Definition of Automation:
Automation could be defined as the technology that deals with the design of machine tools and systems using electronics and computer systems to produce the final product with minimum cost, involving minimum labor intervention, producing components of high precision and desired tolerances repeatedly without causing rejections.
Automation System
A fully automated production system would involve automatic machine tools such as machining center to remove material as desired, industrial robots and material handling systems, automated assembly lines, automated inspection systems such as machine vision, and automated production control systems. quality, and computer system for planning, data collection, feedback, decision making to take control measures and present the desired information in visual display units in a concise and easily assimilable form.
Types of automation systems
Automation systems can be fixed, programmable or flexible.
In fixed automation, the processing sequence is fixed for a specific product. Such a system can be used for mass production of a product. Its initial cost is high and any changes to the product design may be difficult to incorporate. If the product has to be changed, many modifications, new additions, etc. may be necessary and accommodating them would be very expensive and time-consuming.
types of production automationIn programmable automation (as with numerically controlled machines and robots), it is possible to accommodate the change in the sequence of operations of a new product by changing the program (set of instructions). Such a system is therefore suitable for batch production. For new products, not only do programs need to be changed, but also new tools and accessories may have to be loaded and machine settings changed.
In flexible automation systems , no time is wasted in producing a product and switching to a new product. Complete information and programs for the products to be produced are available on the computer system and only the new product code must be reported to the computer and changes to all settings, tools, etc. These systems are best suited for the production of a wide variety of spare parts for large plants/processes/industrial complexes.
The latest trend in automation is computer-integrated manufacturing, that is, using the computer not only for actual production and manufacturing, but also designing the product, carrying out complete manufacturing planning, performing all business-related functions such as inventory of raw materials and others. inventories, actual sales, sales forecast, orders in hand, maintenance needs of various machine tools.
Advantages of automation:
The advantages of automation are:
(i) Increased productivity (higher production per hour of work),
(ii) Better product quality,
(iii) Scrap reduction (particularly beneficial for expensive raw materials),
(iv) Greater safety (due to the operator assuming the role of supervision instead of active and direct physical participation),
(v) Reduction in manufacturing lead time,
(vi) Reduction of in-process stock, etc.
It is always advantageous to automate monotonous and dangerous jobs. With more and more automation, human errors are completely eliminated and product quality is improved, rejects are minimized, prices are reduced and, ultimately, people's standard of living is increased.
Disadvantages of automation
Less versatility – having one machine that can perform a certain task limits the flexibility and variety of tasks an employee could perform.
More pollution – different types of machines operate using engines that may require gases or chemicals to operate. This can cause increased pollution in the workplace.
Large initial investment – automated machines can be one of the most expensive operating costs for a company. With automated machines operating between thousands and millions of dollars depending on the type and degree of automation.
Increased unemployment – by increasing the amount of automation, there are fewer employees needed, causing high unemployment rates.
Unpredictable costs – There may be several unpredictable costs that may exceed the actual cost saved by the automation itself. Some of these costs may include research and development costs to automate a process, preventative maintenance costs, and costs of training employees to operate automated machines.
