Automation Notes 1

AUTOMATION
HAKAM SINGH DIWAKAR

Asst. Professor (Mechanical Engineering Department)
INTRODUCTION TO AUTOMATION
The word ‘Automation’ is derived from greek words “Auto”(self) and “Matos”
(moving). Automation therefore is the mechanism for systems that “move by
itself”.
Definition:
• Automation is a set of technologies that results in operation of machines and
systems without significant human intervention and achieves performance
superior to manual operation.
• Automation can be defined as the technology by which a process or procedure
is accomplished without human assistance.
“Automation = Automatic Control”
• Automation refers to the use of mechanized equipment that performs the
physical tasks without the need for oversight by a human worker.
AUTOMATION IN PRODUCTION SYSTEMS
Automation in production system can be defined as a technology concerned with the

application of mechanical, electronic, and computer-based systems to operate and
control production.
The automated elements of the production system can be separated into two
categories:
1. Automation of the manufacturing systems in the factory and
2. computerization of the manufacturing support systems.
In modern production systems, the two categories are closely related, because the
automated manufacturing systems on the factory floor are themselves usually
implemented by computer systems that are integrated with the manufacturing
support systems and management information system operating at the plant and
enterprise levels.
Opportunities for automation and computerization in a
production system.
Types of Automation Systems
Automation systems can be categorized based on the flexibility and

level of integration in manufacturing process operations. Various
automation systems can be classified as follows –
1. Fixed Automation
2. Programmable Automation
3. Flexible Automation
Fixed Automation: Fixed automation is a system in which the sequence of

processing (or assembly) operations is fixed by the equipment configuration.
Each of the operations in the sequence is usually simple, involving perhaps a
plain linear or rotational motion or an uncomplicated combination of the two;
• It is used in high volume production with dedicated equipment, which has a
fixed set of operation and designed to be efficient for this set.
• Continuous flow and Discrete Mass Production systems use this automation. e.g.
Distillation Process, Conveyors, Paint Shops, Transfer lines etc.
• A process using mechanized machinery to perform fixed and repetitive
operations in order to produce a high volume of similar parts.
Programmable Automation: In programmable automation, the production

equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations. The operation
sequence is controlled by a program, which is a set of instructions coded so
that they can be read and interpreted by the system. New programs can be
prepared and entered into the equipment to produce new products.
Features of programmable automation systems:
• 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
Flexible Automation: Flexible automation is an extension of programmable
automation. A flexible automated system is capable of producing a variety of parts (or
products) with virtually no time lost for changeovers from one part style to the next.
• It is used in Flexible Manufacturing Systems (FMS) which is invariably computer
controlled.
• Human operators give high-level commands in the form of codes entered into computer
identifying product and its location in the sequence and the lower level changes are
done automatically.
• Each production machine receives settings/instructions from computer.
• These automatically loads/unloads required tools and carries out their processing
instructions.
• After processing, products are automatically transferred to next machine.
• It is typically used in job shops and batch processes where product varieties are high
and job volumes are medium to low. Such systems typically use Multi purpose CNC
machines, Automated Guided Vehicles (AGV) etc.
The features of flexible automation
can be summarized as follows:
• High investment for a custom-

engineered system
• Continuous production of variable
mixtures of products
• Medium production rates
• Flexibility to deal with product design
variations
The relative positions of the three types of automation

for different production volumes and product varieties
AUTOMATION PRINCIPLES AND STRATEGIES
USA Principle - The USA Principle is a common sense approach to

automation projects.
USA stands for:
1. Understand the existing process
2. Simplify the process
3. Automate the process.
Understand the Existing Process
The first step in the USA approach is to understand the current process in all
of its details.
• What are the inputs?
• What are the outputs?
• What exactly happens to the work unit between input and output?
• What is the function of the process?
• How does it add value to the product?
• What are the upstream and downstream operations in the production
sequence, and can they be combined with the process under consideration?
Simplify the Process
Once the existing process is understood, then the search can begin for ways to
simplify. This often involves a checklist of questions about the existing
process.
• What is the purpose of this step or this transport?
• Is this step necessary?
• Can this step be eliminated?
• Is the most appropriate technology being used in this step?
• How can this step be simplified?
• Are there unnecessary steps in the process that might be eliminated without
detracting from function?
Automate the Process
Once the process has been reduced to its simplest form, then automation can
be considered. The possible forms of automation include the ten strategies.
Ten Strategies for Automation and Production Systems
If automation seems a feasible solution to improving productivity, quality, or

other measure of performance, then the following ten strategies provide a
road map to search for these improvements.
1. Specialization of operations- The first strategy involves the use of special—
purpose equipment designed to perform one operation with the greatest
possible efficiency.
2. Combined operations- Production occurs as a sequence of operations.
Complex parts may require dozens, or even hundreds, of processing steps.
The strategy of combined operations involves reducing the number of
distinct production machines or workstations through which the part must
be routed. This is accomplished by performing more than one operation at
a given machine, thereby reducing the number of separate machines
needed.
3. Simultaneous operations- A logical extension of the combined operations

strategy is to simultaneously perform the operations that are combined at
one workstation. In effect, two or more processing (or assembly) operations
are being performed simultaneously on the same work part, thus reducing
total processing time.
4. Integration of operations- Another strategy is to link several workstations
together into a single integrated mechanism, using automated work handling
devices to transfer parts between stations. In effect, this reduces the number
of separate machines through which the product must be scheduled.
“With more than one workstation, several parts can be processed simultaneously, thereby increasing the overall
output of the system.”
5. Increased flexibility- This strategy attempts to achieve maximum utilization

of equipment for job shop and medium volume situations by using the same
equipment for a variety of parts or products. It involves the use of the flexible
automation concepts.
Prime objectives are to reduce setup time and programming time for the
production machine. This normally translates into lower manufacturing lead
time and less work-in-process.
6. Improved material handling and storage- A great opportunity for reducing
non-productive time exists in the use of automated material handling and
storage systems.
“Typical benefits include reduced work-in-process and shorter manufacturing lead times”
7. On-line inspection- Inspection for quality of work is traditionally performed

after the process is completed. This means that any poor quality product has
already been produced by the time it is inspected. Incorporating inspection
into the manufacturing process permits corrections to the process as the
product is being made.
“This reduces scrap and brings the overall quality of product closer to the nominal specifications
intended by the designer”
8. Process control and optimization- This includes a wide range of control

schemes intended to operate the individual processes and associated
equipment more efficiently. By this strategy, the individual process times can
be reduced and product quality improved.
9. Plant operations control- Whereas the previous strategy was concerned with the
control of the individual manufacturing process, this strategy is concerned with
control at the plant level. It attempts to manage and coordinate the aggregate
operations in the plant more efficiently.
“Its implementation usually involves a high level of computer networking within the factory”
10. Computer-integrated manufacturing (CIM)- Taking the previous strategy

one level higher, we have the integration of factory operations with
engineering design and the business functions of the firm.
CIM involves extensive use of:
1. Computer applications,
2. Computer data bases, and
3. Computer networking throughout the enterprise.

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AUTOMATION

HAKAM SINGH DIWAKAR

Automation in production system can be defined as a technology concerned with the

Automation systems can be categorized based on the flexibility and

Fixed Automation: Fixed automation is a system in which the sequence of

Programmable Automation: In programmable automation, the production

• High investment for a custom-

The relative positions of the three types of automation

USA Principle - The USA Principle is a common sense approach to

If automation seems a feasible solution to improving productivity, quality, or

3. Simultaneous operations- A logical extension of the combined operations

5. Increased flexibility- This strategy attempts to achieve maximum utilization

7. On-line inspection- Inspection for quality of work is traditionally performed

8. Process control and optimization- This includes a wide range of control

10. Computer-integrated manufacturing (CIM)- Taking the previous strategy

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