ME637: Manufacturing

Automation

Chapter 1b: Introduction to Manufacturing

Automation

K.P. Karunakaran

Indian Institute of Technology Bombay

 Outline

• Definition of Automation
• Aims of Automation
• Historical Developments
• Classification of Manufacturing Automation
• Low Cost Automation
 Definition of Automation

• Execution of a set of events without human intervention.

• It aims at elimination, at least minimization, of human intervention;
the latter is known as semi-automation. ‘semi-’ here refers to
partial.
 Aims of Automation

• Safety: Relieving human beings from risky, tedious and

monotonous operations so that man power is deployed safely and
efficiently. Examples: Hazardous environments (radioactive,
underwater, space etc.), security patrolling, security at gates …
• Scarcity: To cope up with shortage of man power of the required
skills. Examples: Vast lawn maintenance, sweeping, agriculture,
ticket vending machines for buses & trains, vending machines for
regular consumables like coke & chocolate. This was applicable
mainly to the West in the past; but now we also feel it with the
presence of multi-nationals here.
• QCD: To improve quality and productivity and bring down the cost.
 False Apprehensions about Automation

Unemployment: Common apprehension is that automation will lead to

unemployment. It is often a temporary phase, that too arising out of
poor planning to retrain the affected personnel and unpreparedness of
the employees. Proper training and redeployment with the strong
commitment of both the employer and the employees is essential. In
my village, weaving was a major income for the dominant caste
people. When power looms came, they all lost jobs. But within about 5
years, all moved to other jobs and places. Their redeployment was
painful and slow because of poor education in spite of free dress and
meals.

Automation shall be implemented only when the sum of tangible and

intangible costs is justified. Intangible benefits arise out of relieving human
being from the risk, reduction in rejection etc. converted into money value.
 Historical Developments
Replacement of muscle power: Taming animals
• Taming and domestication of animals (horse, bullock, donkey … )
 Historical Developments …
Replacement of muscle power: Invention of wheel
• Invention of wheel – wheeled locomotion, understanding of friction
 Historical Developments …
Replacement of muscle power: Invention of wheel …

Nothing rotates in nature (except at the extremes of celestial and

atomic scales!)

Is wheel really the greatest

invention of mankind? Could
have been something else? Our
imaginations are blocked by the
symmetry of wheel!
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 Historical Developments …
Replacement of muscle power: Invention of wheel …

Mathematically simpler horizontal flat surface “z=0” is more

expensive to produce than a cylindrical surface which is
mathematically more complex “x2 + y2 – r2 = 0”

The
cheapest
machine is
lathe, then
shaper,
milling
machine
etc.
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 Historical Developments …
Discovery of fire: Usage of metals
• Discovery of fire – Cooking, Evolution of Stone Age to Bronze Age
 Historical Developments …
Invention of windmill, waterwheel, steam engine, electricity …

• Water wheel
• Wind mill
• Electricity
- Battery by Alessandro Volta (1800)
- Bulb by Thomas Alva Edison (1880)
- Electric motor by Moritz Jacobi
(1840)
• Steam engine (James Watt -
1781)
• Automobile (Henry Ford - 1908)
• Airplane (Wright brothers - 1903)
 Historical Developments …
Managerial and technological growth
• F.W. Taylor (1856-1915) – Father of Scientific Management:
- Division of Labor: Lack of multi-skilled manpower and limited muscle power
were responsible for lower production rate and shortage. Training could not
go beyond some point in generating this multi-skilled manpower. So the
tasks were divided and people were trained in specific tasks. This
dramatically improved skill levels (turner, miller, fitter, welder, …) and hence
productivity.
- incentive schemes: This further enhanced production although the
inspection had to be more rigorous as the workers tended to ignore quality in
order to produce fast.
- Methods Study (Time and Motion Study) and Work Measurement: This is the
scientific basis for incentive scheme. Optimization of working procedure
through Methods Study. Work Measurement assigns standard time. This
facilitated Rating of Worker.
- Technology development: Taylor also focused on improving productivity
using new technology also. High Speed Steel and the famous Tool Life
Formula.
 Historical Developments …
Managerial and technological growth
• Mass production through the concepts of Interchangeability &
Special Purpose Machines (Eli Whitney – 1798):
– In division of labor, there were mismatch of dimensions. So parts produced
by different people did not match or assemble. This was bad for mass
production.
– So standardization of dimensions and features (Eg.: screw heads) were
introduced.
– Dimensions were attached with tolerances.
– Designers made use of fits to ensure interchangeable assembly.
Eli Whitney accepted a contract to supply 10,000 musket locks (a part of
gun) in 28 months to the US military in 1798. In order to meet this tight
deadline, he introduced novel ideas such as interchangeable assembly and
Special Purpose Machines (SPMs). Although he took over 10 years to
execute this order, these experiments to mass production were remarkable.
In 1801, he demonstrated interchangeable assembly in New Haven,
Connecticut. He is regarded as pioneer in mass production.
 Historical Developments …
Managerial and technological growth
• Innovations in Material Handling (1793):
– In 1793, Oliver Evan introduced conveyors at various stages and showed
that just two operators could run the flour mill.

• Further Division of Work (Elihu Root - 1849):

– In 1849, Elihu Root demonstrated that a task could be divided into finer
elements so that each could be performed fast by the same or different
operators. This avoided the mind to focus on simple elements one at a time.
This contribution was a parallel to that of Taylor. Taylor’s was a macro and
Root’s was a micro. Taylor divided the human beings into experts of trades
such as turner, fitter, machinist, welder etc. whereas Root divided the task of
any of them into finer elements. He demonstrated these during the
manufacture of “Colt Six Shooter”
– This subsequently led to transfer lines.
– This also led to a more systematic time and motion study or work
measurement.
 Historical Developments …
Managerial and technological growth
• Further Contributions to Mass Production through Transfer Lines
and Line Balancing:
– Henry Ford developed assembly lines for mass producing automobiles of
the popular Model T. His is so much into standardization that he used to say
“Choose any color you want – as long as it is black”. He used the following
principles:
• Plant layout: Make workplace layout to minimize the movement of men,
tools and parts.
• Use slide/ramp or some other form of conveyors for moving the parts.
Wherever possible, he used gravity to assist such movements.
• Use sliding assembly lines by which parts to be assembled are delivered
at convenient intervals spaced to make it easier to work on them. These
are called Transfer Lines. He also introduced concepts like line
balancing.
 Historical Developments …
Managerial and technological growth
• Mechanization of Parts Manufacture and Assembly Lines:
– Mechanized means replaced human muscle power wherever economically
possible. Initially water wheel, wind mill, …. Now, pneumatic, hydraulic,
electric systems are employed.

• Hard Automation: Automats, copying machines, SPMs, Transfer

lines etc. are examples of these.
• Flexible Automation:
– NC, DNC-I, CNC, DNC-II and PLCs were introduced since 1960s.
– Soon robots were developed. They were introduced for material handling
and assembly.
– An optimal collection of CNC machines and robots is called Flexible
Manufacturing System.
– When the downstream functions and upstream functions to the hardcore
production functions were integrated with (a) computers and (b) networks
and (c) communication protocols, CIM systems evolved.
 Historical Developments …
Mass production vs. artisan production → CIM
• Initial “artisan-based manufacturing” vs. (CIM-C=IM):
- Only simple products possible since complex ones required expertise of other
fields.
- Production rate was limited by muscle power, simple hand tools and limited
number of skilled man power.
- No interchangeability.

+ But it had two great advantages: [i] Complete integration of activities existed;
[ii] Customers had personal touch.

Both these advantages were lost in automated mass production. Division of labor
led to poor integration. There were inconsistencies due to variations in their skill and
motivation levels. There were delays and communication failures
(miscommunication, break etc.). Companies are even now struggling to establish
synergy among the activities. CIM is an attempt to achieve this synergy through
computerization.
 Classification of
Manufacturing Automation
 Design and Manufacturing Information
Design Information
• Geometry (nominal)
• Fits and tolerances
• Material specifications
• Codes and Standards
• ...
CAD models are still not able
to absorb tolerances and fits.
So, drawings are still required!
Manufacturing Information
• Sequence of different processes involved
• Sequence of operations or steps in each
process
• Description of each operation
• Tooling for each operation (machine tool, work
holding devices, cutting tool, press tools etc.)
• Motions and switching/ toggle functions
• Set up and unit time for each operation
• ...
 Two Types of
Manufacturing Information

1. Data in continuum domain

- Position, velocity, acceleration, spindle speed etc.
- Temperature, pressure, force, torque etc.

2. Data in discrete domain (ultimately implemented

in binary)
- Switching functions: spindle on/ off, coolant on/ off, door
open/ close etc.
- Toggle functions: tool change.
- Discrete functions: gear change
Storage of Data in Continuum
in Form Tools
Storage of Data in Continuum
in Cams
Storage of Binary Data
in Clutch Settings
Kinematic Diagram of an Automat
Kinematic Diagram of an Automat …
 Classification of
Manufacturing Automation

Manufacturing
Automation

Hard/ Rigid/ Mechanized Soft/ Flexible/ Programmable

Automation Automation
Copy milling machines PLC
Automats NC machines
Special purpose machines CNC Machines
DNC
Robots
Automatically Guided Vehicles (AGVs)
Reconfigurable conveyors
 Communication/ Storage of the
Manufacturing Information to the Machine

Hard Soft
Function
Automation Automation
Data in Form tools, templates, Preparatory functions (G-
masters, cams etc. codes*)
continuum
Data in binary/ Trip-dog settings and Miscellaneous functions
clutches (M-codes*)
discrete domain
* Only in the context of old CNC machines. This does not hold good for modern
machines, robots etc.
 Benefits of Flexible Automation

• Unlimited muscle power

• Speed
• Accuracy
• Unmanned operation
• Flexibility achieved through independent axes coordinated
through software
• Simplified generic tooling even for the most complex jobs
 Applications of
Manufacturing Automation

• Assembly
• Casting
• Forging
• Forming
• Welding
• …
 Automation Systems

• Mechanical
• Pneumatic
• Hydraulic
• Electric
• Hybrid
 Low Cost Automation

• Definition 1: Payback is within the same financial year.

• Definition 2: The investment required is below some limit; this limit

may keep changing. This is similar to the way Small Scale
Industry is defined; SSI is one with less than 10 employees.

• Definition 3: An incremental approach to automation – Kaizen. It

shall make use of well-established technologies such as electro-
pneumatics etc. The high end technologies may involve
development of new knowledge/ technologies – akin to Business
Process Reengineering (BPR).
Thank You!