INTRODUCTION TO

AUTOMATION
By: Nurdiana Nordin
Learning Outcomes
At the end of this lecture, students are able to:

i. Define the term of automation

ii. Explain the reason & advantages of automation
iii. Brief the automation principle & strategies
iv. Distinguish the categories & type of automation
v. Identify and explain the basic elements of
automated system
vi. List and brief the advance automation functions
vii. Identify and summarize the levels of automation
Lecture Contents
i. Automation history
ii. Definition of Automation
iii. Reason & Advantages of Automation
iv. Automation Principles & Strategies
v. Automation Categories
vi. Elements of Automated System
vii. Advance Automation Functions
viii. Levels of Automation
 Automation History

Basic Flying-ball Machine Moving Numerical

Mechanical Steam Engine governor programming Assembly Control
Device (1765) (1785) (1800) Line (1913) Machine
Development (1952)
 Automation History

Flexible Programmabl Personal Continuous

Industrial Manufacturing e Logic Computer development
Robot (1954) System Controller (1978) (1980s-now)
(1960s) (1969)
Definition of Automation
‘The process of following a predetermined sequence
of operation with little or no human labor, using
specialized equipment and devices that perform
and control manufacturing processes. It is
achieved through the use of variety devices,
sensors, actuators, techniques and equipment that
are capable of observing the manufacturing
process, making decisions concerning the changes
that need to be made in the operation and
controlling all aspect of it.’
Definition of Automation

‘is the technology by which a process or

procedure is accomplished without human
assistance. It’s implemented using a program of
instructions combined with a control system that
executes the instructions’

‘as a technology concerned with the application

of mechanical, electronic, and computer-based
systems to operate and control production’
Advantages of Automation
Increase Greater
production output per
rate & labor hour
productivity

Increase
Labor
Productivit
y
Advantages of Automation

• Higher investment, replace

Reduce Labor manual operations
Cost • Substitute human labor,
reduce per unit cost

• Shortage of labor in
Mitigate the advanced nations
Effect of Labor • Automated operation as
Shortages substitute for labor
Advantages of Automation

Reduce/Eliminate Improve worker Improve product

routine manual safety quality
and clerical tasks • Transfer active • Performs greater
• Routine, boring, participation to uniformity and
fatiguing task monitoring role conformity to quality
• Possibly irksome • OSHA specifications of
implementation, products
provide an impetus
for automation
Advantages of Automation

Reduce Accomplish process High Cost of Manual

manufacturing lead that cannot be done Work
time manually
• Reduce elapsed • Certain operation • Hire greater
time between order must be aided with number of workers,
& delivery machine not productive,
• Reduce work-in- • Precision, company not
process inventory miniaturization, competitive
complexity
geometry realizes
by computer control
system
Automation Principles & Strategies
o Approaches to deal with automation projects:

i. The USA Principle

ii. Ten Strategies for Automation & Process

Improvement

iii. Automation Migration Strategy

The USA Principle
- Good first step in any automation project

- U : understand the existing process

- S : simplify the process

- A : automate the process

The USA Principle:
Understanding existing process

Comprehend the
current process

Mathematical Identify the inputs &

models, formulating outputs
algorithm

Search & analyze Operation chart /

the strength & flow process chart
weakness
The USA Principle:
Simplify the process

 Involves question to existing process

 Make use of 10 strategies for automation

 10 Strategies for Automation & Process
Improvement

Specialization Simultaneous Increased

of operations operations flexibility

Combined Integration of
operations operations
10 Strategies for Automation & Process
Improvement (cont..)

Improved Computer-
material Process integrated
handling and Control and manufacturing
storage optimization (CIM)

On-line Plant
inspection operations
control
The USA Principle:
Automate the Process

- Possible forms of automation are according

to 10 strategies of automation

- Automation migration strategy might be used

for a new product / process
Automation Migration Strategy

Phase 3:
Automated
Phase 2: Integrated
Automated Production
Production
Phase 1:
Manual
Production
 Advantages of
Automation Migration Strategy

Allow
Avoid the introduction of
commitment to new product
high level at in shortest
beginning possible time

Allow automation
to be introduced
gradually
Categories of Automation

Automation of
the
manufacturing
systems in the
factory

Computer–
Integrated
Manufacturing
(CIM)
Computerization
of the
manufacturing
support systems
 Automation & Computerization in
Manufacturing System

Potential
Manufacturing Computerization
support system applications

Production CIM
system
Facilities: Potential
Factory Automation
equipment applications
Manufacturing Industries and Products

Tertiary
(service sector
of the
economy)

Secondary
(Convert
primary
output into
product)

Primary
(exploit natural
resources)
Types of Secondary Industries

Process Industry Manufacturing

(continuous Industry
products) (discrete products)

Chemicals, Automobiles, Aircraft,

Pharmaceuticals, Appliances,
Petroleum, Computers, Machinery,
Basic Metal, Food, Machine Components
Beverages, Electric
Power Generation
Continuous vs. Batch Production
Production System Facilities
Types of Plant Layout
Types of Automated Manufacturing
System

Fixed
Flexible Automation
Automation

Programmable
Automation
Fixed Automation

- Sequence of processing / assembly operation is fixed by the equipment

configuration.

- Simple operation of each sequence

- Typical features:

i. High initial investment for custom engineered equipment

ii. High production rates, very large quantities
iii. Relative inflexibility equipment for product variety
Types of Automated Manufacturing
System

Flexible Fixed
Automation Automation

Programmable
Automation
Programmable Automation
Programmable Automation:

- Production equipment is designed for any changes of product

configurations
- Operation sequence is controlled by a program
- Typical features:
i. High investment in general purpose equipment
ii. Lower production rates than fixed automation
iii. Flexibility to deal with variations and changes in product configuration
iv. High suitability for batch production

- Used in low & medium volume production

- Consume time for changeover procedure
Types of Automated Manufacturing
System

Flexible Fixed
Automation Automation

Programmable
Automation
Flexible Automation
- An extension of programmable automation

- Capability to produce variety of products with no time lost for

changeover

- Typical features:
i. High investment for a custom-engineered system
ii. Continuous production of variable mixtures of products
iii. Medium production rates
iv. Flexibility to deal with product design variations
Types of Automation
Elements of Automated System
An automated system consists of three basic elements:

i. Power to accomplish the process and operate the system

ii. Program of instructions to direct the process

iii. Control system to executes the instructions and drive the process

Power

Program of
Control system Process
instructions
Advanced Automation Function
- Advance automation function may include:

i. Safety monitoring

ii. Maintenance repair & diagnostics

iii. Error detection & recovery

Level of Automation
Enterprise
Level 5 Level Corporate Information System

Level 4 Plant Level

Production System

Cell/System
Level 3 Manufacturing system-groups of machines
Level

Machine
Level 2 Level
Individual machines

Device Sensors, actuators, hardware elements

Level 1 Level
My 2 cents
Pick battles big enough to matter,
small enough to win.
Jonathan Kozol