ẞdffcmjnkhigfufyfkbjvuvjvjvjgydyvigvudtxhvigyxhgihigudtxuggiguftcjjoufyfihihiftsjgohkvhchcknkvhchgibobjvhchvknlnkvhchckbhkjvjvjcjfhchchfjfjvjvkbkvjchchc

1. AUTOMATION IN
MANUFACTURING
INTRODUCTION
PRODUCTION SYSTEMS
AUTOMATED MFG
SYSTEMS
REASONS
PRINIPLES & STRATAGIES
BASIC ELEMENTS
PNEUMATIC AND
HYDRAULIC CIRCUIT
COMPONENTS
UNIT - I

2. “Automation can be defined as a
technology concerned with the
application of electronic,
mechanical and computer- based
systems to operate and control
the production”.

3. “To perform a task ,without
human intervention to
improve the productivity and
quality”.
CNC Machines, Automated guided
vehicles, robots etc……
Automation

4. 1. To Increase labor productivity.
2. To reduce labor cost.
3. To mitigate the effects of labor shortages.
4. To reduce or eliminate routine manual and clerical
tasks.
5. To improve worker safety.
6. To improve product quality
7. To reduce manufacturing lead time.
8. To accomplish processes that cannot be done
Reasons for automation

5. - That are used to manufacture products and the parts assembled into those
products.
- Production system is the collection of people equipment and procedures
organized to accomplish the manufacturing process of a company.
Production Systems

6. Manufacturing support systems
Facilities :
Factory Equipment
Production systems can be devided in two
categories

7. Facilities
•The facilities of the production consist of the factory, the equipment in the factory and
the way the equipment is organized.

8. Hard product
-The variety between different product categories
Soft product
-The variety between different models within the same product categories

9. Automation:
Automation is a Technology concerned with the application of Mechanical,
Electrical and Computer Based systems to Operate and Control Production.
Robotics, CAD/CAM, FMS, CIM, Machine Vision CAE, SAP, CAPP etc.
Mechanization.
AUTOMATION IN
MANUFACTURING

10. Factory Requirements.
To survive in the competitive atmosphere of
modern manufacturing, the company must
adhere strictly to standards. While
customers must satisfied with all aspects of
products, service and the company must
make profit and protect its workers.

11. A Successful Modern Factory
• Sell at a price consumers are willing to pay.
• Make only what consumers need.
• Make products that will satisfy consumers.
• Always meet delivery schedules.
• Turnout safe products safely.

12. All About DEFECTS
• Errors are Inevitable: People always make
mistakes. We accept the mistakes and blame the
people who make them. This attitude overlook
defects as they occur in production. They may be
detected at final stage or by the customer.
• Errors can be eliminated: Any kind of mistake
people make can be reduced or even eliminated if
proper training, by proper care in process and by
proper technology.

13. Types of Automation.
• Fixed Automation.
• Programmable Automation.
• Flexible Automation.
• CIM

14. 1. Fixed Automation
System in which the sequence of processing
operations is fixed by the equipment
configuration.
In this integration and co-ordination of many such
operations into one and the systems is
Complex.

15. Main features of Fixed Automation
• High initial investment for custom engineered
equipment.
• High production Rate.
• Difficult to accommodate product changes.
• Unit cost is reduced.

16. 2.Programmable Automation:
In this production equipment is designed with
the capability to change the sequence of
operation to accommodate different product
configurations.
The operation sequence is controlled by a
programme which is a set of instructions.

17. Main Features:
• High investment
• Low production rates.
• Flexibility to deal with changes in product
changes/configuration.
• More suitable for batch Production.

18. 3. Flexible Automation:
It is capable of producing a variety of products or
parts with Virtually no time lost for
changeovers from one product to the next .

19. Main Features:
• High Investment.
• Continuous Production of variable mixtures of
Products.
• Medium Production Rate.
• Flexibility to deal with product design
variation.

20. 4 CIM (Computer Integrated Manufac.)
CIM denote the use of computers to design the
products, control the operations and perform the
various business related functions need in a
manufacturing firm.
It include all the Engineering functions of CAD/CAM and
business functions that are related to manufacturing.
CIM applies to communication technology to all of the
operational functions and information processing
functions in manufacturing from order receipt
through design production to product shipment.

21. Types of automations used for different levels of
production quantity and product variety
Different parts
Job shop
Batch Prod.
Mass Prod.
Fixed automation
Flexible automation
Programmable automation
Product
variety
Production
Quantity

22. Reasons for Automation
• Increased Productivity
• High Cost of Labor
• Labor Shortages
• Trend of Labor toward the service sector
• Safety
• High Cost of Raw Materials
• Improved Product Quantity
• Reduced manufacturing Lead Lime
• Reduction of in Process inventory
• High Cost of Not Automating

23. AUTOMATION PRINCIPLES AND
STRATEGIES:
I. USA Principle
2. Ten Strategies for Automation an production
systems
3. Automation migration strategy

24. 1.USA Principle:
Understand the existing
process.
Simplify the process.
Automate the process.

25. 2. Ten Strategies for Automation and
production systems:
-Specialization of operations.
-Combined operations.
-Simultaneous operations.
-Integration of operations.
-Increased flexibility.
-Improved material handling and storage.
- On-line inspection.
-Process control and optimization.
-Plant operation control.
-Computer integrated Manufacturing.

26. 3. Automation migration strategy:
A formalized plan for evolving the
manufacturing systems used to produce
new products. The three phases are:
-Manual Production.
-Automated Production.
-Automated Integrated Production.

27. Types of Production
• Job Shop Production
Low production - in the range of 1 to 100 units per year.
• Batch Production
Medium production - in the range of 100 to 10,1000 units per year.
• Mass Production
High production - in the range of 10,000 to millions of units.

28. Functions in Manufacturing Unit
• Processing
• Assembly
• Material Handling
• Inspection and testing
• Control

29. Processing, Assembly
Material Handling
Inspection & Testing
Raw
Material
Control
Finished
Products

30. Information processing in manufacturing
(Organizational Function)
Factory
Operation
Product Design
Product Development
Engineering Drawing
Bills of Materials
Manufacturing Control
Shop floor control
Quality control
Inventory control
Business
Functions
Marketing
Sales
Order entry
Customer
Building
Manufacturing
Planning
Processes Planning
Required Planning
Master scheduleing
Capacity Planning

31. Basic Elements of an Automated
System
1. Power to Accomplish the Automated Process and
operate the system.
2. Program of instructions to direct the process.
3. Control System to actuate the instructions.
Advanced Automation Functions
1. Safety Monitoring
2. Maintenance and repair Diagnostics
3. Error Detection and Recovery
Level of Automation

32. BASIC ELEMENTS OF AN AUTOMATION SYSTEMS
1. Power – to accomplish the process & operate systems.
2. A program of instructions – to direct the process.
3. A control system – to actuate the instructions.
Program of
instructions
Control system Process
POWER
ELEMENTS OF AN AUTOMATED SYSTEM

33. 1. Power to Accomplish the
Automated Process
Power is required to drive the process and controls. The
principal source of power is electricity.
Advantages of Electrical power are :
-Widely available at moderate cost.
-Can be converted to mechanical. Thermal, light,
acoustic and pneumatic energies.
-power at low intensity levels can be used to
accomplish functions such as signal transmission,
information processing, data storage and
communication.
-Can be stored in long-life batteries for use.

34. Power for Process
Manufacturing process like casting, forging, heat
treatment, machining etc consume power to
accomplish operation on the work piece. Power for
each operation is usually converted from electrical
energy.
Alternate power sources like fossil fuels (coal, oil, etc),
solar, water and wind energy are vary rarely used in
automation. In casting and heat treatment, the
furnace may be heated by fossil fuels, but control
system to regulate temperature and time cycle is
electrically operated.

35. Common Manufacturing Processes and Power Requirements
• Casting Thermal
• EDM Electrical
• Forging Mechanical
• Heat treatment Thermal
• Injection Molding Thermal and
Mechanical
• Laser Beam Cutting Light and
Thermal
• Machining Mechanical
• Welding Thermal and
Mechanical
Melting the metal before pouring into mold cavity.
Metal removal by a series of electrical discharges between
electrode (tool) and work it causes very high localized
temperatures that melt the metal.
Heated Metal work part is deformed by opposing dies under
pressure.
Workpiece is heated to temperatures below melting point to
effect microstructural changes.
Heat is used to raise temperature of polymer to highly
consistency , and mechanical force is used to inject the
polymer into mould.
A highly coherent light beam is used to cut material by
vaporization and melting.
Cutting of metal is accomplished by relative motion between
tool and workpiece.
Work is heated to cause fusion and coalescence of two or
more metal parts and allowed to solidify with or
without pressure.

36. Power is Also Required For :
• Loading and Unloading the work Unit - To accomplish
operation the part must be placed and oriented in position
and removed after completion, Hence power is required for
this transport and placement function. If the process is
manually operated or semiautomated then human power
may be used to locate the work unit.
• Material Transport between operations – This is associated
with the work movement from one machine to next
machine.

37. Power for Automation:
• Controller Unit – digital computers required
electrical power to read program, make control
calculations and execute the instructions.
• Power to actuate the control signals – controller
unit such as electromechanical devices
(switches, motors, actuators, etc.) are require
power to operate.
• Data acquisition & information Processing-

38. 2. Program of Instructions:
It defines the action of Automated manufacturing
system. The processing steps are performed during
the work cycle. Work cycle program are called part
program in NC.
Work cycle program may be simple with one step for
example maintaining the temperature of furnace
during heat treatment for a given time or program
may be multi step like loading, performing the
operation & unloading the part as it happens in
many production operations.

39. 3.Control System
Program is executed by control system. The
controls in an automated system can be either
(i) Closed loop control system or
(ii) Open loop control system
A closed loop control system also called feedback
control system, is one in which the output variable
is compared with the input parameter, and any
difference between the two is used to drive the
output in agreement with the input.

40. (i) Closed loop control has:
1. Input parameter-set point.
2. Process –Function being controlled.
3. Output variable- Process variable.
4. Feedback sensor – to measure the output variable./
5. Controller – Compares the output with input and makes
required adjustments.
6. Actuator – Physically carry out the control action. Stepper
Motor.
Controller Actuator Process
Feedback Sensor
Input
parameter
Output
Variable
Closed loop or Feedback Control System

41. (i) Open loop control System
It operate without feed back.
Output measurement is not required
Controller Actuator Process
Output
variable
Input
parameter
Open loop control System