Unit –I

Automation
Definition :- It is technology concerned with the application of Mechanical, electronic &
computer –based systems to operate and control production in order to improves productions.

If Includes :-

1) Automated m/c tools.

2) Automated assembly m/c‟s
3) Industrial robots.
4) Automated material handling & storages system
5) Automated inspection system for quality control
6) Feedback control & computer process control
7) Computer integrated system for planning, data collection decision making.

Examples : Automotive, Electronics, Applications, Aircraft manufacturing industries.

Type of Automation :

1) Fixed Automation
2) Programmable Automation
3) Flexible Automation

1) Fixed Automation :-

 Fixed automation is a system in which the sequence of processing is fixed by equipment

configuration.
 The operation sequence are simple.
 Higher initial investment of custom equipment
 High production capacity
 Inflexible to accommodate product changes

Example : Automated material handling & transfer lines & assembly equipments.

2) Programmable Automation:-

 In it production equipment is designed with the capability to change the sequence of

operation to accommodate change of product design.
 The operation sequence is controlled by a program in form of coded instructions.
 For producing new batch of new design product the system can be reprogrammed.
 High investment initially
 Low production as compare to fixed automation.
 Flexibility to accommodate new design of product.
 It is most suitable of batch production.
Examples: - NC controlled m/c tolls & Industrial robots.

3) Flexible Automation :-
  It is an extension of programmable automation.
 It is flexible automated system which can accommodate design change of product.
 In it one advantage is that there is time lost for change over‟s from one product to the
next.
 There is no production time lost while reprogramming the system and allotting the
physical setup of tolling, fixtures, machines setting.
 High investment initially
 Continuous production with Varity of product.
 Medium production rate.
 Flexibility for verity of product design change over.
Example: - CNC m/c tools, reprogrammable Industrial robots.

Diagraph:

Reasons for Automation:-

1) Increased productivity due competition

 Due to Industrialization and globalization the global competition escalates which causes
increase the demand the stoner of productivity & quality.
 Automation of manufacturing operations promise to in erasing the productivity of labour.
 Automation causes higher out put to lesser input.
 Higher production rates are achieved with automation as compare to manual operations.

2) High cost of Labour:-

 Automation system required less Labour hence increasing cost of Labour don‟t of heat
on it.
 Higher cost of Labour is forcing businesses to substitute m/c‟s for human Labour.
 Machines can produce higher rates of output the use of automation results in a lower
cost per unit of product.
3) Labour shortage:-

 Many Advanced nations, there has been a shortage of Labour.

 Labour shortages stimulate the development of automation as a substitute of Labour.

4) Trend of Labour toward the sector :-

 There are some social & institutional forces Labour toward the service sector.
 There has been a tendency for people to view factory work as tedious, demeaning &
dirty.
 This view h as caused them to seek employment in the service sector of the economy.

5) Safety:-

 Automation delaminates the human role, work is made safer.

 The safety and physical well being of the worker is main objective of todays industries.

6) High cost of raw materials:-

 The high cost of raw materials in manufacturing results in the need for reater efficiency in
using there materials.
 The reduction of scrap is one of the benefits of automation.

7) Improved Product Quality:-

 Automated operation not only produces parts of faster rates but they produce parts with
greater consistency and conformity to quality.

8) Reduced manufacturing Lead time:-

 For automation allows the manufacturer to reduce the time between custom order and
product delivery.

9) Reduction of in process inventory:-

 Holiday large inventories of work in process represent a significant cost to the

manufacturer because it ties up capital.
 In process inventory is of no value.
 It is to the manufacturer‟s advantage to reduce work in progress to a minimum.
 Automation play big role to reducing time a work part spends in the factory.

10) High cost of not automation:-

 The benefits of automation often show up in intangible and unexpected ways. Such as
improved quality, higher sales, better Labour relations and better company image.
Companies that donot automate are likely to final themselves of a competitive
disadvantage with their customers, their employees & the general public.

Automation Strategies:-

There are certain fundamental strategies that can be listed as follows.

1) Specialization of operations:-

 It is strategies which involves use of specialized purpose equipments designed to

perform one operation with greatest efficiency.
 It is strategy which involves used of specialized Labour to handle automation for
improving the productivity.

2) Combined operations:-

 It is the strategy of combined operations on some complex parts reducing the number of
distinct production m/c‟s or workstations through which the part must be routed.

3) Simultaneous operations:-

 It is a extension of combined operation strategy to perform same operations with less

time simultaneously.
 In effect, two or more processing operations are being performed simultaneous on same
work part reducing processing time.

4) Integration of operations:-

 It is link several workstations into a single integrated mechanism using automated work
handling devices.

5) Increased flexibility:

 It attempts to use maximum utilizations of equipments for productions.

 By using the one equipment for variety of products. There by reducing set up time and
programming time for production m/c‟s.

6) Improved material handling and storage:-

 It is useful for reducing lots of non-operative time hence reduction in lead time.

7) On- line inspection:-

 Inspection for quality of work is performed after the process traditionally.

 On line inspection into the manufacturing process permits corrections to the process as
product is being made.
 This reduces scrap and brings the overall quantity of product closer to the nominal
specifications intended by the designer.

8) Process control & optimization:-

 It is included a wide range of control schemes intended to operate the individual process
and associated equipment move efficiently.

9) Plan operations control:-

 This strategy is concerned with control at the plant – Level.

 It is to manage and co-ordinate the aggregate equipment more efficiently.
10) Computer Integrated manufacturing (CIM):-

 This is use of computer applications, computer database and computer networking in the
company.

Arguments in favor of automation & against: - Argument in favor:-

1) Automation brings safer working conditions for the workers.

2) Automation is the they to minimize working time due to which increases production,
hence higher quality of life.
3) Automated production has resulted in better products at lower prices.
4) The growth of automation industry has created newer Job opportunities. This has
resulted incretion of various specialized departments.
5) Automation is the mean of increasing standard of living & increases productivity which
resulted into increases in wages salaries & incentives etc.

Argument in against:-

1) Automation has resulted in unemployment.

2) As productivity will be increased but creation of job will not occurs faster
3) Automation tends to transfer the skill required to perform work from human to machines.
4) Automation causes inflation and unemployment due to automation causes increase of
poorly.
5) Due to the poorly the product will not sale which resulted in to markets will be flooded
with the products and also inventories in industries increases in industry. Which would
result in stopping the production and hence economic depression?

Functions of Automation in manufacturing

For a firm engaged in making discrete products. The certain basic functions as –

1) Processing
2) Assembly
3) Material handling & storage
4) Inspection & Testing
5) Control

1) Processing operations:-

 It is the operations which transforms the product from one state of completion into a
more advanced state of completion.
 It classified.

Into one of the following four categories.

1) Basic processes
2) Secondary processes
3) Finishing operations
 4) Operations to enhance physical properties.

1) Basic process:-

Basic process is those which gives the work material its initial form.

For example: - Metal casting & plastic molding both cases the raw material are converted into
basic geometry of the desired product.

Diagraph:

2) Secondary Processes:-

 It follow the basic process and are performed to give the work parts final desired
geometry.
For example :- machines like turning, drilling milling etc. & press working operations like
blanking forming, drawing etc.

3) Operations to enhance physical properties:-

 It is to change the physical geometry of the work part. Instead the physical properties of
the materials are improved in some way. Heat treating operations to strengthen metal
parts and preshrinking used in the garment industry are examples in this category.

4) Finishing operations:-

 It is the final processes performed on the work part.

 It is for improving appearance or to provide to protective coating.
For example: - Polishing, painting and chrome plating.

Most manufacturing process required five inputs.

1) Raw materials
2) Equipment (machine tools)
3) Tooling and fixtures.
4) Energy
5) Labour
The manufacturing process produces two outputs.

1) The completed workplace

2) Scrap & waste

Diagram :

5) Assembly operation :-

 In it the distinguishing feature is that two or more separate components are joined
together.
 It included mechanical fostering operations, which make use of screws nuts, rivets and
so on, and going processes such as welding, brazing & soldering.

6) Material handling and storage :-

 A means of moving and storing materials between the processing and assembly
operations must be provided.
 Material spend move time being moved and stored than being processed.
 Mostly the cost would be required for handling, moving & storing of materials.

7) Inspection & Testing :-

 It is purpose of inspection is to determine the product meets the established design

standards & specifications.

Control :-

 The control function in manufacturing includes both regulation of individual processing

and assembly operation.
 Control at the process level involves the achievement of certain performance objectives.
 It is included effective u se of Labour maintenance of the equipment, moving materials in
the factory.

Plant Layout :-
  It refers to the arrangement of these physical facilities in a production palnt.
 Therefore three principal types of plant Layout.
1) Fixed position layout
2) Process layout
3) Product flow layout
4) Group technology layout

Diagram :

1) Fixed position Layout:-

 In this type of layout, because of size & weight the product remains in one Location and
the equipment used in it is brought to it.
 Larger aircraft assembly and ship-building are comes under the fixed position layout.
 In it product is even totally moved but of the plant and the plant remains for the next job.

2) Process layout:-

 In it the production machines are arranged into groups according to the general type of
manufacturing process.
 The advantage of this type of layout is its flexibility. Different parts, requires its our
unique sequence of operation.

Milling Dept. Drill Dept.

Lathe Dept.

Shipping
and office
Receiving Finishing Grinding
Dept. Dept.
Assembly

3) Product flow layout:-

  In this type of layout, the processing and assembly facility and placed along the line of
flow of the product.

Diagram:

 The product is progressively lubricated as it flows through the sequence of workstations.

4) Group technology Layout:

 It is the layout in which combines the efficiency of flow layout with process layout.
 In it machines arranged in to cells.
 Each cell is organized to specialize in the manufacture of a particular part of the family.
 Its advantages are gained in perform of reduced work piece manufacturing lead time,
Lower setup prime, less in process inventory etc.

Diagram

Functions of automation information processing in manufacturing :-

It consisting of four functions :-

Diagram :
1) Business functions :

 It is the mean of communicating with the customer.

 It is beginning & end of the information processing cycle.
 It included category are sales, marketing, forecasting, order entry, cost accounting,
customer billing & soars.

2) Product design :-

 The product is to be manufactured to customer specifications.

 It is provided by customer.
 The new product often originate in sales & marketing department.
 This department includes research & development, design engineering, drafting &
prototyping.

3) Manufacturing Planning :-

 In it the organization that perform manufacturing engineering, industrial engineering &

products on planning & control.

4) Manufacturing control :

 It is concerned with managing & controlling the physical operation in the factory to
implement the manufacturing plan.
 The flow of information is from planning to control as indicated in fig. broadly
manufacturing control consist of shop floor control, quality control & inventory control.

Automated flow line :-

 It consists of several machines or workstations which are linked together by work

handling devices that transfer parts between the stations is called automated flow line.

The objective of use of flow line automation are :-

 1) To reduce Labur cost
2) To increase the production rate
3) To reduce work in progress
4) To minimise distance moved between operations
5) To achieve specialization of operations.
6) To achieve integration of operations.

Types of automated flow line :-

 It is basically divided into two types depending upon the forms in which the work flow can
take place as.

1) In – Line type :-

 It consists sequence workstationsing more –or- less straight line arrangement.

 The flow of work can take a few 900 turns either for work piece orientation.
 Factory layout limitation or other reason are also responsible for straight line
configuration.

Diagram :

2) Rotary types :-

 In this type work parts are indexed around a circular table or dial.
 The workstations are stationary and usually located around the periphery of the dial.
 The parts on the table are positioned at processing station for the operation.

Diagram:

Various methods of work part transports :-

Method of work part transport :

1) Continuous transfer
2) Intermission or synchronous transfer
3) Asynchronous transfer

1) Continuous transfer :-

 In this method the work part are moved continuously at constant speed
 This requires the work heads to move during processing in order to maintain continuous
registration with the work part.

2) Intermittent transfer :-

 In this method the work pieces are transported with an intermittent or discontinuous
motion..
 The work stations are fixed in position and parts are moved between stations then
registration.
 All work parts are transported at the same time and for this reason it called synchronous
transfer system.

3) Asynchronous transfer :-

 In this system each work parts to move to next stations when processing at the current
station has been completed.
 In it each parts moves in dependently of other parts.
 Asynchronous transfer systems move flexible than the other two system.
 It is used where there are one or more manually operated stations and cycle time
variation station.

Difference Between Automation and Mechanization

Automation Mechanization

 It is concern with application of  It is concern with machineries to

electronics and computer based operate production
system to operates production

 It operates without human  It operates with the help of

human

 It has close loop system in which  No feed back process is

feedback is provided by sensors available

 It is controlled by automatic control  It involves human efforts for

system operation
Different type of transfer mechanisms:

1. Linear transfer mechanism

2. Rotary transfer mechanism

1. Linear transfer mechanism:

a) Walking beam systems

b) Powered roller conveyor system

c) Chain-drive conveyor system

) Walking beam systems:

 In it the work-parts are lifted up from their workstation locations by a transfer bar and
moved one position ahead, to the next station.

 The transfer bar then lowers the pans into nests which position them more accurately for
processing

b) Powered roller conveyor system:

 This type of system is used in general stock handling systems as well as in automated
flow lines.

 The conveyor can be used to move pans or pallets possessing flat riding surfaces.

 The rollers can be powered by either of two mechanisms. The first is a belt drive, in
which a flat moving belt beneath the rollers provides the rotation of the rollers by friction
c) Chain-drive conveyor system:

 In it either a chain or a flexible steel belt is used to transport the work carriers.

 The chain is driven by pulleys in either an "over-and under“ configuration, in which the
pulleys turn about a horizontal axis, or an" around-the-corner" configuration, in which the
pulleys rotate about a vertical axis.

 It can be used for continuous, intermittent, or asynchronous movement of work parts. In

the asynchronous motion,

2. Rotary transfer mechanisms

a) Rack and pinion

b) Ratchet and pawl

c) Geneva mechanism

d) CAM Mechanisms

a) Rack and pinion:

 This mechanism is simple but is not considered especially suited to the high-speed
operation often associated with indexing machines.
  A piston to drive the rack, which causes the pinion gear and attached indexing table to
rotate, A clutch or other device is used to provide rotation in the desired direction.

b) Ratchet and pawl:

 A ratchet is a device that allows linear or rotary motion in only one direction, while
preventing motion in the opposite direction.

 Ratchets consist of a gearwheel and a pivoting spring loaded finger called a pawl that
engages the teeth. the spring for forcing it back with a 'click' into the depression before
the next tooth.

 When the teeth are moving in the other direction, the angle of the pawl causes it to catch
against a tooth and stop further motion in that direction

c) Geneva mechanism:

 The Geneva mechanism uses a continuously rotating driver to index the table

 If the driven member has six slots for a six-station dial indexing machine, each turn of the
driver will cause the table to advance one-sixth of a turn.
d) CAM Mechanisms:

 Cam mechanism provide probably the most accurate and reliable method of indexing the
dial.

 They are in widespread use in industry despite the fact that the cost is relatively high
compared to alternative mechanisms.

 The cam can be designed to give a variety of velocity and dwell characteristics.

Elements of the parts delivery system:

 The hardware system that delivers components to the work head in an automated
assembly system typically consists of the following elements

Hopper:
  This is the container into which the components are loaded at the workstation.

 The components are usually loaded into the hopper in bulk. This means that the parts
are randomly oriented initially in the hopper.

Parts feeder:

 This is a mechanism that removes the components from the hopper one at a time for
delivery to the assembly work head.

 The hopper and parts feeder are often combined into one operating mechanism.

Selector and/or orienteer:

 These elements of the delivery system establish the proper orientation of the
components for the assembly work head.

 A selector is a device that acts as a filter, permitting only parts that are in the correct
orientation to pass through. Components that are not properly oriented are rejected back
into the hopper.

 An orientor is a device that allows properly oriented pans to pass through but provides a
reorientation of components that are not properly oriented initially

Feed track:
  A feed track is used to transfer the components from the hopper and parts feeder to the
location of the assembly work head, maintaining proper orientation of the parts during
the transfer.

Two general categories of feed tracks:

1. Gravity: The force of gravity is used to deliver the components to the work head.

2. Powered: vibratory action, air pressure, or other means to force the parts to travel along
the feed track toward the assembly work head.

Different Type of Chutes:

1. Straight slide chutes

2. Roller chutes

3. Spiral chutes

4. Spiral roller chutes

5. A vertical open core chute

6. A zig-zag or curvilinear chute

7. A ladder chute of retarding type

8. Powered chutes

[Link] controlled chute

Control strategies to control the operation of automatic transfer system as

follows:

1. Sequence control

2. Safety monitoring

3. Quality monitoring

a) Instantaneous control

b) Memory control
1. Sequence control:

 The purpose of this function is to coordinate the sequence of actions of the transfer
system and its workstations.

 The various activities of the automated flow line must be carried out with split-second
timing and accuracy.

2. Safety monitoring:

 This function ensures that the transfer system does not operate in an unsafe or
hazardous condition.

 Sensing devices may be added to make certain that the cutting tool status is satisfactory
to continue to process the work part in the case of a machining-type transfer line.

 Other checks might include monitoring certain critical steps in the sequence control
function to make sure that these steps have all been performed and in the correct order.

3. Quality monitoring:

 The third control function is to monitor certain quality attributes of the work part

 Its purpose is to identify and possibly reject defective work parts and assemblies.

 The inspection devices required to perform quality monitoring are sometimes

incorporated into existing processing stations or separate stations are included

There are alternative control strategies

a) Instantaneous control

b) Memory control.

a) Instantaneous control:

 This mode of control stops the operation of the flow line immediately when a malfunction
is detected.

 It is relatively simple, inexpensive, and trouble-free.

  Diagnostic features are often added to the system to aid in identifying the location and
cause of the trouble to the operator so that repairs can be quickly made.

 stopping the machine results in loss of production from the entire line, and this is the
system's biggest drawback.

b) Memory control:

 In contrast to instantaneous control, the memory system is designed to keep the

machine operating.

 It works to control quality and/or protect the machine by preventing subsequent stations
from processing the particular work part and by segregating the part as defective at the
end of the line.

 The flow line will continue to operate, with the consequence that bad parts will continue
to be produced.

Assembly involves the joining together of two or more separate parts to form a new
entity is called assembly or subassembly.

the assembly of the components can be divided into three major categories.

1. Mechanical Fastening: Screws, bolts, nuts etc. Rivets, crimping and other methods Press
fits Snap fits –temporary interface of the two parts C-ring. Sewing and stitching –for soft, thin
material.

2. Joining Methods: Welding, brazing and soldering

3. Adhesive Bonding: Thermoplastic, thermosetting (chemical reaction

There are various methods used in industry to accomplish the assembly processes.
Major methods can be classified:

1. Manual Single-Station Assembly

2. Manual Assembly Lines

3. Automated Assembly System

1. Manual Single-Station Assembly:

 It consist of a single workplace to accomplish the product or some major subassembly of

the product.

 It used on a product that is complex and produced in small quantities, one or more
workers depending on the size of the product and the production rate.

Such as machine tools, industrial equipment, aircraft, ships and complex consumer products
(appliances, car,...)
2. Manual Assembly Lines

 Consist of multiple workstations in which the assembly work is accomplished as the

product (subassembly) is passed from station to station along the line.

 At each workstation one or more human workers perform a portion of the total assembly
work on the product, by adding one or more components to the existing subassembly.

 Manual Assembly Lines Are used in high-production situations where the work to be
performed can be divided into small tasks and tasks assigned to the workstations on the
line.

 Key advantage of using manual assembly line is specialization of labour –By giving each
worker a limited set of tasks to do repeatedly.

Automated assembly system refers to the use of mechanized and automated devices to
perform various functions like handling and fastening with following strategies

1. Reduce the amount of assembly required

2. Use modular design

3. Reduce no of fasteners required

4. Reduce the no of component to handle

5. Limiting the no. of unnecessary motion

1. Reduce the amount of assembly required:

It implies the combining the functions of same part that previously accomplished by
separate components in product.
2. Use modular design:
It reduces the no. of assembly stations for assembling the complicated assembly products.
3. Reduce no of fasteners required:
It reduces the no of fastener parts to simplify the design
4. Reduce the no of component to handle:
It reduces the no of component that requires for assembly to handle
5. Limiting the no. of unnecessary motions:
Its reduces the unnecessary motion of work part and assembly machines
Types of automated Assembly flow line:

1. Continuous Transfer System

2. Synchronous transfer system

3. Asynchronous transfer system

4. Stationary base part system

Classification on basis of Physical configuration:

1. Dial- type assembly machines

2. Inline assembly machines

3. Carousel system

1. Dial- type assembly machines:

 The base part are indexed around a circular table or dial. The workstations are
stationary and usually located around the outside periphery of the dial.

2. Inline assembly machines:

 The in-line configuration assembly system consists of a sequence of workstations in a

more-or-less straight-line

3. Carousel assembly system:

 It represents a hybrid between the circular flow of work provided by the dial assembly
machine and straight work flow of the in-line
Assembly line balancing:

 It means that arranging the individual processing and assembly task at the work stations
so that time required on each station on each station is same

 It is the concept in which we have to integrate the all work station and balance the time
required in such a way that the flow of work part should be smooth

Following are the benefit of line balancing:

1. Allocating Balance work load

2. Increase production rate

3. Reduce idle time of machine

4. Reduce wastage

5. Reduces material handling

Different constraints for assembly line balancing:

1. Precedence Constraint

2. Zoning Constraint

3. Position Constraint

1. Precedence Constraint:

 It is refer to as „technological sequencing requirement‟

 It causes the delay in work progress and line become unbalance

For example: A threaded hole must be dilled before tapped

A nut can be turned and tighten after washer must placed