Automation

What
is Automation?
The process of writing a set of instructions that are designed,
scripted, tested, and checked in by a person, then executed
by a machine, to produce results that can be analyzed.

The theory, art or technique of making a process more

automatic; the investigation, design, development and

application of methods for rendering processes automatic,
self-moving or self-controlling; the conversion of a
procedure, a process or equipment to automatic operation.

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Types of Automation
Fixed automation

A system in which the sequence of processing or assembly operations is

fixed by the equipment configuration.
Features
High initial investment for custom engineered equipment
High production rates
Relatively inflexible in accommodating product variety
Eg:automated assembly machines

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 Programmable automation
The production equipment is designed with the capability to change the
sequence of operations 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

Features
high investment in general purpose equipment
lower production rates than fixed automation
flexiblility to deal with variations and changes in product configuration
most suitable for batch production
eg; NC machine tools ,industrial robots,programmable logic controllers

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 Flexible automation
An extension of programmable automation.flexible automation system is
capable of producing a variety of parts or products with virtually no time lost
for changeover from one parts to the next .there is no lost production time
while reprogrming the system and altering the physical setup(tooling
,fixtures,machine settings)

Features

high investment for custom engineered system

continuous production of variable mixtures of products
medium production rates
flexibility to deal with product design variations

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Levels
of
Automation
Device level

:actuators,sensers other hardware elements.the devices are

combined into the individual control loops of machine eg:feedback control loop for 1
axis of a cnc machine

Machine level:

hardware at device level is assembled into individual

machines eg:cnc machine tools,industrial robots.control function at this level include
performing sequence of steps in the program of instructions in the correct order and
making sure each step is properly executed

System level;this is the manufacturing cell,which operates under instructions

from plant level .a cell is a group of machines connected and supported by a material
handling system ,computer etc appropriate to manufacturing process.eg:part
dispatching,material handling systems,coordination among machines

Plant level:

This factory level or production system level it receives instruction

from corporate information system and translates them into operational plans for
production.likely functions : order processing,process planning, inventory
control,materials req planning,QC

Enterprise

level:consisting of corporate information systems.it is concerned

with all functions necessary to manage the company eg:Mark and sales,accounting
.design,master production scheduling,ERP

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Expectations of automation

Increase labor productivity

Improve product Quality
Increased efficiency
Reduce manufacturing lead
time
Lower cost
Improve worker safety
Accomplish processes that
cannot be done manually

Automation in action

Data Collection
Manufacturing Planning and

CAD/CAM
CNC

Rapid Prototyping
Inspection
Robots
Conveyors
Process Controls
FMS

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Control
Intranets
EDI
Accounting Systems
Material handling
Sales Force Automation

Non-Manufacturing:
Communications and networking
Facilities controls
Amusements and games
Universal Studios
Disney

Deciding Among Automation

Alternatives
Economic factors

Effect on product quality

Effect on manufacturing flexibility
Effect on labor relations
The amount of time required for implementation
Effect of automation implementation on ongoing production
Amount of capital required

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Robot Palletizes Putters

Pickles: A Case Study

Aliment Putters Food, Inc., a well-known eastern Canadian

producer of a wide variety of pickled vegetable products

The Challenge
Their manual end-of-line palletizing operation was limiting their processing

capacity.
Even with three people palletizing, they couldnt take product away as fast as it
was produced.
Cases weigh up to 20 lbs each. Stacking them onto pallets for shipment is a
backbreaking, physically demanding job.
People were quitting left and right.

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The Solution

In September 2005, Putters

implemented a four-axis Motoman
SP100X palletizing robot into their
operation.

The Benefits

The palletizing robot does a physically

demanding job that people dont want
to do.
Now they are able to take product
away as fast as they are produced.
they have been able to hire more
people for the processing line and
increase production because the robot
can handle it.
unit cost for the product has gone
down.
The robot gives the flexibility to add a
second infeed conveyor, automatic
pallet feed and product feed
robot has been very reliable. It just
keeps working.

Automation principle
USA Principle
Understand the existing process
Simplify the process
Automate the process (last!)

Strategies for Automation

Specialization of operations
Combined operations
Simultaneous operation
Integration of operations
Increased flexibility
Improved material handling and storage
on-line inspection
Process control and optimization
Plant operation s control
CIM

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AS/RS: A case study

1500 pallet spaces
2 automated stacker cranes
Computer controlled inventory

records
Cost $1.5 million+

The AS/RS message

Consider the total operation

Never automate an inefficient process
SIMPLIFY FIRST
Automate where it makes good sense

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