Automation in Leather Production Systems

Automation in leather
production systems
Automation in production systems
▪ Automation can be defined as the use of technology

with the application of electronic, mechanical, and
computerized systems to operate and control
production.
▪ Automation in production can be of two different
categories: (1) automation of manufacturing systems
in the factory and (2) computerization of the
manufacturing systems.
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▪ In leather product manufacturing industries

have adopted the automation, robotics, and
application of advanced tools and software
for PPC, MRP, and effective control of flow
of materials in production and supply chain.
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▪ The recent advancements can be classified

as automation of manufacturing systems
and advancements in production planning.
▪ On the other hand we need to describes the
role of manual labor in production systems
and the importance of automation.
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Manual labor in
production systems
Manual labor in production systems
▪ On asking the question, if there is any

place for manual labor in the modern
production.
• The answer is yes. Even in the highest-

automated production systems, human
labor is needed in one or the other
form.
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▪ They will be required to manage and maintain

the plant or even any advanced production
systems.
▪ In addition, there are many reasons or
situations in which manual labor is usually
preferred over automation in leather product
manufacturing.
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▪ Tasks are too technologically difficult to

automate—certain tasks are difficult to be
automated such as problems with physical
access to the work location, adjustments
when required in the task, and when it
demands hand-eye coordination.
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▪ Short product life cycle—if a product needs to be

designed and brought into the market within a short
period and the product needs to be in the market is for
a relatively short period, then instead of designing a
new automatic manufacturing system, manual labor is
preferred for a faster production over an automated
system. Tooling for such production can be done in
less time and less cost than automated production.
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▪ Customized product—on designing and

producing one of a kind product with
unique features, manual labor may have
an advantage over automated because of
its versatility.
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▪ Coping with ups and downs in demand—

changes in the input demand of a product changes
the output production, and this is possible only
during manual labor mode of production.
▪ Automated manufacturing system might have a
fixed cost involved, where, if output is reduced the
unit cost of the product increases.
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▪ Reducing the risk of product failure—

introduction of a new product to the market is
always uncertain, where some products will have
short and some have long product life cycles.
▪ Therefore, using manual labor reduces the
probable losses associated with a big investment
in the form of automation.
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Reasons for automation
and advanced tools
Reasons for automation and advanced tools
▪ Companies mostly undertake projects

in manufacturing automation for various
reasons as described below:
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▪ To increase labor productivity—automation

of any manufacturing operation, irrespective of
the size, increases production rate and labor
productivity.
▪ This means that the amount of output per hour
is increased with automation.
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▪ To reduce labor cost—higher investment in

automation in a global competitive market
is justifiable on the basis of the reduced
labor cost and increased productivity by
automation.
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▪ To moderate the effects of labor

shortages—there is either a general
shortage of labor or costly labor charges
in most advanced nations, which led to
automated operations.
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▪ To reduce or eliminate routine manual

tasks—it can be argued that a similar kind of
work done by a worker over and over makes
it monotonous, boring, and possibly irksome.
Automating such tasks serves a purpose of
improving the general work condition.
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▪ To improve worker safety—by adopting

automation into some risky operation can
make the worker safe. Furthermore, it gives
the worker to divert his attention in to a
supervisory role, and the work is made safer.
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▪ To improve product quality—automation not

only results in higher production rates but
also leads to greater uniformity and
conformity to quality specifications, thereby
leading to an almost zero-defect rate.
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▪ To reduce the manufacturing lead time—

automation reduces the elapsed time or lead
time between the customer order and
product delivery, thereby providing the
manufacturer with a competitive edge.
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▪ To avoid the high cost of not automating—the benefits of automation are not
seen directly but often in unexpected and intangible ways, such as higher
sales, improved quality, and better brand image.
▪ Companies who do not go for automation, see themselves at a competitive
edge with regard to their customers, employees, and competitors.
22
Strategies for automation
and production systems
Strategies for automation and production systems
▪ Specialization of operations: This

involves the use of specific equipment
designed to perform one operation with
the greatest possible efficiency.
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▪ Combined operations: Production occurs in a sequence of operations.

▪ Complex products require a lot of processing steps, therefore, ongoing for
combined operations reduces the number of machines through which the
product was routed.
▪ This strategy might save a lot of set up time, and material handling.
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▪ Simultaneous operations: Logical extension of

combined operation is performing simultaneous
operations that are combined at one point.
Therefore, as operations are performed
simultaneously, the total processing time is
reduced.
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▪ Integration of operations: This strategy involves

linking several workstations together into an
integrated mechanism by the use of automatic
handling devices to transfer the products between
the stations. This reduces the movement of the
products through various machines.
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▪ Increased flexibility: This strategy is adopted to

obtain maximum utilization of equipment for
medium volume situations by using the same
equipment for manufacturing a variety of products.
It also involves the usage of flexible automation.
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▪ Improved material handling and storage: This strategy is adopted to

reduce work-in-progress and shorter manufacturing lead times.
▪ Online inspection: Inspection is done on completion of a product to

assess the quality of work. Incorporating online inspection permits
corrections to the process as the product is being made.
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▪ Process control and optimization: This involves a

range of control schemes that are intended to
operate the individual process and related equipment
efficiently.
▪ The individual process times can be reduced and the
product quality is improved.
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▪ Plant operations control: This strategy is

concerned with the control at the plant level.
It therefore attempts to manage and
coordinate the plant more efficiently.
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▪ Computer-integrated manufacturing (CIM): This

leads to the integration of the factory operations
with engineering design and business functions of
the firm. CIM involves extensive use of:
Computer applications
Computer databases
Computer networking
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The 10 strategies described above act as a

checklist of the possibilities for improving the
production system through automation and
should not be considered mutually exclusive.
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Advantages and disadvantages of
automation
Advantages of automation
▪ Fast planning and scheduling

▪ Reduced production time—increased efficiency in shop floor operation
▪ Improved data collection
▪ Control of production at multi locations
▪ Reduced waste as the operations can be paperless
▪ Less human error and more repeatability
▪ Increase in accuracy
▪ Less employee costs—less safety issues and reduced payroll
▪ Higher production—increase in profitability
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Disadvantages of automation
▪ Less versatility—limitation on flexibility and variety

▪ Larger initial investment—higher installation costs
▪ Increase in unemployment
▪ Unpredictable costs—maintenance costs, training employees and
expensive spare parts
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Automation in
manufacturing systems
Automation in manufacturing systems
▪ Automated manufacturing systems are

applied on a physical product replacing
the labor-intensive work.
▪ The mode of manufacturing involves
the use of automated machines and
robotics where the level of human
intervention is reduced.
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▪ The automated operations may involve:

processing, assembling, inspection, or
material handling, where more than one
automated system can be used for the
operations of the same product.
▪ Examples of automated manufacturing
systems include
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▪ Automated machine tools

▪ Transfer lines performing a series of machinery operations
▪ Automated assembly systems
▪ Manufacturing systems using industrial robots to perform
operations
▪ Automatic material handling and storage systems
▪ Automatic inspection for quality control
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▪ Automation can be classified into three basic

types based on the function of production
volume and product in a manufacturing
enterprise. The three types of automated
manufacturing systems are: (1) fixed
automation, (2) programmable automation, and
(3) flexible automation
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1. Fixed automation
▪ As the name indicates, it is a system in

which the sequence of processing
operations is fixed in terms of
equipment configuration. The sequence
for each of the operation is simple,
involving a linear or rotational motion or
perhaps a combination of two.
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1. Fixed automation
Features of fixed automation are as follows:

▪ Higher initial investment cost
▪ Higher production rates
▪ Reduced flexibility toward
accommodating product variety
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2. Programmable automation
▪ In this type of automation, the

production equipment is designed with
the capability of changing sequence of
operations to accommodate different
product configurations.
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▪ The whole sequence of operations is

controlled by a program, which is a set of
instructions coded that can be read and
interpreted by the system.
▪ Similarly, to produce new products, new
programs can be created and entered into the
equipment. Some features of programmable
automation are as follows:
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▪ Higher investment cost for the equipment

▪ Lower production rates in comparison to fixed automation
▪ Flexibility to deal with changes in product configuration
▪ Suitability for batch production
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3. Flexible automation
▪ It is an extension of programmable automation, which is capable of

producing a variety of products with no time loss for any changeovers
from one style to the other, no loss in production time, while
reprogramming the system.
▪ As the amount of changeovers being very minimal, the system can
produce various combinations and schedules of products. Features of
flexible automation are as follows:
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3. Flexible automation
▪ High investment involved for custom design

▪ Production of variable products
▪ Medium rates of production
▪ Flexibility to deal with product design variations
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Advancements in
production planning
Advancements in production planning
▪ In responding to the ever changing globalization,

customization, and technology-driven competition,
leather product manufacturers and trading firms
must shift the traditional operation of production
toward a new paradigm of manufacturing.
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▪ One of the important operations in

leather product manufacturing is the
PPC .
▪ With the increased demand on quality
and productivity, accurate planning is
essential to meet the date of shipment
and reduce bottlenecking
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▪ In addition the use of enterprise resource

planning (ERP) and APS system assists
in PPC and MRP.
ERP
APS
MRP
IS
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Computerized manufacturing support
systems
▪ Automation is aimed at reducing the manual

labor during product design and planning
phases and also during the business function
phase.
▪ In the current scenario, all the manufacturing
support systems are implemented using
computer systems.
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systems
▪ Computer technology is used for automation in

the factories as well.
▪ CIM is used for designing the products,
production planning, control of the operations,
and perform other business related functions
within the firm.
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systems
▪ CIM involves integration of all the above

functions in one system that operates
throughout the enterprise.
▪ Computer-aided design (CAD)/computer-
aided manufacturing (CAM) is the other
terms used to identify the CIM system.
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Thank you
By: Biniyam Solomon
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Automation in Leather Production Systems

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Automation in Leather Production Systems

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Automation in leather

▪ Automation can be defined as the use of technology

▪ In leather product manufacturing industries

▪ The recent advancements can be classified

▪ On asking the question, if there is any

• The answer is yes. Even in the highest-

▪ They will be required to manage and maintain

▪ Tasks are too technologically difficult to

▪ Short product life cycle—if a product needs to be

▪ Customized product—on designing and

▪ Coping with ups and downs in demand—

▪ Reducing the risk of product failure—

▪ Companies mostly undertake projects

▪ To increase labor productivity—automation

▪ To reduce labor cost—higher investment in

▪ To moderate the effects of labor

▪ To reduce or eliminate routine manual

▪ To improve worker safety—by adopting

▪ To improve product quality—automation not

▪ To reduce the manufacturing lead time—

▪ Specialization of operations: This

▪ Combined operations: Production occurs in a sequence of operations.

▪ Simultaneous operations: Logical extension of

▪ Integration of operations: This strategy involves

▪ Increased flexibility: This strategy is adopted to

▪ Improved material handling and storage: This strategy is adopted to

▪ Online inspection: Inspection is done on completion of a product to

▪ Process control and optimization: This involves a

▪ Plant operations control: This strategy is

▪ Computer-integrated manufacturing (CIM): This

The 10 strategies described above act as a

▪ Fast planning and scheduling

▪ Less versatility—limitation on flexibility and variety

▪ Automated manufacturing systems are

▪ The automated operations may involve:

▪ Automated machine tools

▪ Automation can be classified into three basic

▪ As the name indicates, it is a system in

Features of fixed automation are as follows:

▪ In this type of automation, the

▪ The whole sequence of operations is

▪ Higher investment cost for the equipment

▪ It is an extension of programmable automation, which is capable of

▪ High investment involved for custom design

▪ In responding to the ever changing globalization,

▪ One of the important operations in

▪ In addition the use of enterprise resource

▪ Automation is aimed at reducing the manual

▪ Computer technology is used for automation in

▪ CIM involves integration of all the above

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