Automation Systems and Production Types

Lecture 1: Principles and an Overview of Automation in Manufacturing

• The lecture covers principles and an overview of automation in manufacturing.
• Manufacturing systems involve integrating facilities, people (operators, designers, managers), etc.
• Effective manufacturing depends critically on the organization of facilities and people within the system.
• Automation is a key issue in improving the efficiency of manufacturing operations.

Manufacturing Systems

• Facilities include: factories, production machines, tooling, material handling equipment, inspection equipment, and computer control systems.
• Manufacturing systems involve integrating facilities with people.

People and Manufacturing Systems

• People are important parts of a manufacturing system.
• Not all equipment and processes are automated.
• Direct labor (blue-collar) workers operate facilities.
• Professional staff (white-collar) handle tasks like design, delivery, and material order.

Variables Affecting Production

• Product quantity and variety are crucial in determining production type and automation level.
• Low production: 1 to 100 units per year
• Medium production: 100 to 10,000 units per year
• High production: 10,000 to millions of units per year
• Product variety refers to the different product designs/types produced.

Relationship Between Product Variety and Quantity

• A graph illustrates a negative correlation between product variety and quantity.
• Higher variety corresponds to lower quantity, and vice-versa.

Types of Production

• Three types: mass, batch, and job shop.
• These types depend on product quantity and variety.

Mass Production

• This involves continuous dedicated production of large amounts of bulk product (e.g., continuous chemical plant, oil refinery, automobiles).
• Characterised by very high production and demand rates, dedicated and specialized machines, and high installation costs.
• Labour skill level for this is usually lower.

Batch Production

• Production of medium quantities of similar products (e.g., books, clothing, furniture, some industrial machinery).
• Typically produced with regular intervals or once; production rate is often higher than demand.
• Uses general-purpose equipment with high utilization rates, and specially designed jigs/fixtures.

Job Shop Production

• Low quantities of specialized products (e.g., prototypes, aircraft, machine tools).
• Often triggered by customer orders, resulting in customized designs and higher variety.
• Requires relatively high-skilled labor.
• Relies on flexible and general-purpose equipment.

Plant Layouts

• The physical size, quantity, and variety of products determine plant layouts.
• Types include:
  • Fixed-position layout (product remains in one location; workers and equipment move).
  • Process layout (operations are grouped together; suited to one product or class of products in large volumes).
  • Cellular layout (manufacturing cells specialize in producing similar products).
  • Product layout (workers and stations are set up for the production of specific products).

Introduction to Automation

• Automation is the technology to complete processes/procedures without human assistance.
• It uses programs of instructions and a control system.
• Power is required to drive the process and operate the system.
• Automation is closely associated with manufacturing industries.

History of Automation

• Automated devices have evolved from ancient mechanical inventions (the wheel, lever) to modern technology (assembly lines, computers).
• Key milestones include the moving assembly line (1913), mathematical theory of control systems, the first electronic digital computer, and the concept of numerical control machines.
• Commercial development of industrial robots and programmable logic controllers followed.
• Recent advances include random-access memory, the development of more powerful microprocessors, new computer languages, and the emergence of flexible manufacturing systems.

Basic Elements of an Automated System

• Automation systems require three basic elements: Power, Program of instructions, and Control system.

Power to Accomplish the Automated Process

• Various power forms are central to different manufacturing processes. (e.g., thermal, electrical, mechanical, light)

Program of Instructions

• Operations use a program of instructions, which is either low, medium or high production. Individual products have specific processing steps.
• A new part/product is finished each work cycle. These steps are part of the work cycle program.

Control System

• Controls in automated systems include closed or open loop systems.
• Closed loop (feedback control): the system continuously monitors the output and compares it to the desired output and adjusts the process as needed.
• Open loop (no feedback): the system does not monitor the output; it runs based on a pre-determined set of instructions.

Types of Automation

• Three types: fixed, programmable, and flexible.

Fixed Automation

• The sequence of operations is fixed by the equipment configuration.
• Ideal for high production volume, high demand products, and relatively rigid product configurations (e.g., automobiles).

Programmable Automation

• The sequence of operations is controlled by a program, and the system can adapt to various product configurations.
• Suitable for low to medium production rates and diverse product configurations (e.g., batch production).

Flexible Automation

• The system can produce various combinations and schedules of products with limited time for changeovers.
• Ideal for production settings with a variety of products, medium production volumes, and the necessity to deal with changes in product configurations.

Advanced Automation Functions

• Advanced Functions: safety monitoring, maintenance diagnostics, and error detection and recovery.

Safety Monitoring

• Safety monitoring employs various sensors to detect issues like improper part positioning, high temperatures, and potential fire hazards.

Maintenance and Repair Diagnostics

• Diagnostics mode monitors key system sensors and parameters.
• Failure diagnostics mode is activated when malfunctions occur.
• Recommendations for repair procedures are provided.

Error Detection and Recovery

• Automated systems incorporate error detection and recovery to address hardware and software malfunctions.
• Systems diagnose, and potentially address issues automatically.

Levels of Automation

• Hierarchy of levels (Device, Machine, Cell, Plant, Enterprise).
• Each level has different responsibilities; each level relies on the one below it, with Enterprise being the top level.

Automation Strategies

• Nine different strategies for the design and implementing of various automation strategies.
• Emphasis on specialization, combining operations, simultaneous operations, integration, flexibility, material handling, on-line inspection, process control, coordination, and computer integration.

Multi-stage Manufacturing

• Multi-stage manufacturing denotes the complexity that emerges when material handling and multiple processes occur.

Production Types and Automation

• Different production types require different approaches to automation.
• For continuous flow production, fixed automation is required, and sensors for process variables and control are paramount.
• For mass production of discrete products, programmable or flexible automation can be utilized.

Reasons for Automating/Not Automating

• Reasons to automate include increased labor productivity, reduced labor costs, mitigating labor shortages, minimizing routine tasks, improving safety, enhanced product quality, and reduced manufacturing lead time.
• Reasons not to automate include technological difficulty, short product life cycles, customized product requirements, and the need for system flexibility.

Communication (in an Automated System)

• Communication between components is vital for operation.
• Protocols like MPI, Profibus, Profinet, and Ethernet enable reliable data exchange between devices.

Explore the fundamentals of automation with this quiz covering types of production, elements of automated systems, and various communication protocols. Test your knowledge on fixed and programmable automation, as well as advanced functions in automation technology.