prepared by Dr.V.CHITTARANJAN DAS

1. 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)
Automation is a technology concerned with the application
of mechanical, electronic, and computer based systems to
operate and control production

2. Automation and Computer Integrated Manufacturing

3. 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

4. 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

5. 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)

6. 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

7. Product Variety and Production
Quantity for Three Automation Types

8. 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

9. Model of manufacturing showing factory operations and
the information Processing activities for manufacturing
support

10. 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 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 what cannot be done manually
9. To avoid the high cost of not automating

11. 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

12. 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

13. 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

14. RELATIVE STRENGTHS OF HUMANS
Sense unexpected stimuli
Develop new solutions to problems
Cope with abstract problems
Adapt to change
Learn from Experience
Make difficult decisions based on incomplete
data

15. RELATIVE STRENGTHS OF MACHINES
Perform repetitive tasks consistently
Store large amounts of data
Retrieve data from memory reliably
Perform multiple tasks at same time
Apply high forces and power
Perform simple computations quickly
Make routine decisions quickly

16. Automation Principles and Strategies
1. The USA Principle
2. Ten Strategies for Automation and Production systems
3. Automation Migration Strategy

17. 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

18. 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

19. 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

20. Automation Migration Strategy

21. Advantages
Phase-3 Avoids the commitment to a high level of
automation from the start, since there is always a risk
that demand for the product will not justify.
Phase-2 Allows automation to be introduced gradually, as
demand for the product grows, engineering changes in
the product are made, and time is allowed to do a
thorough design job on the automated manufacturing
system.
Phase-1 Allows the introduction of new product in the
shortest possible time , since the production cells based
on manual work stations are the easiest to design and
implement.

22. Manufacturing Operations
Manufacturing - Technological Definition
Application of physical and chemical processes to alter the
geometry, properties, and/or appearance of a given starting
material to make parts or products
 Manufacturing also includes the joining of multiple parts to
make assembled products
 Accomplished by a combination of machinery, tools, power, and
manual labor.
 Almost always carried out as a sequence of operations

23. Manufacturing as technological Process

24. Manufacturing – as an Economic Process
Transformation of materials into items of greater value by
means of one or more processing and/or assembly operations
 Manufacturing adds value to the material
 Examples:
 Converting iron ore to steel adds value
 Transforming sand into glass adds value
 Refining petroleum into plastic adds value

25. Manufacturing – as an Economic Process

26. Classification of Industries
1. Primary industries – cultivate and exploit natural resources
 Examples: agriculture, mining
2. Secondary industries – convert output of primary industries
into products
 Examples: manufacturing, power generation,
construction
3. Tertiary industries – service sector
 Examples: banking, education, government, legal
services, retail trade, transportation

27. Manufacturing Industries
ISIC Code
 Food, beverages, tobacco 31
 Textiles, apparel, leather and fur products 32
 Wood and wood products, cork 33
 Paper, printing, publishing, bookbinding 34
 Chemicals, coal, petroleum and their products 35
 Ceramics, glass, mineral products 36
 Basic metals, e.g., steel, aluminum 37
 Fabricated products, e.g., cars, machines, etc. 38
 Other products, e.g., jewelry, toys 39

28. More Industry Classifications
 Process industries, e.g., chemicals, petroleum, basic
metals, foods and beverages, power generation
 Continuous production
 Batch production
 Discrete product (and part) industries, e.g., cars, aircraft,
appliances, machinery, and their component parts
 Continuous production
 Batch production

29. Process Industries and Discrete Manufacturing
Industries
Continuous production in the Process industries
Continuous production in the discrete manufacturing industries

30. Batch production in the process industries
Batch production in the discrete manufacturing industries

31. Manufacturing Operations
 There are certain basic activities that must be carried out in
a factory to convert raw materials into finished products
 For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control
A processing operation transforms a work material from one state of
completion to a more advanced state using energy to alter its shape,
properties or appearance to add value to the material.

32. Classification of manufacturing processes

33. Processing Operations
 Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
4. Material removal processes
 Property-enhancing operations (heat treatments)
 Surface processing operations
 Cleaning and surface treatments
 Coating and thin-film deposition

34. Assembly Operations
 Joining processes
 Welding
 Brazing and soldering
 Adhesive bonding
 Mechanical assembly
 Threaded fasteners (e.g., bolts and nuts, screws)
 Rivets
 Interference fits (e.g., press fitting, shrink fits)
 Other

35. Assembly Operations
An assembly operation joins two or more
components to create a new entity which is called
an assembly, subassembly, etc.

36. Other Factory Operations
 Material handling and storage
 Inspection and testing
 Coordination and control

37. Material Handling
A means of moving and storing materials between processing
and/or assembly operations
 Material transport
 Vehicles, e.g., forklift trucks, AGVs, monorails
 Conveyors
 Hoists and cranes
 Storage systems
 Unitizing equipment
 Automatic identification and data capture (AIDC)
 Bar codes
 RFID
 Other AIDC equipment

38. Time Spent in Material Handling

39. Inspection and Testing
Inspection – examination of the product and its components
to determine whether they conform to design specifications
 Inspection for variables – measuring
 Inspection of attributes – gaging
Testing – observing the product (or part, material,
subassembly) during actual operation or under conditions
that might occur during operation

40. Coordination and Control
 Regulation of the individual processing and assembly
operations
 Process control
 Quality control
 Management of plant level activities
 Production planning and control
 Quality control