The document outlines the concept of manufacturing automation, detailing definitions, types, levels, and strategies for automation within manufacturing systems. It describes various automated manufacturing systems such as fixed, programmable, flexible, and integrated automation, alongside their advantages, reasons for automation, and a migration strategy for evolving automation processes. The document emphasizes the benefits of automation, including increased productivity, improved safety, and enhanced product quality.

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