Assignment No: 1

FACULTY OF ENGINEERING

EMM3706

PRODUCTION PLANNING AND AUTOMATION

SYSTEM

LECTURER: PROF DATIN DR NAPSIAH ISMAIL

GROUP :

Matric No NAME
188804 MUHAMMAD ANIS BIN KHALIQUZZAMA
189983 ONG ZI JIANG
188327 LOO KAI XEN
187790 HENG KOR JIN
 Title: Distributed Control System in Manufacturing Industries
Muhammad Anis bin Khaliquzzama, Ong Zi Jiang, Loo Kai Xen, Heng Kor Jin

ABSTRACT

Nowadays, there are numerous inventions in automation manufacture industries. This is due
to the advancement of technology all around the world and the competitiveness among each
other is very intense. Throughout this process, the duration of inventing a new technology take
years yet has evolve to within a year which mean the process is being enhanced frequently.
One of the well-known automation application trends in the field of manufacture industries is
Distributed Control System. A distributed control system is widely used in processing industry
today compared to former centralized control system which has been use frequently in the past
century due to invention of smart devices. This system brings a lot of benefits such as enhance
reliability of control, process quality and efficiency of plant in the field of architecture around
the plant. Moreover, this system is not only limited in the industries of plant but also in chemical,
oil and gas industries, water management, automation and essentials.

Keywords: Application, Automation, Distributed control system, Industrial field, Manufacture.

1.0 INTRODUCTION TO AUTOMATION

Automation is the control of machines which processed by independent systems using various
technologies that based on computer software or robotics. It is the technology that performs
process or procedure with minimum or no human intervention or assistance. Today, industry
implements automation to increase productivity, save electricity costs, save material costs,
improve the quality, accuracy and precision and lastly reduce labour costs. Automation uses
various control systems to operate equipment such as machinery, processes, boilers, aircraft,
vehicles etc. There are basic elements of an automated system:

 Power – to accomplish the process and operate the automated system.

 Program of instructions – to direct the process.
 Control system – to actuate the instructions.

Figure 1: Elements of an automation system.

Automation utilises various industrial communication devices such as programmable logic

controllers (PLCs), programmable automatic controllers (PACs). It has been achieved by
various means including mechanical, hydraulic, pneumatic, electrical, electronic devices and
computers, normally in combination. In industries, control strategies use a set of technologies
implemented to achieve desired results, causing automation systems necessary in industries.
Automation covers applications ranging from a household thermostat controlling an oven, to a

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large industrial control system with tens of thousands of input measurements and output control
signals. In control complexity it ranges from simple on-off control to multi-variable high-level
algorithms. Furthermore, it can be classified into five levels as stated below.

 Device level – actuators, sensors, and other hardware components to form

 Machine level
 Cell or system level
 Plant level
 Enterprise level
individual control loops for the next level.
– CNC machine tools and similar production equipment,
industrial robots, material handling equipment.
– manufacturing cell or system.
– factory or production systems level.
– corporate information system.

Figure 2: Levels of automation.

2.0 TYPES AND APPLICATION OF AUTOMATION IN MANUFACTURING

INDUSTRIES

2.1 Fixed Automation

A manufacturing system in which the sequence of processing or assembly operations is fixed

by the equipment configuration or parameters. Each of the operation in a fixed or hard
automation sequence is usually simple; it is the combination and coordination of many
operations into one piece of equipment that makes the system more complicated. It is suitable
for products with very high demand and volumes. Examples of this automation are Machine
transfer lines, automatic assembly machines and certain chemical processes instruments. It has
the following typical features:

 Suited to high production quantities.

 High initial investment for custom-engineered equipment.
 High production rates.
 Relatively inflexible in accommodating product variety.

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2.2 Programmable Automation

A manufacturing system designed with the capability to change the sequence of operations to
accommodate different product configurations. The sequence of operation is controlled by
programming, which is a set of coded instructions allowing the system to read and interpret
them. This automation is particularly appropriate for batch production process where
production volume is medium to high. It is hard to change and recognize the system for a new
product or sequence of operations. Examples of this automation system are numerically
controlled machines, steel rolling mills, paper mills and industrial robots. It has the following
typical features:

 High investment in general purpose equipment.

 Lower production rates than fixed automation.
 Flexibility to deal with variations and changes in product configuration.
 Most suitable for batch production.
 Physical setup and part program must be changed between jobs (batches).

2.3 Flexible Automation

A flexible or soft automated system is an extension of programmable automation in which the

system can change over from one job to the next with no lost time between jobs. The system
can produce different combinations and schedules of products instead of requiring them to be
manufactured in separate batches. Examples of this automation system are self-guided vehicles,
automobiles and CNC machines. It has the following typical features:

 High investment for custom-engineered system.

 Continuous production of variable mixes of products.
 Medium production rates.
 Flexibility to deal with soft product variety.

Figure 3: Product variety versus Production quantity for all 3 types of automation.

3.0 DISTRIBUTED CONTROL SYSTEM

Distributed Control System (DCS) is a unique system that need to be design particularly.
Although most of the functions are similar to Programmable Logic Controller (PLC), the

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special part of DCS is, it able to conduct and synchronize the whole plant including every
controller that establish inside the plant. That’s mean it can manage multi-process at the same
time. Hence, the efficiency of the manufacturing process increases especially in arranging the
plant-wide performance. In order to make this happen, DCS requires a strong connection
toward the rapid communication network by allocate great number of local controllers in the
plant control areas.

In addition, each of the elements which are sensors, computer, and controllers that consist in
DCS are important because every element has its own unique duties to complete such as data
gathering, data accession, operation control and graphical display. However, all these elements
will still interface with the centralized computer which is the brain of the system across the
plant’s local network. The decision is automated in DCS based on the manufacturing tendency
over the time across the plant system without any human being control it. In other words, DCS
can make adjustment of multi-function by itself throughout the whole system depending on the
environment and the demands through the sensors and the actuators.

DCS normally utilize in big companies such as Emerson Electric, Honeywell International,
Siemens and essentials on organize multiplex operation process such as petrochemical industry
which require huge and sustained manufacturing plants. Centralized network of computer in
DCS bring convenient to operators by maximise synchronize adjustment through top-down
approach. The independent controllers receive instruction from the DCS that locate across the
plant and proceed to the operation. Obviously, safety is guaranteed while the productivity is
maximised with the implementation of DCS.

You may note peculiarities. For example, the heading margin in this template measures
proportionately more than is customary. This measurement and others are deliberate, using
specifications that anticipate your paper as one part of the entire proceedings, and not as an
independent document.

3.0 RESULTS AND DISCUSSIONS

Assignment I …….

A. Figures and Tables

Figure captions should be below the figures; table headings should appear above the tables.
Insert figures and tables after they are cited in the text as close to the citation as possible.

Figure 1: Example of a figure caption. (figure caption)

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 Table 1: Title of table here
Table Column Heading
Table
Table column Subhea Subheadi
Heading
subheading ding ng
More table
copy
copy

Figures and tables should be numbered consecutively.

4.0 CONCLUSIONS

Write your conclusion here.

REFERENCES

[1] Groover (2016) Automation, Production Systems, and Computer-Integrated

Manufacturing, 4th Edition, Pearson Education Ltd., United Kingdom.
[2] Meet (2018) An Introduction to Automation in Industry,
https://www.azorobotics.com/Article.aspx?ArticleID=274, AZO Robotics.com,
AZoNetwork UK Ltd., NEO, 4th Floor, 9 Charlotte Street, Manchester M1 4ET, UK.
(accessed: 9 March 2019).

Examples:
[3] Baumann, J.W. (1981) Application of enzymes in fruit juice technology. In G.G. Birch, N.
Blakebrough, and K.J. Parker (Eds.), Enzymes and Food Processing (pp.129-147), Applied
Science Publication, London.
[4] Mohd Saiah, H.R (2006) Heat transfer measurements on flat plate surface film cooling.
Bachelor of Engineering (Aerospace) Project Report, Department of Aerospace
Engineering, UPM, Malaysia.
[5] Abu Talib, A.R (2003) Detailed investigation of the low-temperature analogy of an aircraft
engine standard fire-test. D.Phil Thesis, Department of Engineering Science, University of
Oxford, United Kingdom.
[6] Mills, R. (1973) Self-diffusion in normal and heavy water in the range 1-45 deg C,
http://nmr-relaxation.com/handbook/general/water.htm, NMR-Relaxation.com, 835
Sextant Ave., Roseville, 55113 MN, USA. (accessed: 17 Dec 2002).

References should be of reputable sources such as company reports, journals, magazines,

conference proceedings. Do not quote from WIKIPEDIA.