ASSIGNMENT

Course Code MEE403A

Course Name Automation in Manufacturing
Programme B – TECH
Department MECHANICAL
Faculty FET

Name of the Student MANOJ SP

Reg. No 16ETME005311

Semester/Year 6th / 3rd

Course Leader/s Sandeep N

i
 Declaration Sheet
Student Name MANOJ SP
16ETME005311
Programme B-TECH Semester/Year 6th / 3rd
Course Code MEE403A
Course Title Automation in Manufacturing
Course Date To
Course Leader Sandeep N

Declaration

The assignment submitted herewith is a result of my own investigations and that I

have conformed to the guidelines against plagiarism as laid out in the Student
Handbook. All sections of the text and results, which have been obtained from
other sources, are fully referenced. I understand that cheating and plagiarism
constitute a breach of University regulations and will be dealt with accordingly.

Signature of the
Date
Student
Submission date
stamp
(by Examination &
Assessment Section)
Signature of the Course Leader and date Signature of the Reviewer and date

ii
 Faculty of Engineering and Technology
Ramaiah University of Applied Sciences
Department Mechanical and Manufacturing Programme B.Tech in Mechanical
Engineering Engineering
Semester/Batch 6th /2016
Course Code MEE403A Course Title Automation in Manufacturing
Course Leader Sandeep N

Assignment – 01
Name of
Reg. No.
Student
Marks

Max Marks
First
Marking Scheme
Sections

Examiner Moderator
Marks

A1.1 Introduction to automation hierarchy 1

Challenges in selection of automation
A1.2 3
technologies
Part-A

A1.3 Conclusion 1
Part-A Max Marks 05
B1.1 Relevance of FMS in manufacturing 02
Major Challenges and opportunities for FMS
B1.2 06
Part B 1

adoption
B1.3 Concluding remarks 02
Part-B 1 Max Marks 10
B2.1 Description of the machine and its functions 02
Selection of any two functions that can be
B2.2 02
Part B 2

automated with justification

Description of the proposed automation
B2.3 04
solutions
B2.4 Discuss the benefits of the proposed solution 02
10
Total Assignment Marks 25

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Course Marks Tabulation
Component- 1 (B) First Moderat
Remarks Remarks
Assignment Examiner or
A
B.1
B.2
Marks (Max 25 )

Signature of First Examiner

Signature of Moderator

Please note:
1. Documental evidence for all the components/parts of the assessment such as the reports,

photographs, laboratory exam / tool tests are required to be attached to the assignment
report in a proper order.
2. The First Examiner is required to mark the comments in RED ink and the Second

Examiner’s comments should be in GREEN ink.

3. The marks for all the questions of the assignment have to be written only in the

Component – CET B: Assignment table.

4. If the variation between the marks awarded by the first examiner and the second

examiner lies within +/- 3 marks, then the marks allotted by the first examiner is
considered to be final. If the variation is more than +/- 3 marks then both the examiners
should resolve the issue in consultation with the Chairman BoE.

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Part A

“Selection of automation technologies for a manufacturing company”

ABSTRACT:
The oil and gas industry will continue to boom in the coming few decades. Obtaining oil and
gas from conventional and non-conventional resources will become more and more
challenging.
Our objectives are to identify potential applications and research directions of robotics and
automation in the oil & gas field and explore the obstacles and challenges of robotic and
automation applications to this area.
 This study performs the necessary survey and investigation about the work conditions
of robotics and automation equipment in the oil and gas industry, especially offshore
oil rigs.
 The challenges and requirements are identified for robotics and automation
equipment in the oil and gas industry.
A1.1 Introduction to automation hierarchy
The five levels of automation can be identified, and their hierarchy is depicted in Figure 1.1:

 Device level. This is the lowest level in the automation hierarchy. It includes the
actuators, sensors, and other hardware components that comprise the machine level.
The devices are combined into the individual control loops of the machine

 Machine level. Hardware at the device level is assembled into individual machines.
Examples include CNC machine tools powered conveyors, and automated guided
vehicles.

 Cell or system level. This is the manufacturing cell or system level, which operates
under instructions from the plant level.

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  Plant level. This is the factory or production systems level. It receives instructions from
the corporate information system and translates them into operational plans for
production.

 Enterprise level. This is the highest level, consisting of the corporate information
system. It is concerned with all of the functions necessary to manage the company:
marketing and sales, accounting, design, research, aggregate planning, and master
production scheduling.

A1.2 Challenges in selection of automation technologies for a chosen application

The challenges faced by oil and gas industry during implement of robotics and automation in
offshore oil & gas environments.

The work conditions on offshore installations are the first thing to look at when analyzing the
environments. The most important ones are as follows:

• Atmosphere
• Unsheltered maritime environment: Except for the living quarters and a few technical
rooms offshore platforms are partially sheltered and unsheltered. This means there is no
sufficient protection against saltwater spray and direct sun light which is also reflected from
the sea surface.

After implementation of robotics and automation, there are scheduled and occasional
operations. The scheduled operations are tasks planed in the daily operation schedule. They
are:

• Inspection: gauge readings

• Monitoring: gas level, check for leakage,
• Maintenance: gas and fire detector test,
The most frequent occasional operations are:
 Valve and lever operation: change pressure, change flow rate and start or stop
equipment operation.
 Gas leakage: identify and locate, stop dangerous operations (welding, cutting,)
 Fire: identify and locate fire.

Most important challenges are:

Requirements for Hardware Development: In order to be suitable for dependable and useful
offshore operations, the following basic requirements must be met by the hardware of the
mobile inspection and manipulation robots.

Requirements for Software Development

A mobile robot for inspection and manipulation in offshore environments may only be
acceptable if it can be used without expert knowledge but rather easily and intuitively as a
daily-used tool. This implies that:
• The robot can be controlled manually, semi-automatically and autonomously;
• New inspection and manipulation tasks can be programmed quickly and without the
assistance of specialists;
• Anyone working next to the robot can interact with it safely.

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These are main challenges that oil and gas industry faces during implement of robotics and
automation in offshore oil & gas environments. But with the challenges it has its own
advantages

 There is little doubt that the oil & gas companies would benefit greatly from the use of
more intelligent technologies, not only increasing their efficiency, but also cutting
down on human risk factors that are ever present in rig environments.
 There is a clear incentive for oil and gas companies to automate their oil and gas
facilities, starting with isolated operations, such as pipe handling and assembly for
drilling and tasks related to rig operations.
 These examples represent high-risk operations for humans and therefore provide
opportunities to improve health, safety and environmental (HSE) performance.
 In addition to productivity and efficiency gains, robots used for high-risk tasks will also
lead to improvements in HSE performance.

A1.3 Conclusion
By seeing above details we can say that selection of automation technologies plays an
important role in a manufacturing company:
If proper automation technologies is used for any application or process it improves
1. Efficiency and productivity
2. Reduces time consumption
3. Less hazardous to human
4. Less error, etc.

Part –B
Abstract
Flexibility in manufacturing system is one of the most important issues of present scenario, to
fulfill the desired customer’s requirement & getting low cost and high quality of product that
enforced to adopting the flexible manufacturing system for various modern manufacturing
enterprises.
 The basic of FMS is to convert & increases positivity throughout the manufacturing
process for achieving higher productivity and best quality of product.
 This paper highlights the merits, demerits, application of FMS and also why In spite of
such benefits, the world population of FMS is decreasing year on year.

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B1.1 Relevance of FMS in manufacturing
The principle objectives of FMS are
1. To improve operational control through:
 Providing tools to recognize and react quickly to deviations in the manufacturing plan
2. To reduce direct labor:
 Removing operators from the machining site
 Eliminating dependence on highly skilled machines (their manufacturing skills can be
better Utilized in manufacturing engineering functions).
3. To improve short run responsiveness consisting of:
 Engineering changes
 Processing changes
 Machining downtime or unavailability
 Late material delivery
4. To improve long-run accommodations through quicker and easier assimilation of:
 Changing product volumes
 New product additions and introductions
 Increase Machine Utilization by:
 Eliminating machine setup
 Utilizing automated features to replace manual intervention
 Reduce inventors by:
 Reducing lot sizes
 Providing the planning tools for JIT manufacturing

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B 1.2 Major Challenges and opportunities for FMS adoption for chosen application
The various advantages and disadvantages of FMS implementation are
1. Advantages:
 Faster, lower-cost changes from one part to another which will improve capital
utilization
 Lower direct labor cost, due to the reduction in number of workers
 Reduced inventory, due to the planning and programming precision
 Consistent and better quality, due to the automated control
 Savings from the indirect labor, from reduced errors, rework, repairs and rejects

2 Disadvantages:
 Limited ability to adapt to changes in product or product mix (ex. machines are of
limited capacity and the tooling necessary for products, even of the same family, is not
always feasible in a given FMS)
 Substantial pre-planning activity
 Expensive, Sophisticated manufacturing systems

Case study:
1. The Hattersley Newman Hender (H.N.H.) F.M.S.: -
This company is located at Ormskirk, U.K.
Why they prefer FMS?
Manufactures high and low pressure bodies and caps for water, gas and oil valves. These
components require a total of 2750 parts for their manufacture. That is why they decided to
go for the system of F.M.S. to fulfil their machining requirements in a single system.
Their F.M.S. consists of primary and secondary facilities.
The primary facilities include 5 universal machining centers & 2 special machining centers.
The secondary facilities consist of tool setting and manual workstations.

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 Fig: 1.3 System layout and facilities
Secondary facilities: -
1. Auxiliary stations: -
 Load/unload stations
 Fixture-setting station
 Administration of tools
2. Auxiliary facilities: -
 Transport system
 Buffer stores
 Maintenance Area
 Raw Material Stores

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 2. The Vought workshop F.M.S.

Reasons for an Adopting F.M.S:

The Vought Aerospace plant located at Dallas makes two elements for the B-1 Bomber
fuselage which is made up of some 2000 machined parts, 600 of which are suitable for
reduction in an F.M.S.
 This programme is somewhat shorter than the majority of American aerospace
production runs which often require 1000s of parts.
 This presented a problem to the company since it is not profitable to introduce
specialised equipment for such short runs. So the company decided to develop an
F.M.S. for this particular project.

Figure 1.4: - Installation plan of the Vought workshop F.M.S

Courtesy: - Flexible Manufacturing Systems in Practice, Bonetto

The implementation of F.M.S. brought the following benefits to the company: -

 The manufacturing process of the parts on traditional machines took about 200,000
hours. It same set of machining operations could be accomplished on the F.M.S. in
about 70,000 hours. Thus it reduced the manufacturing time by 65%.
 The total cost of installation of the F.M.S. was about 15 million dollar. The operation of
the F.M.S. in a period of three years resulted in an estimated saving of 25 million
dollars. This represents a return of 40% on the initial investment.
 The whole workshop occupies an area of 2,800 square metres, which is relatively small
as compared to that of the traditional workshops of the same capacity

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B1.3 Conclusions
In spite of such benefits, the world population of FMS is decreasing year on year in India
because
Indian Context
Some companies in India have adopted F.M.S. technology for its operations. However
this technology is still not widely implemented in India. For the Indian industries to
sustain itself and compete in the global market it is necessary that they adopt some
new generation manufacturing process like F.M.S.
 For this to happen the Government should also take an active part
in encouraging the development of F.M.S. in India.
 If everything goes on proper way F.M.S. technology will be able to
fulfil the needs of the industry quite successfully. Therefore,
implementation of F.M.S. will benefit both the Manufacturer and
the Consumer.

B2
B2.1Description of the machine and its functions

FIG: 2.1 drilling machine

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FUNCTIONS:
1. Head
The head part of the drill press houses the spindle as it is attached at the top region of the
spindle. It is responsible for the spindle movement because the spindle can only move upward
or downward
2. Spindle
Spindle is the most important part of the drill press that is used to hold the tool and is
responsible for its rotation.
•The spindle of the tool is held with the help of arm that is gripped with the column. In
order to keep the spindle in its place, the manufacturer has used a spindle return
spring and the spindle moves up and down easily.
•The weight of the spindle is very useful in the performance of the drill press as
counter balances the spindle spring. At the bottom side of the spindle, chuck is placed
and this chuck is used to hold the drill bit in place.
3. Column
The column of the drill machine is used to tie the table. The work is hold in place by the table
during the drilling process.
 It is a long rod in shape that stands vertical with the table. Both the column and the
tables are placed at the 90 degree with each other.
4. Table
Table is also one of the best parts of the drill press. This is used to hold the working material in
place. It is adjusted right at 90 degree to the column.
 It can be moved upward, downward and rotated around the column as required. The
shape of the table does not matter. You can make a round shape or a rectangular
shape table for your drill press.

5. Base
The base of the drill press is made up of the steel or iron.
 The main function of the base of the drill press is used to support the column and
stabilize it. With the help of the base or the foot, the drill press can be placed in the
upward direction.

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6. Power transmission
The part of the drill press that is used to transmit the power for its working is known as the
power transmission.
• This power is supplied from the electric motor. The process of transmission
takes place with the help of the v-bolt and the pair of pulley stacks opposite
to each other.
• The speed of the spindle is fixed or controlled with the help of the pulley
stacks.

OPERATIONS PERFORMED ON DRILLING MACHINE

1. Drilling 2. Reaming
3. Boring 4. Counter boring
5. Countersinking 6. Spot facing
7. Tapping 8. Lapping
9. Grinding 10. Trepanning.

TYPES OF DRILLING MACHINE:

(1) Portable drilling machine
(2) Sensitive drilling machine
(3) Upright drilling machine
(4) Radial drilling machine
(6) Multiple spindle drilling machine
(7) Automatic drilling machine

B2.2Selection of any two functions that can be automated with justification

The two functions that can be automated in a conventional drilling machine are:
1. Drilling of blind holes can be automated
2. Changing of Reaming tool after drilling can be automated

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Justifications:

1. Drilling of blind holes normally cannot be possible even if it can it cannot provide
accurate dimensions therefore if it is automated it can be done easily.
2. The changing of tool will take too much time for next process if it is automated it can
be time saver.
B2.3 Description of the proposed automation solutions with block diagram and flow chart
The block diagram and flow chart of proposed automation solution:
1.

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B2.4 Discussion on the benefits of the proposed solution
The benefits of proposed solution are:
• Overall accuracy of product is improved
With conventional drilling machines the accuracy of product cannot be obtained because
human cannot operate 100% perfect efficiently therefore there are some error induced while
operating which effects the product but with automation it can
• Precision
• Less time consumption

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References:
 Groover MP. Automation, Production Systems, and Computer- Integrated
Manufacturing. 3rd ed. Essex (UK): Pearson; 2014.
 Handbook of Flexible Manufacturing Systems.
 Flexible Manufacturing, David Parrish.

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