Definition of Automation Automated Manufacturing Systems Types of Manufacturing Automation Levels of Automation Computerized Manufacturing Support Systems Reasons for Automation Automation Strategies-The USA Principle Ten Strategies for Automation and Process Improvement Automation Migration Strategy Benefits of Automation References

1. MANUFACTURING AUTOMATION
PREPARED BY: DHAVAL CHAUHAN
GUIDED BY: PROF. M. Y. PATIL

3. OUTLINE
• Definition of Automation
• Automated Manufacturing Systems
• Types of Manufacturing Automation
• Levels of Automation
• Computerized Manufacturing Support Systems
• Reasons for Automation
• Automation Strategies-The USA Principle

4. OUTLINE
• Ten Strategies for Automation and Process
Improvement
• Automation Migration Strategy
• Benefits of Automation
• References

5. DEFINITION OF AUTOMATION
• The technology by which
a process or procedure is
accomplished without
human assistance.
• It is implemented using a
program of instructions
combined with a control
system that executes the
instructions.

6. DEFINITION OF AUTOMATION
• 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 accurate the instructions

7. AUTOMATED MANUFACTURING SYSTEMS
• An Automated Manufacturing System (AMS) is an
interconnected system of material processing
stations capable of automatically processing a wide
variety of part types simultaneously under computer
control.
• They perform operations such as processing,
assembly, inspection, material handling etc.

8. AUTOMATED MANUFACTURING SYSTEMS
• Examples of automated manufacturing systems
include:
Automated machine tools
Transfer lines
Automated assembly systems.
Manufacturing systems
Automatic inspection systems
Automatic material handling and storage systems

9. TYPES OF MANUFACTURING AUTOMATION
• Fixed Automation
• Programmable Automation
• Flexible Automation
• Integrated Automation

11. FIXED AUTOMATION
• In a Fixed Automation System, the production
equipment is fixed with a fixed set of operations or
tasks.
• There are rarely any changes to these operations.
• Fixed Automation System is usually used in
assembly processes, machining, painting,
continuous flow processes like conveyors and mass
production systems.

12. FIXED AUTOMATION
• The typical features of fixed automation are:
1. High initial investment for customized equipment
(jig, die, etc.)
2. High production rates.
3. Relatively inflexible in accommodating product
changes.
4. Only product with high demands and volumes –
automobile.

13. PROGRAMMABLE AUTOMATION
• In Programmable Automation System, the sequence
of operations as well as the configuration of the
machinery can be changed using electronic controls.
• The operation sequence is controlled by a program.
• The program is a set of instructions coded so that
the system can read and interpret them.
• New programs can be prepared and entered into the
equipment to produce new products.

14. PROGRAMMABLE AUTOMATION
• This system requires a significant amount of time
and effort to reprogram the machines.
• Some of the features that characterize
programmable automation are:
1. High investment in general-purpose equipment;
2. Low production rates relative to fixed automation;
3. Flexibility to deal with changes in product
configuration; and
4. Most suitable for batch production.

15. PROGRAMMABLE AUTOMATION
• The parts or products are typically made in batches.
• To produce each new batch of a different product,
the system must be reprogrammed with the set of
machine instructions that correspond to the new
product.
• Examples of programmed automation include
numerically controlled machine tools and industrial
robots etc.

16. FLEXIBLE AUTOMATION
• It is an extension of programmable automation.
• It is controlled by computers and are often
implemented where the product varies frequently.
• CNC machines are the best example for this system.
• The code given by the operator to the computer is
unique to a particular job and based on the code, the
machine acquires the necessary tools and equipment
for the production.
• Another example of this is Tesla’s manufacturing,
Amazon warehouses etc.

17. FLEXIBLE AUTOMATION
• The features of flexible automation can be
summarized as follows:
1. High investment for a custom-engineered system.
2. Continuous production of variable mixtures of
products.
3. Medium production rates.
4. Flexibility to deal with product design variations.

18. FLEXIBLE AUTOMATION
• There is no production time lost while
reprogramming the system and altering the physical
setup (tooling, fixtures, and machine setting).

19. INTEGRATED AUTOMATION SYSTEM
• It is a set of independent machines, processes and
data, all working synchronously under the command
of a single control system to implement an
automation system of a production process.
• CAD (Computer Aided Design), CAM (Computer
Aided Manufacturing), computer-controlled tools
and machines, robots, cranes and conveyors are all
integrated using complex scheduling and production
control.

20. LEVELS OF AUTOMATION
• There are two levels of automation:
1. semi-automated and
2. fully automated.
• A semi-automated machine performs a portion of
the work cycle under some form of program control,
and a human worker tends to the machine for the
remainder of the cycle, by loading and unloading it,
or by performing some other task in each cycle.

21. LEVELS OF AUTOMATION
• A fully automated machine is distinguished from its
semi-automated counterpart by its capacity to
operate for an extended period of time with no
human attention.

22. COMPUTERIZED MANUFACTURING
SUPPORT SYSTEMS
• All modern manufacturing support systems are
implemented using computer systems.
• Automation of the manufacturing support systems is
aimed at reducing the amount of manual effort in;
Product design
Manufacturing planning
Manufacturing control and
Business functions

23. REASONS FOR AUTOMATION
• To increase labor productivity
• To reduce labor cost
• To mitigate the effects of labor shortages
• To reduce or eliminate routine manual and clerical
tasks
• To improve worker safety
• To improve product quality
• To reduce manufacturing lead time

24. REASONS FOR AUTOMATION
• To accomplish processes that cannot be done
manually
• To avoid the high cost of not automating

25. AUTOMATION STRATEGIES - THE USA
PRINCIPLE
• The USA Principle is a common sense approach to
automation and process improvement projects.
• USA stands for:
Understand the existing process
Simplify the process
Automate the process

26. AUTOMATION STRATEGIES - THE 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.

27. TEN STRATEGIES FOR AUTOMATION
AND PROCESS IMPROVEMENT
• Specialization of operations - involves the use of
special-purpose equipment designed to
perform one operation with the greatest possible
efficiency. e.g. labor specialization.
• Combined operations - by performing more than
one operation at a given machine, thereby
reducing the number of separate machines needed.
• Simultaneous operations - to simultaneously
perform the operations that are combined at one
workstation. Thus reducing total processing time.

28. TEN STRATEGIES FOR AUTOMATION
AND PROCESS IMPROVEMENT
• Integration of operations - to link several
workstations together into a single integrated
mechanism. Thus reduces the number of separate
machines.
• Increased flexibility - to achieve maximum
utilization of equipment for job shop and medium
volume situations by using same equipment for
variety of parts or products.
• Improved material handling and storage - reduces
non-productive time. It reduces work-in-progress
and shorter manufacturing lead times.

29. TEN STRATEGIES FOR AUTOMATION
AND PROCESS IMPROVEMENT
• On-line inspection - reduces scrap and brings the
overall quality of product closer to the nominal
specifications intended by the designer.
• Process control and optimization - By this, the
individual process times can be reduced and product
quality improved.
• Plant operations control - involves a high level of
computer networking within the factory. It attempts
to manage the aggregate operations in the plant
more efficiently.

30. TEN STRATEGIES FOR AUTOMATION
AND PROCESS IMPROVEMENT
• Computer-integrated manufacturing - the integration
of factory operations with engineering design and
the business functions of the firm.

31. AUTOMATION MIGRATION STRATEGY
• An automation migration strategy is a formalized
plan for evolving the manufacturing systems used to
produce new products as demand grows.
• Three phases of automation migration strategy are:
1. Manual Production
2. Automated Production
3. Automated Integrated Production.

33. AUTOMATION MIGRATION STRATEGY
Phase 1 – Manual Production
• Manual production use single station manned cells
operating independently.
• It have advantage which is quick to set up and low
cost tooling to get started.

34. AUTOMATION MIGRATION STRATEGY
Phase 2 – Automated Production
• Automated production use single station automated
cells operating independently.
• As demand for the product grows, then the
automation must be used.
• It will reduce labor rate and increase production
rate.

35. AUTOMATION MIGRATION STRATEGY
Phase 3 – Automated Integrated Production
• Automated integrated production use a multi-station
automated system with serial operations and
automated transfer of work units between stations.

36. BENEFITS OF AUTOMATION
• Reduction or total elimination of tedious and routine
operations like loading, unloading, assembly,
inspection etc.
• Creation of new and more interesting jobs.
• Increase in the productive capacity of industry.
• Greater flexibility through the use of standard
production units.

37. REFERENCES
• PPT on Manufacturing Automation by K.P.
Karunakaran, IIT Bombay
• PPT on Manufacturing Automation by Prof. Sounak
Kumar Choudhury, IIT Kanpur
• What is Industrial Automation? Types, Levels,
Advantages, April 19, 2019
• 9 Reasons for automation of manufacturing
processes by Edvard, January, 11th 2016

38. REFERENCES
• 10 Strategies for Automation and Production
Systems by Edvard, May, 7th 2014
• Automation Migration Strategy in 3 phases by
Edvard, October, 27th 2014