Levels of Automation Overview

Levels of Automation

• The automated system can be applied to various levels of operations, starting from individual machines and progressing through different levels of integration.

Device Level

• The lowest level of automation, encompassing actuators, sensors, and other hardware components that make up a machine.
• Devices are combined to form control loops, creating the next level: the machine level.

Machine Level

• Hardware at the device level is assembled into individual machines, such as CNC machine tools, industrial robots, and material handling equipment.

Cell or System Level

• A group of machines connected through material handling systems, computers, and other equipment, operating under instructions from the plant level.

Plant Level

• The factory production level, receiving instructions from the corporate information system and translating them into operational production plans.
• Includes various functions such as order processing, process planning, inventory control, and quality control.

Enterprise Level

• The highest level of automation, encompassing the corporate information system and functions like marketing, sales, accounting, design, and research.
• Includes aggregate planning and master production scheduling.

Types of Automation

Fixed Automation

• The sequence of processing or assembly operations is predetermined by the equipment configuration.
• Difficult to adapt to changes in product design.
• Suitable for high-volume production where product changes are rare.
• Example: Automobile industries.

Programmable Automation

• Equipment designed to handle various product configurations through programmable control.
• Sequences of operations can be adjusted by changing the control program.
• Used in batch production with medium to low volumes.
• A new control program is loaded for each new batch of different products.
• Example: Industrial robots, NC machine tools.

Flexible Automation

• A computer-integrated manufacturing system (extension of programmable automation).
• Minimizes time loss between batch changes, enabling quick product transitions.
• Produces different products with no reloading time.
• More flexible in interconnecting workstations through material handling and storage systems.
• Requires custom engineering and is suited for medium production rates.