Automation is the use of machines or technology to perform tasks without muchhuman intervention.

The approach
tries to streamline processes, enhance efficiency, and reduce human error.

On the other hand, automation replaces the human involvement with the use of logical programming commands and
powerful machineries.

Industrial Automation is the replacement with computers and machines to that of human thinking. The word
Automation gives the meaning ‘self dictating’ or ‘a mechanism move by itself’ that derived from the Greek words Auto
and Matos where auto means self while Matos means moving

In a brief, industrial automation can be defined as the use of set technologies and automatic control devices that
results the automatic operation and control of industrial processes without significant human intervention and achieving
superior performance than manual control.
Industrial automation can improve quality, productivity, and safety in warehouses, factories, industrial manufacturing,
and other processes.

Advantages of Automation System

•Higher production rate: Automation reduces production time, giving a higher production rate and larger production
volume.

•Increase productivity: Improved production rate through better production control of production, reduced downtime,
reduced errors, reduced assembly time per product, etc.

•Reduced operating costs: Reduced need for human labor and time leads to reduced costs in production and
maintenance such as workers’ wages, benefits, healthcare, pension, bonus, etc.

•Lower maintenance costs: Industrial automation machines have lower maintenance because they rarely fail.

•Consistency in product quality: Automation reduces human involvement, eliminating human errors and encouraging
product quality and consistency uniformity.

•Improved work safety. Automation creates better working conditions. Machines handle processes that involve
excessive pressures, extreme temperatures, high forces, toxic material or fast movements, which pose safety hazards to
personnel.

•Increased repeatability. Automated systems in a production line are efficient because the repeated sequence is
“programmed” to perform tasks with a given precision.

•Reduce routine checks. Automation reduces the need for routine manual checks of various process parameters using
closed-loop control techniques.

•Better decision-making. More connected devices controlled with industrial automation tools give managers more
accurate data to use in decision-making. This is more applicable in warehouse systems, supply chains, banking, and
finance.

Three types of automation in production can be distinguished:

(1) Fixed automation,

(2) Programmable automation, and

(3) Flexible automation.

Types of Automation System

Fixed automation, also known as “hard automation,” refers to an automated production facility in which the sequence
of processing operations is fixed by the equipment configuration.

In effect, the programmed commands are contained in the machines in the form of cams, gears, wiring, and other
hardware that is not easily changed over from one product style to another.

This form of automation is characterized by high initial investment and high production rates. It is therefore suitable for
products that are made in large volumes.

This type of automation is employed to perform fixed and repetitive operations in order to achieve high production
rates.

This type of automation is not possible to providing product variety, but increases the efficiency with higher production
rate and reduces unit cost.

This type of automation is best suited for: High demand and generic products that require no change.
Examples of fixed automation include machining transfer lines found in the automotive industry, automatic assembly
machines, and certain chemical processes.

Advantages :

 High levels of production

 Consistent quality in production

 Low cost per unit produced

Disadvantages :

 High initial cost

 Difficult to accommodate changes

Programmable Automation System

Programmable automation is a form of automation for producing products in batches. The products are made in batch
quantities ranging from several dozen to several thousand units at a time.

For each new batch, the production equipment must be reprogrammed and changed over to accommodate the new
product style. This reprogramming and changeover take time to accomplish, and there is a period of nonproductive time
followed by a production run for each new batch.

Production rates in programmable automation are generally lower than in fixed automation, because the equipment is
designed to facilitate product changeover rather than for product specialization.

This type of automation is well suited for: Low/Medium demand and occasional changes in products.

Examples of this automation system are numerically controlled machines, paper mills, steel rolling mills, industrial
robots, etc.

Advantages :

 Flexibility to change products if needed

 Suitable if batch production is required

Disadvantages :

 Expensive for equipment

 Lower production levels

 Often time-consuming to change products

Flexible Automation System

Flexible automation is an extension of programmable automation. The disadvantage with programmable automation is
the time required to reprogram and change over the production equipment for each batch of new product. This is lost
production time, which is expensive.

In flexible automation, the variety of products is sufficiently limited so that the changeover of the equipment can be
done very quickly and automatically.

The reprogramming of the equipment in flexible automation is done off-line; that is, the programming is accomplished
at a computer terminal without using the production equipment itself.

 Accordingly, there is no need to group identical products into batches; instead, a mixture of different products can be
produced one after the other.
This type of automation is best suited for: Medium demand and constant changes/large variety in products.

Examples of this automation system are automatic guided vehicles, automobiles, and multipurpose CNC machines.

Advantages :

 Flexibility of products

 No time lost with new changes to production

Disadvantages :

 High custom machinery/automation cost

 Higher cost per unit

The chart below shows what options might be best when choosing an automation type, depending on the variety and
product demand.

Basic elements of Automated system

An automated system consists of three basic elements:

1) Power to accomplish automated process

2) A program of instructions to direct the process and

3) A control system to actuate the instructions.

The relationship amongst these elements is illustrated in Figure. All systems that qualify as being automated include
these three basic elements in one form or another another.
1) Power to accomplish automated process :

An automated system is used to operate some process, and power is required to drive the process as well as the
controls. The principal source of power in automated systems is electricity. Electric power has many advantages in
automated as well as non automated processes.

Power is required in automation for the followings:

 Loading and unloading the work unit

 Material transport between operations

 Power to actuate the control signals

 Data acquisition and information processing

2) A program of instructions to direct the process:

The actions performed in an automated process are defined by a program of instructions. Each part or product style
made in the operation requires one or more processing steps that are unique to that style, These processing steps are
performed during a work cycle.

3) A control system to actuate the instructions:

The control element of the automated system executes the program of instructions. The control system causes the
process to accomplish its defined function which is to carry out some manufacturing operation. The controls in an
automated system can be either closed loop or open loop.