This document provides information about an MT 308 Industrial Automation course at Sana'a University, including instructor details, grading policy, textbook, and syllabus. The course covers topics like automation and control technologies, numerical control systems, manufacturing systems, assembly lines, and flexible manufacturing cells over 13 weeks. It will include homework, quizzes, labs, midterm and final exams, and mini-projects. The goal is to introduce students to automation and various manufacturing operations, models, and systems.

1. MT 308 Industrial Automation
Mechatronics Engineering Department
Faculty of Engineering
Sana’a University
Dr. Khalil A. Al-Hatab

2. 2
Course Information
 Instructor
 Associate Professor Dr. Khalil Al-Hatab, (PhD)
 k.alhatab@eng-su.edu.ye
 Time and venue
 Lecture: Wed. 8-10
 Lab (class): Wed. 10-12
 Lab (practicing): Wed. 12-2
 Grading Policy
 Homework (after each part): 10%
 Quizzes : 5%
 Labs: 10%
 Mid-term: 15%
 Final Exam: 50%
 Mini-Projects 10%
 Textbook : Mikel P. Groover, Automation, Production Systems, and Computer-Integrated
Manufacturing, 4th ed., Pearson Higher Education, 2015.

3. Course Syllabus (Class)
Week # Part Name Chapter Title
We 1 13-2-2019 PART 1: OVERVIEW
OF MANUFACTURING
Ch.01 Introduction
We 2 20-2-2019 Ch.02-03 Manufacturing Operations, Models And Metrics)
We 3 27-2-2019
PART 2:
AUTOMATION AND
CONTROL
TECHNOLOGIES
Ch.04 Introduction to Automation
We 4 6-3-2019 Ch.05 Industrial Control Systems
We 5 13-3-2019
We 6 20-3-2019
We 7 27-3-2019
Ch.06 Numerical Control
We 8 3-4-2019 Midterm Exam
We 9 10-4-2019
PART 3: Manufacturing
Systems
Ch.13-14 Overview of Manufacturing Systems
We 10 17-4-2019 Ch.15-17 Manual and Automation Assembly Lines
We 11 24-4-2019 Ch.18 Group Technology and Cellular Manufacturing
We 12 1-5-2019 Holiday
We 13 8-5-2019 Chapter 19 Flexible Manufacturing Cells and Systems
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 3

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 4
Ch 1 Introduction
Sections:
1. Overview of Industrial Automation
2. Production Systems
3. Automation in Production Systems
4. Manual Labor in Production Systems
5. Automation Principles and Strategies

5. OVERVIEW OF INDUSTRIAL
AUTOMATION
 An automated system is a collection of devices working
together to accomplish tasks or produce a product or
family of products.
 Industrial automated systems can be one machine or a
group of machines called a cell.
 The term “programmable automation technology” actually
refers to three individually distinct technologies that have a
common thread: programmability. These technologies are
computer numerical control (CNC) technology, robotics
technology, and programmable logic control (PLC).
©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 5

6. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 6
The Realities of Modern
Manufacturing
 Globalization - Once underdeveloped countries (e.g.,
China, India, Mexico) are becoming major players in
manufacturing
 International outsourcing - Parts and products once made
in the United States by American companies are now
being made offshore (overseas) or near-shore (in Mexico
and Central America)
 Local outsourcing - Use of suppliers within the U.S. to
provide parts and services

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 7
More Realities of Modern
Manufacturing
 Contract manufacturing - Companies that specialize in
manufacturing entire products, not just parts, under
contract to other companies
 Trend toward the service sector (economy)
 Quality expectations - Customers, both consumer and
corporate, demand products of the highest quality
 Need for operational efficiency - manufacturers must be
efficient in in their operations to overcome the labor cost
advantage of international competitors

8. ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 8
Modern Manufacturing Approaches
and Technologies
 Automation - automated equipment instead of labor
 Material handling technologies - because
manufacturing usually involves a sequence of activities
 Manufacturing systems - integration and coordination
of multiple automated or manual workstations
 Flexible manufacturing - to compete in the low-
volume/high-mix product categories
 Quality programs - to achieve the high quality expected
by today's customers
 CIM - to integrate design, production, and logistics
 Lean production - more work with fewer resources

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 9
Production System Defined
A collection of people, equipment, and procedures
organized to accomplish the manufacturing
operations of a company
Two categories:
 Facilities – the factory and equipment in the facility
and the way the facility is organized (plant layout)
 Manufacturing support systems – the set of
procedures used by a company to manage
production and to solve technical and logistics
problems in ordering materials, moving work through
the factory, and ensuring that products meet quality
standards

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 10
The Production System
Fig. 1.1

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 11
Production System Facilities
Facilities include the factory, production machines and
tooling, material handling equipment, inspection
equipment, and computer systems that control the
manufacturing operations
 Plant layout – the way the equipment is physically
arranged in the factory
 Manufacturing systems – logical groupings of equipment
and workers in the factory
 Production line: More complex manufacturing systems
consist of collections of machines and workers.
 Stand-alone workstation and worker

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 12
Manufacturing Systems
Three categories in terms of the human participation in the processes
performed by the manufacturing system:
1. Manual work systems - a worker performing one or more tasks without
the aid of powered tools, but sometimes using hand tools (i.e. A
quality control inspector using a micrometer to measure the diameter
of a shaft)
2. Worker-machine systems - a worker operating powered equipment. A
combinations of one or more workers and one or more pieces of
equipment (i.e. A machinist operating an engine lathe to fabricate a
part for a product)
3. Automated systems - a process performed by a machine without
direct participation of a human. Automation is implemented using a
program, control system & Power. Two levels of automation can be
identified: semiautomated and fully automated.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 13
Manual Work System
Fig. 1.2 (a)

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 14
Worker-Machine System
Fig. 1.2 (b)

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Automated System
Fig. 1.2. (c)

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Manufacturing Support Systems
Involves a cycle of information-processing activities that consists of four functions:
1. Business functions - sales and marketing, order entry, cost accounting,
customer billing
2. Product design - research and development, design engineering, prototype
shop
3. Manufacturing planning - The information and documentation that constitute
the product design flows into the manufacturing planning function. The
information- processing activities in manufacturing planning include: process
planning, master scheduling, material requirements planning, and
capacity planning.
4. Manufacturing control - is concerned with managing and controlling the
physical operations in the factory to implement the manufacturing plans. The
flow of information is from planning to control. Included in this function are
shop floor control, inventory control & quality control

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 17
Information Processing Cycle in
Manufacturing Support Systems
Fig. 1.3

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Automation in Production Systems
Two categories of automation in the production system:
1. Automation of manufacturing systems in the
factory
2. Computerization of the manufacturing support
systems
 The two categories overlap because manufacturing
support systems are connected to the factory
manufacturing systems
 Computer-Integrated Manufacturing (CIM)

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 19
Computer Integrated Manufacturing
Fig. 1.4

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 20
Automated Manufacturing Systems
Examples:
 Automated machine tools
 Transfer lines
 Automated assembly systems
 Industrial robots that perform processing or
assembly operations
 Automated material handling and storage systems to
integrate manufacturing operations
 Automatic inspection systems for quality control

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 21
Automated Manufacturing Systems
Three basic types:
1. Fixed automation
2. Programmable automation
3. Flexible automation

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22
Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by the
equipment configuration
Typical features:
 Suited to high production quantities
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product variety

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 23
Programmable Automation
A manufacturing system designed with the capability
to change the sequence of operations to
accommodate different product configurations
Typical features:
 High investment in general purpose equipment
 Lower production rates than fixed automation
 Flexibility to deal with variations and changes in
product configuration
 Most suitable for batch production
 Physical setup and part program must be changed
between jobs (batches)

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 24
Flexible Automation
An extension of programmable automation in which the
system is capable of changing over from one job to the
next with no lost time between jobs
Typical features:
 High investment for custom-engineered system
 Continuous production of variable mixes of products
 Medium production rates
 Flexibility to deal with soft product variety

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 25
Product Variety and Production
Quantity for Three Automation Types
Fig. 1.5

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 26
Computerized Manufacturing Support
Systems
Objectives of automating the manufacturing support
systems:
 To reduce the amount of manual and clerical effort in
product design, manufacturing planning and control, and
the business functions
 Integrates computer-aided design (CAD) and computer-
aided manufacturing (CAM) in CAD/CAM
 CIM includes CAD/CAM and the business functions of
the firm

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 27
Reasons for Automating
1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 28
Manual Labor in Production Systems
Is there a place for manual labor in the modern
production system?
 Answer: YES
 Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 29
Manual Labor in Factory Operations
The long term trend is toward greater use of
automated systems to substitute for manual labor
 When is manual labor justified?
 Some countries have very low labor rates and
automation cannot be justified
 Task is too technologically difficult to automate
 Short product life cycle
 Customized product requires human flexibility
 To cope with ups and downs in demand
 To reduce risk of product failure

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 30
Labor in Manufacturing Support
Systems
 Product designers who bring creativity to the design task
 Manufacturing engineers who
 Design the production equipment and tooling
 And plan the production methods and routings
 Equipment maintenance
 Programming and computer operation
 Engineering project work
 Plant management

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 31
Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 32
U.S.A 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
 Automation migration strategy

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 33
Ten Strategies for Automation and
Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10.Computer-integrated manufacturing

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 34
Automation Migration Strategy
For Introduction of New Products
1. Phase 1 – Manual production
 Single-station manned cells working independently
 Advantages: quick to set up, low-cost tooling
2. Phase 2 – Automated production
 Single-station automated cells operating
independently
 As demand grows and automation can be justified
3. Phase 3 – Automated integrated production
 Multi-station system with serial operations and
automated transfer of work units between stations

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 35
Automation
Migration
Strategy