Intro to Automation

8/2/2019 Intro to Automation

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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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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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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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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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System

FixedAutomation


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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System

FixedAutomation


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

Documents

Intro to Automation