, cost accounting, customer
billing
– Product design - research and development, design engineering, prototype shop
– Manufacturing planning - process planning, production planning, MRP, capacity
planning
– Manufacturing control- shop floor control, inventory control, quality control
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Automation in Production Systems

• Automation in Production Systems can be considered as the technology concerned with
application of electronic, mechanical and computer based system to operate and control
the production system.
• The automated elements of the production system can be separated into two separate
categories:
• (i) automation of manufacturing system in the factory.
• (ii) computerization of manufacturing support system.
• The two categories overlap because manufacturing support systems are connected to the
factory manufacturing systems
– Computer-Integrated Manufacturing (CIM)
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Automated Manufacturing Systems

• Machines
• Transfer lines
• Assembly
• Material Handling
• Inspection (coordinate measuring machines, CMM)
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Types of Automation
• Fixed Automation (transfer lines): Fixed automation is a system in which the sequence of
processing (or assembly) operations are fixed by the equipment configuration.
– Hard automation, automation for mass production
– Produces large numbers of nearly identical parts
– High initial investment for custom engineered equipment
– Product design must be stable over its life
– Advantages: equipment fine tuned to application - decreased cycle time, infrequent
setups, automated material handling - fast and efficient movement of parts, very little
WIP
– Disadvantage: inflexible
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• Programmable Automation (NC, CNC, robots): In programmable automation, the

production equipment are designed with the capability to change the sequence of operation
to accommodate 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.
– Sequence controlled by a program
– High investment in general purpose equipment
– Lower production rates
– Flexibility to deal with variation
– Suitable for batch production, smaller volumes (than fixed) of many different parts
– More flexible than fixed automation
– Major disadvantage: setup prior to each new part
– Speed sacrificed for flexibility
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Flexible Automation: Flexible automation is an extension of programmable automation. A

flexible automated system is capable of producing a variety of parts or products with virtually
no time lost for changeovers from one design to the next. There is no lost production time
while reprogramming the system and altering the physical setup (tooling, fixtures, machine
settings). Accordingly, the system can produce various mixes and schedules of parts or
products instead of requiring that they be made in batches. System is capable of changing over
from one job to the next with little lost time between jobs
– Extension of programmable automation
– No time lost for change over
– High investment in custom-engineered systems
– Production of product mix
– Flexibility to deal with design variations
– Low to medium quantities
– Compromise between fixed and programmable automation in speed and flexibility
– Advantage: programming and setup performed off-line
– More expensive - size and tool change capabilities
– Small batch sizes are justified - reduced WIP and lead time
– Typical parts are expensive, large and require some complex machining
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Reasons for Automating

• Increase production rate eliminate portions of process that directly increase production
time machine processing time, handling time, setup times
• Remove humans from hazardous environments
exposure to chemicals, fumes, temperature or radiation
robotic applications: furnaces, spray painting, welding
• Remove humans from processes that require extremely clean environments: e.g.,
semiconductors, drugs
• Reduce number of defective products
• Reduce direct labor one worker monitors a larger number of machines
• Reduce work-in-process parts being processed, part waiting to be processed large WIP:
longer time to fill orders, more storage space, value of unfinished goods that could be
invested elsewhere reduced WIP: better control and scheduling
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• Reduce manufacturing lead time processing time, setup time, waiting time setup
time: flexible automation, common fixtures and tooling processing time: combining
or eliminating operations, increase speed (work measurement principles)
• Increase quality repeatable operations through every cycle - tighter control limits,
easier detection when process is out of control status of manufacturing operations
• Increase productivity
• Reduce labor cost
• Address labor shortages
• Reduce or eliminate routine manual and clerical tasks
• Health and Safety
• Increase the product quality
• Reduce manufacturing lead time
• May be the only option
• Stay up-to-date (avoid cost of catching up)
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Manual Labour Vs Automation

• A number of situation can be listed in which manual labour is usually preferred over
automation
– Task is too technologically difficult to automate
– Short product life cycle
– Customized product
– To cope with the ups and downs of demand
• Strengths of Humans
– Sense unexpected stimuli
– Develop new solutions to problems
– Cope with abstract problems
– Adapt to change
– Generalize from observations
– Learn from experience
– Make difficult decisions based on incomplete data
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Manual Labor in Automated Systems

• Strengths of (computer-based) machines
– Perform repetitive tasks consistently
– Store large amounts of data
– Retrieve data from memory reliably
– Perform multiple tasks simultaneously
– Apply high forces and power
– Perform computations quickly
Even if all of the manufacturing systems in the factory are automated, there will still be a need for the following
kinds of work to be performed:
Equipment maintenance. Maintain and repair, improve the reliability, of automated systems.
Programming and computer operation.
Engineering project work. Upgrades, design tooling, continuous improvement.
Plant management.
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AUTOMATION PRINCIPLES AND STRATEGIES

USA Principle:
1. Understand the existing process
2. Simplify the process
3. Automate the process (if needed)
USA Principle:
1. Understand the existing process
– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process
– Reduce unnecessary steps and moves
3. Automate the process
– Ten strategies for automation and production systems
– Automation migration strategy
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Ten Strategies for Automation
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 (CIM).
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Automation Migration Strategy
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Automation Migration Strategy For Introduction of New Products

1. Phase 1 – Manual production
– Single-station manned cells working independently
– Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
– Single-station automated cells operating independently
– As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
– Multi-station system with serial operations and automated transfer of work units
between stations
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Automation is a higher degree of mechanization in which human
participation is replaced by mechanical or electrical technologies
capable of doing physical and mental work as in NC or adaptive
control machines.
To most of the situations, automation or higher degree mechanization
must be meaningful to the basic premise of cost reduction in large
scale production technology.
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Advantages of automation include:
• Increase in productivity both qualitative and quantitative
• Decrease in unit cost
• Improved accuracy
• Better safety
• Less wastage through automatic controls
• More resource utilization
• Stimulates, intellectual activities.
The disadvantages of automation include:
•Skill displacement requiring rehabilitation of obsolete skills
•Initial cost is high for including additional features for mechanization of drives and
controls
•Higher maintenance cost
•Higher organizational cost due to higher managerial to worker ratio
•Indirect cost for research, development and programming, etc.
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Development in the History of Automation of Manufacturing Processes
Date Development
1500–1600 Water power for metalworking; rolling mills for coinage strips.
1600–1700 Hand lathe for wood; mechanical calculator.
1700–1800 Boring, turning, and screw cutting lathe, drill press.
1800–1900 Copying lathe, turret lathe, universal milling machine; advanced mechanical calculators.
1808 Sheet-metal cards with punched holes for automatic control of weaving patterns in looms.
1863 Automatic piano player (Pianola).
1900–1920 Geared lathe; automatic screw machine; automatic bottlemaking machine.
1920 First use of the word robot.
1920–1940 Transfer machines; mass production.
1940 First electronic computing machine.
1943 First digital electronic computer.
1945 First use of the word automation.
1948 Invention of the transistor.
1952 First prototype numerical-control machine tool.
1954 Development of the symbolic language APT (Automatically Programmed Tool); adaptive control.
1957 Commercially available NC machine tools.
1959 Integrated circuits; first use of the term group technology.
1960s Industrial robots.
1965 Large-scale integrated circuits.
1968 Programmable logic controllers.
1970 First integrated manufacturing system; spot welding of automobile bodies with robots.
1970s Microprocessors; minicomputer-controlled robot; flexible manufacturing systems; group technology.
1980s Artificial intelligence; intelligent robots; smart sensors; untended manufacturing cells,
1990s Integrated manufacturing systems; intelligent and sensor-based machines; telecommunications and global manufacturing
networks; fuzzy logic devices; artificial neural networks; Internet tools.
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Goals of automation
• Automation has the following primary goals:
• Integrate various aspects of manufacturing operations so as to improve the product quality
and uniformity, minimize cycle times and effort involved, and thus reduce labour costs.
• Improve productivity by reducing the manufacturing costs through better control of
production: Raw materials and parts are loaded, fed, and unloaded on machines faster and
more efficiently; machines are used more effectively; and production is organized more
effectively.
• Improved quality by improving the repeatability of manufacturing processes.
• Reduced human involvement.
• Economize on floor space by arranging machines, materials movement and auxiliary
equipment more efficiently.
• Raise the level of safety.
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Automation and production quantity

• Production quantity is crucial in determining the type of machinery and the level of
automation required to produce parts economically.
• Piece-part production usually involves very small quantities and is suitable for job shops.
The majority of piece part production is in the lot size of 50 or less. Quantities for small
batch production typically ranges from 10 to 100, using general purpose machines and
machining centers with various computer controls.
• Batch production involves lot sizes between 100 to 5000; it utilizes machinery similar to
that used for small batch production, but with specially designed fixtures for higher
production rates.
• Mass production often involves quantities over 100000; it requires special purpose
machinery and automated equipment for transferring materials and parts. Labour skills
required and labor costs are less in this type of automation. However this type of
automation lack flexibility.
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07-Feb-20
Automation Defined
• “Automation is the technology by which a process or procedure is accomplished without
human assistance”
• Basic elements of an automated system:
– 1. Power - to accomplish the process and operate the automated system
– 2. Program of instructions – to direct the process
– 3. Control system – to actuate the instructions
• It is implemented using a Program of Instructions combined with a Control System that
executes the instructions.
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Program of Instructions
• “Set of commands that specify the sequence of steps in the work cycle and the
details of each step”
• Example: CNC part program
• During each step, there are one or more activities involving changes in one or
more process parameters
– Examples:
• Temperature setting of a furnace
• Axis position in a positioning system
• Motor on or off
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Decision-Making in a Programmed Work Cycle

• The following are examples of automated work cycles in which decision
making is required:
– Operator interaction
• Automated teller machine system
– Different part or product styles processed by the system
• Robot welding cycle for two-door vs. four door car models
– Variations in the starting work units
• Additional machining pass for oversized sand casting
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Control System – Two Types

• Closed-loop (feedback) control system – a system in which the output
variable is compared with an input parameter, and any difference between the
two is used to drive the output into agreement with the input
• Open-loop control system – operates without the feedback loop
– Simpler and less expensive
– Risk that the actuator will not have the intended effect
– E.g. Car parking sensors
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07-Feb-20
(a) Feedback Control System and (b) Open-Loop Control System
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When to Use an Open-Loop Control System

• Actions performed by the control system are simple
• Actuating function is very reliable
• Any reaction forces opposing the actuation are small enough as to have no
effect on the actuation
• If these conditions do not apply, then a closed-loop control system should be
used
Advanced Automation Functions
• Safety monitoring
• Maintenance and repair diagnostics
• Error detection and recovery
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07-Feb-20
Safety Monitoring
• “Use of sensors to track the system's operation and identify conditions that are
unsafe or potentially unsafe”
• Reasons for safety monitoring
– To protect workers and equipment
• Possible responses to hazards:
– Complete stoppage of the system
– Sounding an alarm
– Reducing operating speed of process
– Taking corrective action to recover from the safety violation
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Maintenance and Repair Diagnostics

• Status monitoring
– Monitors and records status of key sensors and parameters during system
operation
• Failure diagnostics
– Invoked when a malfunction occurs
– Purpose: analyze recorded values so the cause of the malfunction can be
identified
• Recommendation of repair procedure
– Provides recommended procedure for the repair crew to effect repairs
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Errors
• Random errors occur as a result of the normal stochastic nature of the
process
• Systematic errors are those that result from some assignable cause such as a
change in raw material properties
• Aberrations (disorders) result from either an equipment failure or a human
mistake
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Error Detection and Recovery

• Error detection – functions:
– Use the system’s available sensors to determine when a deviation or malfunction has occurred
– Correctly interpret the sensor signal
– Classify the error
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07-Feb-20
• Error recovery – possible strategies:

– Make adjustments at end of work cycle
– Make adjustments during current work cycle
– Stop the process to invoke corrective action
– Stop the process and call for help
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Levels of Automation
• 1. Device level – actuators, sensors, and other hardware components to form
individual control loops for the next level
• 2. Machine level – CNC machine tools and similar production equipment,
industrial robots, material handling equipment
• 3. Cell or system level – manufacturing cell or system
• 4. Plant level – factory or production systems level
• 5. Enterprise level – corporate information system
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07-Feb-20
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07-Feb-20

Manufacturing Automation & Robotics

Dr. Binay Kumar

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

This course enables the students:

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Manufacturing Defined -Technological Definition

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Manufacturing Defined - ECONOMIC Definition

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Process Industries and Discrete Manufacturing Industries

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Classification of manufacturing processes

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Automation of manufacturing Processes

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Fixed position layout

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Line layout cafeteria

Cell layout buffet

Fixed-position layout service

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Manufacturing Support Systems

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Manufacturing Support Systems

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Automation in Production Systems

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Automated Manufacturing Systems

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

• Programmable Automation (NC, CNC, robots): In programmable automation, the

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Flexible Automation: Flexible automation is an extension of programmable automation. A

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Reasons for Automating

Dr. Binay Kumar, Deptt. of Production Engg., BIT Mesra, Ranchi

Dr. Binay Kumar, Deptt. of Production Engg.,

Manual Labour Vs Automation