Presentation Title: Manufacturing Industries And Products This PowerPoint presentation provides an in-depth overview of It covers key concepts, data analysis, visual aids, and relevant case studies to support a clear understanding of the subject. Designed for students.

1. UNIT 4
MANUFACTURING
OPERATIONS AND
AUTOMATION

2. 4.1 MANUFACTURING INDUSTRIES AND PRODUCTS
➢ Definition -
Manufacturing industries involve the production of goods by transforming raw materials into finished products
using machines, tools, and labor.
Manufacturing industries are a key part of the secondary sector of the economy, contributing to GDP by
converting raw materials into marketable goods, which are then distributed for sale or further use.
➢ Importance -
•Drives economic growth and development.
•Creates employment opportunities.
•Supports other industries through supply chains.
➢ Types of Manufacturing Industries –
•Primary Industry – Uses natural resources (e.g., agriculture, mining).
•Secondary Industry – Converts raw materials into finished products (e.g., automobile, textile, electronics).
•Tertiary Industry – Provides services related to manufacturing (e.g., logistics, maintenance).

3. INDUSTRY AND THEIR PRODUCTS
Examples of Manufacturing Industries & Their Products
 Automobile Industry
 Products: Cars, Motorcycles, Trucks, Buses, Auto Parts
 Companies: Toyota, Ford, Tesla, Honda
 Aerospace Industry
 Products: Airplanes, Helicopters, Rockets, Satellites
 Companies: Boeing, Airbus, SpaceX, ISRO
 Electronics Industry
 Products: Smartphones, Laptops, Televisions, Semiconductors
 Companies: Apple, Samsung, Intel, Sony
 Textile & Apparel Industry
 Products: Clothing, Fabrics, Footwear, Accessories
 Companies: Nike, Adidas, Levi’s, H&M
 Food & Beverage Industry
 Products: Packaged Foods, Dairy Products, Soft Drinks, Snacks
 Companies: Nestlé, Coca-Cola, Pepsi, Mondelez

4. 4.2 Manufacturing Processes
Manufacturing operations involve various processes that convert raw materials into finished
products.
 Types of Processing Operations:
Forming Processes (Shape Change)
1.Casting – Pouring molten metal into a mold (e.g., engine blocks).
2.Forging – Shaping metal using compressive forces (e.g., wrenches, bolts).
3.Rolling – Reducing material thickness (e.g., steel sheets).
4.Extrusion – Forcing material through a die to form shapes (e.g., pipes).
Material Removal Processes (Machining)
1.Turning – Cutting material on a lathe (e.g., shafts, screws).
2.Milling – Removing material using rotating cutters (e.g., gears).
3.Drilling – Creating holes in materials (e.g., furniture).
4.Grinding – Smoothing surfaces (e.g., metal finishing).

5.  Joining & Welding Processes
1.Welding – Fusing metals using heat (e.g., car frames).
2.Brazing & Soldering – Joining metals using filler materials.
3.Adhesive Bonding – Using glue or resins (e.g., furniture, aircraft).
Surface Treatment Processes
1.Painting & Coating – Applying protective or decorative layers (e.g., car painting).
2.Plating – Coating metal with another metal (e.g., gold-plated jewelry).
. Assembling Operations (Component Combination)
Assembling operations involve joining two or more components to create a finished product.
 Types of Assembly Operations:
Mechanical Assembly – Using screws, bolts, and rivets (e.g., furniture, machinery).
Welding Assembly – Permanent joining using heat (e.g., pipelines, ships).
Adhesive Bonding – Using glue, resins, or epoxies (e.g., aircraft, electronics).
Automated Assembly – Robots assembling parts (e.g., electronics, car manufacturing).

6. 3 ) Other Factory Operations
Beyond processing and assembling, factories perform other essential operations:
Material Handling & Storage
 Conveyor Belts – Moving products between workstations.
 Automated Guided Vehicles (AGVs) – Transporting materials autonomously.
 Warehousing – Storing raw materials and finished goods.
Quality Control & Inspection
 Non-Destructive Testing (NDT) – Checking product quality without damage.
 Automated Inspection Systems – AI-based defect detection.
Packaging & Distribution
 Automated Packaging – Machines packing goods (e.g., food, pharmaceuticals).
 Logistics & Supply Chain – Managing raw materials and product delivery.

7. 4.3 Costs of Manufacturing Operations
 Manufacturing costs are classified into fixed and variable costs and include expenses like direct labor,
materials, overhead, and equipment usage.
1. Fixed & Variable Costs
Fixed Costs (Constant Regardless of Production Volume)
 These costs do not change with the level of production.
Examples:
 Factory Rent or Lease
 Salaries of Permanent Staff
 Depreciation of Equipment
 Insurance & Taxes
 Utilities (Minimum Electricity & Water Consumption)

8. Variable Costs (Change with Production Volume)
These costs increase or decrease depending on the number of units produced.
Examples:
 Raw Material Costs
 Direct Labor (Wages Based on Hours Worked)
 Energy & Fuel Consumption
 Packaging Costs
 Transportation & Logistics

9. Components of Manufacturing Costs
Direct Costs (Directly Related to Product Manufacturing)
 Direct Material Costs – Raw materials used in production (e.g., steel for cars, cotton for textiles).
 Direct Labor Costs – Wages paid to workers directly involved in production (e.g., machine operators, assembly
line workers).
Indirect Costs (Overheads, Not Directly Related to Each Unit Produced)
 Manufacturing Overheads – Costs related to production but not directly tied to each unit.
 Factory Maintenance
 Supervisor Salaries
 Machine Repairs & Spare Parts
 Administrative Costs – Costs for running the business.
 Office Expenses
 Manager Salaries
 Marketing & Sales Expenses

10. Costs of Equipment Usage
Capital Cost (Initial Purchase & Installation)
 Cost of purchasing machinery
 Installation and setup costs
Operating Costs (Day-to-Day Usage)
 Depreciation – Gradual loss of machine value over time.
 Energy Consumption – Electricity, fuel, or gas used for running machines.
 Maintenance & Repairs – Regular servicing and part replacement.
 Downtime Costs – Loss of production time due to machine breakdowns

11. 4.4 AUTOMATION
➢ General Definition
•Automation refers to the use of technology, machines, and control systems to perform tasks with
minimal human intervention.
➢ Technical Definition
•Automation is the application of mechanical, electronic, and computer-based systems to control and
operate production processes, reducing the need for human effort.
➢ Industrial Definition
•In manufacturing, automation involves robots, AI, sensors, and software to enhance production efficiency,
accuracy, and speed.

12. BASIC ELEMENTS OF AUTOMATED SYSTEM

13. ELEMENTS OF AUTOMATION
1. Power to Accomplish the Automated Process
 In an automated system, power is essential to operate machines, control systems, and execute tasks
efficiently. The choice of power source depends on the type of automation, workload, and energy efficiency
requirements.
2. Program of Instruction in Automation
 A Program of Instruction (POI) in automation refers to the set of commands, codes, or logic used to
control an automated system. It dictates how machines, robots, and control systems operate by following
predefined steps.
3. Control System in Automation
 A control system is a set of components that manage, command, direct, or regulate the behavior of
machines, processes, or devices to achieve a desired output. It ensures the automation system works
efficiently and accurately.

14. Reasons for Automating
•Increases Productivity – Automation allows machines to work 24/7 without breaks,
boosting production speed.
•Improves Quality & Precision – Automated systems ensure consistent product quality with minimal defects.
•Reduces Costs – Automation lowers labor costs, reduces material wastage, and optimizes resource usage.
•Enhances Workplace Safety – Robots and automated machines handle hazardous tasks,reducing accidents.
•Saves Time – Automated processes complete tasks faster than manual labor, increasing efficiency.
•Provides Scalability – Automation systems can be easily adjusted to handle increased workloads.
•Enables Smart Decision-Making – Real-time data collection through sensors helps in better monitoring
and analysis.
•Minimizes Human Fatigue & Errors – Machines perform repetitive tasks without tiring, reducing mistakes.
•Gives Competitive Advantage – Companies using automation can outperform competitors in speed and
efficiency.

15. USA Principles of Automation
 The USA Principle of Automation stands for “Understand, Simplify, Automate.” It is a fundamental
approach used in industrial automation to ensure efficiency and effectiveness before implementing
automation.
1. Understand (U)
 Analyze the existing process thoroughly.
 Identify inefficiencies, bottlenecks, and areas for improvement.
 Example: Studying a production line to find where delays occur.
2. Simplify (S)
 Streamline and optimize the process before automating.
 Remove unnecessary steps and complexity.
 Example: Redesigning a workflow to reduce manual handling before introducing robots.
3. Automate (A)
 Implement automation only after understanding and simplifying the process.
 Apply technology like robots, AI, sensors, and PLCs to enhance efficiency.
 Example: Using robotic arms in car manufacturing after optimizing the assembly layout.

16. LEVELS OF AUTOMATION

17. 1. Enterprise Level (Business & Management)
 Focus: High-level decision-making, resource planning, and business strategy.
 Key Functions:
 Enterprise Resource Planning (ERP) for managing finance, supply chain, and production.
 Market analysis, sales forecasting, and customer relationship management (CRM).
 Strategic planning to optimize manufacturing costs and efficiency.
 Example: SAP and Oracle ERP systems managing production schedules and inventory.
2. Plant Level (Production Management)
 Focus: Supervising and coordinating manufacturing processes at a factory level.
 Key Functions:
 Production scheduling and monitoring.
 Quality control and plant-wide maintenance.
 Communication between enterprise systems and lower-level automation.
 Example: SCADA (Supervisory Control and Data Acquisition) systems overseeing factory operations.

18. 3. System Level (Process Control)
 Focus: Controlling and optimizing industrial systems for efficient production.
 Key Functions:
 Ensures different machines and processes work in sync.
 Uses control systems like Distributed Control Systems (DCS) and Manufacturing Execution Systems (MES).
 Data collection from machines for performance tracking.
 Example: Automated production lines in a car manufacturing plant.
4. Machine Level (Equipment Control)
 Focus: Automating individual machines to perform specific tasks.
 Key Functions:
 Machine-level programming (e.g., CNC machines, robotic arms).
 Uses Programmable Logic Controllers (PLCs) for automation.
 Controls motion, speed, and precision of machines.
 Example: Industrial robots assembling car parts in an automated factory.

19. 5. Device Level (Sensor & Actuator Control)
 Focus: Controlling the smallest components in an automation system.
 Key Functions:
 Sensors collect data (e.g., temperature, pressure, motion).
 Actuators execute actions (e.g., motors, valves, robotic arms).
 Provides real-time feedback for higher automation levels.
 Example: Temperature sensors in an automated HVAC system.

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