AUTOMATION Prof.Shrinivas V K

Prof.S

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Prof.S

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HISTORY

Industrial revolution: Substitute machines for human effort.

Examples from past. Mechanization : Attendant reqd. to operate the valves

to channelize steam.Automation: Later Watt's fly ball governor removed

need for human intervention. Automation decreased need for physical labour

besides reducing the requirement of decision making on part of the attendant.

Prof.S

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MECHANIZATIONMECHANIZATION

Use of machines Replace manual labour of animals or humans. Based on principles of

specialization of tasksAdherence to specificity

Power, compactness and speed of machine operation. Example: Farming practices

Prof.S

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WHEN DOES MECHANIZATION WORK? Straight forward task to perform Stable environment to ensure that the products

produced will be appropriate ones Produce exactly the same product again Precision is at a premium

Prof.S

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WHY NOT MECHANIZATION May lead to difficulty in adapting to frequent

changes in market condition. Conflict of individual goals with respect to

organizational goals Dehumanizing effects upon employees at lower

level of hierarchyJob lossMundane work

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RATIONALIZATION Design of each step in process to contribute most

efficiently to final product Logical evaluation of performance

Conservation of resource, energy, elimination of waste, most efficient attainment of final product.

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WHAT IS AUTOMATIONWHAT IS AUTOMATION

It is a technology dealing with the application of Mechatronics Cybernatics computers

for production of goods and services.Automation is broadly classified into manufacturing automation service automation

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AUTOMATION-CONTD.. Automation has been defined as “Any development

that may cause employee displacement” Automation may:o Wipe out certain jobs o Reduce contents of certain jobso Combining several jobs into one.

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AUTOMATION“Application of computer control systems

which not only read the indiviual measurement devices but analyse the data as received from the devices, reach a decision and adjust the control valves or motors for projected optimum results”

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MECHANISATION Mechanisation replaces the muscle power of

labour but not the labour itself.

Whereas In Automation all aspects of manufacturing are

carried out by computers

Prof.S

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Prof.S

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EXAMPLES OF AUTOMATION automatic machine tools to process parts-CNC m/c

industrial robots

automatic material handling

feedback control systems

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FORMS OF AUTOMATION Automatic Processing

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AUTOMATIC CONTROLP

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ROBOTSP

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TRENDS CIM (Computer Integrated Manufacturing)

CAD (Computer Aided Design)

CAM (Computer Aided Manufacturing)

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COMPUTER-AIDED DESIGN AND MANUFACTURING

Computer-Aided Design (CAD) A computerized process for designing new products,

modifying existing ones, or simulating conditions that may affect the designs.

Computer-Aided Manufacturing (CAM) A computerized process for planning and programming

production processes and equipment.

G.Dessler, 2003

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FLEXIBLE MANUFACTURING SYSTEMS Flexible Manufacturing System (FMS)

The organization of groups of production machines that are connected by automated materials-handling and transfer machines, and integrated into a computer system for the purpose of combining the benefits of made-to-order flexibility and mass-production efficiency.

Automation The automatic operation of a system, process, or

machine.

G.Dessler, 2003

Prof.S

VK

COMPUTER-INTEGRATED MANUFACTURING Computer-Integrated Manufacturing (CIM)

The total integration of all production-related business activities through the use of computer systems.

Automation, JIT, flexible manufacturing, and CAD/CAM are integrated into one self-regulating production system.

G.Dessler, 2003

Prof.S

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FIGURE 15–14Source: Barry Render and Jay Heizer, Principles of Operations Management, 2nd ed. © 1997. Reprinted by permission of Prentice Hall, Inc., Upper Saddle River, NJ.

THE ELEMENTS OF CIM

G.Dessler, 2003

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TYPES OF AUTOMATION Machine Attachments - one operation Numerically Controlled (N/C) - reads

computer or tape inputs Robots - simulates human movements Automated Quality Control - verifies

conformance to specifications Auto ID Systems - automatic acquisition of

data Automated Process Control - adjusts

processes pre set parameters

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AUTOMATED PRODUCTION SYSTEMS Automated Flow Lines (Fixed Automation)

Automated processes linked by automated material transfer

Automated Assembly Systems Automated assembly processes linked by

automated material transfer Flexible Manufacturing Systems (FMS)

Groups of processes, arranged in sequence, connected by automated material transfer, and integrated by a computer system

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MATERIAL-HANDLING AUTOMATION Automated Storage & Retrieval System

(ASRS) Receive orders, pick parts, maintain inventory

records Benefits: increase storage density and

throughput, reduce labor costs, improve product quality

Drawbacks: added maintenance costs Automated Guided Vehicle (AGVS)

Follows wire or track in floor. Newer versions use sensors placed around the factory to figure out where they are.

Prof.S

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Prof.S

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REASONS FOR AUTOMATION

Shortage of labor High cost of labor Increased productivity Competition Safety Reducing manufacturing lead time Lower costs in the long run

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ADVANTAGES Increased output and enhanced productivity Improved and uniform quality Reduced cost Fewer accidents Better production control Better control over production

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DISADVANTAGES Heavy capital investment Displacement of labour Benefit of employee suggestion lost Tighter specification may be required Slack season may be idle Dehumanization Problems of developing countries

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