Automation And Types of Automation in Manufacturing

Automation is generally defined as the process of having machines follow a predetermined sequence of operations with little or no human labor, using specialized equipment and devices that perform and control manufacturing process.

Automation is achieved through the use of variety of devices, sensors, actuator, techniques and equipment that are capable of observing and controlling all aspect of machining process.

In Manufacturing Plant, it has been implemented successfully and in the following basic area of activity:

• It is a machine used for operating single component at a time.
• It has single spindle and has wide range of speeds.
• It can be used for high speed machining.
• Single spindle automats are development of capstan and turret lathe.

They can be further classified as:

1. Automatic Cutting-Off Machine:
   • These are basically used for turning, facing and cutting-off operations.
   • Capable of machining workpiece of small length.
2. Swiss Type Automatic Screw Machine:
   • The general purpose of this machine is widely used for mass production of high quality fasteners such as bolts, screws, pins, shafts, rollers, etc.
   • It is relatively in size but higher spindle speeds.
3. Turret Type Automatic Screw Machine:
   • It is the development of capstan lathe.
   • These are actually for machining internal or external surface on the workpiece.

Transfer mechanism are used to move the workpiece from one station to another in the machine or from one machine to another machine to enable various operation to be performed on the part.

Each machine in the series is called as a station and perform the same operation repeatedly on every workpiece.

Transfer of parts from one station to other station is usually controlled by sensor and other devices.

Tools on transfer machine can be easily changed in tool holders having quick change features.

These machines can equiped with various automatic gauging and inspection system.

The machines are arranged in a sequence, so used for mass production.

Process Required for Manufacturing:

1. Manufacturing Process:
   • Machining, forging, cold extrusion, casting and grinding operations are typical examples of process that have been extensively automated.
2. Material Handling:
   • Materials and parts in various stages of completion are moved throughout a plant by computer controlled equipment without human guidance.
3. Inspection:
   • Parts are automatically inspected for quality dimensional accuracy and surface finish, either at the time of manufacturing(In-Process Inspection) or after they are made(Post-Process Inspection).
4. Assembly:
   • Individually manufactured parts are automatically assembled into sub-assemblies and finally into a product.
5. Packaging:
   • Products are packaged automatically.

1. To improve the productivity by reducing the machining costs through better control of production.
2. Partys are loaded, fed and unloaded on machine more efficiently, machines are used more efficiently and effectively.
3. To improve the quality employing more repeatable processes.
4. To reduce the human involvement, boredom and the possibility of human error.
5. To reduce the working damage caused by manual handling of parts.
6. To raise the level of safety for personal especially under hazardous working conditions.
7. To economize on floor space in manufacturing plant by arranging the machines, material movement and auxillary equipment mor efficiently.

• Its example is Computer Integrated Manufacturing.
• In this type of automation manufacturing functions are like production planning and control, purchasing, marketing, etc. are linked to an integrated computers.

• It is not flexible.
• It cannot accommodate variety of products.
• In Fixed Automation, machines are arranged according to sequence of operations to be performed.
• Production rate are high.
• Initial setup costs are high.

In this production statement is designed with the capability to change the sequence of operation to accommodate different product configurations.

• Some features of programmable automations are:
  • Flexibility to deal with different products configured.
  • High Investment
  • Low production rates relative to fixed automation.

• High initial investment
• It can produce variety of parts
• It is flexible to deal with various product designer by just changing the program of instruction.
• Because of this capability, this type of automation can produce parts with complex shapes.

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