TOPICS TO BE DISCUSSED

• AUTOMATION STRATEGIES

• AUTOMATED FLOW LINES

• AUTOMATED SYSTEMS

• TOYOTA PRODUCTION SYSTEM

• ROBOTICS
EXAMPLES OF AUTOMATION

• Home automation - uses a combination of hardware and software technologies

that enable control and management over appliances and devices within a
home.

• Network automation - the process of automating the configuration,

management and operations of a computer network.

• Office automation - involves using computers and software to digitize, store,

process and communicate most routine tasks and processes in a standard office.
EXAMPLES OF AUTOMATION

• Automated website testing - streamlines and standardizes website testing

parameters for configuration changes that occur during the development phase.

• Data center automation - enables the bulk of the data center operations to be
performed by software programs. Includes automated system operations, also
known as lights-out operations.

• Test automation - software code goes through quality assurance (QA) testing
automatically by scripts and other automation tools.
AUTOMATION STRATEGIES
1. Specialization of operations

The first strategy involves the use of special-purpose equipment designed to perform one
operation with the greatest possible efficiency.

2. Combined operations

The strategy of combined operations involves reducing the number of distinct production
machines or workstations through which the part must be routed. This is accomplished by
performing more than one operation at a given machine, thereby reducing the number of separate
machines needed.

3. Simultaneous operations

A logical extension of the combined operations strategy is to simultaneously perform the

operations that are combined at one workstation.
AUTOMATION STRATEGIES
4. Integration of operations

Another strategy is to link several workstations together into a single integrated mechanism,
using automated work handling devices to transfer parts between stations.

5. Increased flexibility

This strategy attempts to achieve maximum utilization of equipment for job shop and medium
volume situations by using the same equipment for a variety of parts or products. Prime objectives
are to reduce setup time and programming time for the production machine.

6. Improved material handling and storage

A great opportunity for reducing nonproductive time exists in the use of automated material
handling and storage systems.
AUTOMATION STRATEGIES
7. On-line inspection

Inspection for quality of work is traditionally performed after the process is completed.
Incorporating inspection into the manufacturing process permits corrections to the process as the
product is being made.

8. Process control and optimization

This includes a wide range of control schemes intended to operate the individual processes and
associated equipment more efficiently.

9. Plant operations control

Whereas the previous strategy was concerned with the control of the individual
manufacturing process, this strategy is concerned with control at the plant level.
AUTOMATION STRATEGIES
10. Computer-integrated manufacturing (CIM)

Taking the previous strategy one level higher, we have the integration of factory operations
with engineering design and the business functions of the firm.

CIM involves extensive use of:

• Computer applications

• Computer data bases

• Computer networking
AUTOMATED FLOW LINES
An automated flow line consists of several machines or workstations which are linked together
by work handling devices that transfer parts between the stations. The transfer of work parts occurs
automatically, and the workstations carry out their specialized functions automatically.
AUTOMATED FLOW LINES
The objectives of the use of flow line automation are, therefore:

• To reduce labor costs

• To increase production rates

• To reduce work-in-process

• To minimize distances moved between operations

• To achieve specialization of operations

• To achieve integration of operations

AUTOMATED FLOW LINES

Configurations of Automated Flow Lines

1. In-line Type

The in-line configuration consists of a sequence of workstations in a more-or-less straight-line

arrangement as shown below.
AUTOMATED FLOW LINES
2. Segmented In-Line Type

The segmented in-line configuration consists of two or more straight-line arrangement which are
usually perpendicular to each other with L-Shaped or U-shaped or Rectangular shaped as shown in
figure 1-3.
AUTOMATED FLOW LINES
3. Rotary Type

In the rotary configuration, the work parts are indexed around a circular table or dial. The
workstations are stationary and usually located around the outside periphery of the dial. The parts
ride on the rotating table and arc registered or positioned, in turn, at each station for its processing or
assembly operation.
AUTOMATED FLOW LINES
METHODS OF WORK PART TRANSPORT

The general methods of transporting workpieces on flow lines can be classified into the following
three categories:

1. Continuous transfer
2. Intermittent or synchronous transfer
3. Asynchronous or power-and-free transfer

The most appropriate type of transport system for a given application depends on
such factors as:

• The types of operation to be performed

• The number of stations on the line
• The weight and size of the work parts
• Whether manual stations are included on the line
• Production rate requirements
• Balancing the various process times on the line
AUTOMATED FLOW LINES
1. Continuous Transfer

With the continuous method of transfer, the work parts 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. For some types of operations, this movement of the work heads
during processing is not feasible. It would be difficult, for example, to use this type of system on a
machining transfer line because of inertia problems due to the size and weight of the work heads. In
other cases, continuous transfer would be very practical.
AUTOMATED FLOW LINES
2. Intermittent Transfer

As the name suggests, in this method the workpieces are transported with an intermittent or
discontinuous motion. The workstations are fixed in position and the parts are moved between
stations and then registered at the proper locations for processing. All work parts are transported at
the same time and, for this reason, the term "synchronous transfer system" is also used to describe
this method of work part transport.

3. Asynchronous Transfer

This system of transfer, also referred to as a "power-and-free system," allows each work part to
move to the next station when processing at the current station has been completed. Each part
moves independently of other parts. Hence, some parts are being processed on the line at the same
time that others are being transported between stations.
AUTOMATED SYSTEMS
Automated System

Is a combination of both software and hardware which is designed and programmed to work
automatically without the need of any human operator to provide inputs and instructions for each
operation.

Automated system operations had their origins with the introduction of the OS/360 operating
system by IBM. OS/360 allowed automated allocation of system resources and batch processing of
jobs.
AUTOMATED SYSTEMS
Automated operations reduce the complexity of labor-intensive tasks. Some of the most widely
used applications that incorporate ASO include scheduling, management of console messages,
backup and recovery, printing services, performance tuning, network monitoring and bug detection.

Automated system operations are used in a wide range of applications like control and
monitoring systems, data security applications, factory automation systems, automated message
response systems and so on.

Some of the benefits of automated system operations are:

• Eliminates the risk of human errors

• Improves user productivity
• Provides standardized operations
• Provides better operations management and logging
AUTOMATED SYSTEMS
Manual System Vs Automated System

Speed
Accounting software processes data and creates reports much faster than manual
systems. Calculations are done automatically in software programs, minimizing errors
and increasing efficiency. Once data is input, you can create reports literally by pressing a
button in a computerized system.

Cost
Manual accounting with paper and pencil is much cheaper than a computerized
system, which requires a machine and software. Other expenses associated with
accounting software include training and program maintenance. Expenses can add up
fast with costs for printers, paper, ink and other supplies.

Backup
All transactions can be saved and backed up, in case of fire or other mishap. You
cannot do this with paper records, unless you make copies of all pages--a long and
inefficient process.
AUTOMATED SYSTEMS
8 Benefits of Automated Systems

1. Eliminate the manipulation of paper documents.

2. Utilize employee time better.
3. Define business processes.
4. Make better projections
5. Identify unused resources.
6. Allow new business opportunities.
7. Save money, even while sleeping.
8. Easily manage decentralized teams in different time zones.

4 Challenges of Automated Systems

9. Integration compatibility of the system

10. Return on investment
11. Complexity
12. Security
ROBOTICS
Components of Robotics

1. Power Source - robots need power to supply the voltage signals that make the motors turn, the sensors
operate and therefore the robot brain.

2. Actuation - are the "muscles" of a robot, the parts which convert stored energy into movement.

3. Sensing - allow robots to receive information about a certain measurement of the environment, or internal
components.

4. Manipulation - refers to an agent’s control of its environment through selective contact.

5. Locomotion - he collective name for the various methods that robots use to transport themselves from place
to place.

6. Environmental Interaction and Navigation - robots require some combination of navigation hardware and
software in order to traverse their environment.

7. Human-Robot Interaction - is a multidisciplinary field with contributions from human–computer interaction,

artificial intelligence, robotics, natural language understanding, design, and psychology.
ROBOTICS
Applications of Robotics

• Military robots
• Industrial robots
• Cobots (collaborative robots)
• Construction robots
• Agricultural robots
• Medical robots of various types
• Kitchen automation
• Robot combat for sport
• Cleanup of contaminated areas
• Domestic robots
• Nanorobots
• Swarm robotics
• Autonomous drones.
• Sports field line marking