Statement of the Problem:

We are facing slow and reduced production, increased overhead cost and time is being wasted in manual record keeping.

Purpose and Scope:

The purpose of this report is to maximize our production facility, to minimize our running cost and to get instant report on production status. The study will also highlight the benefits of automation production plant and minimum man power involved in production.

Source of Data collection:

Data collected from organization by using following methods: 1. Questionnaire 2. Interview

Table of Content
1-Brief Introduction of Automation 2-Advantages 3-Disadvantages 4-Document Automation 5-Automation in Different Departments a- Production Dept. b- Quality Dept. c- Maintenance Dept. d- Enterprise Information e- Engineering Dept. f- Manufacturing Dept. 6-Analysis 7-Implementation a-Phase 1 - Unit Automation b-Phase 2 Process Cell Automation

Brief Introduction of Automation

Automation (industrial automation, numerical control) is the use of control systems such as computers to control industrial machinery and processes, reducing the need for human intervention. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the physical requirements of work, automation greatly reduces the need for human sensory and mental requirements as well. And processes and systems can also be automated. Nowadays automation plays an increasingly important role in the global economy and in daily experience. Engineers strive to combine automated devices with mathematical and organizational tools to create complex systems for a rapidly expanding range of applications and human activities.

AUTOMATION- ADVANTAGES
1. Replacing human operator in tedious task. 2. Replacing humans in tasks that should be done in dangerous environment. 3. Making tasks that are beyond human capabilities such as handle too heavy loads, too large objects, too hot or cold substances or the requirement to make things too fast or too slow. 4. Economy improvement- sometimes some kinds of automation imply improves in economy of enterprises, society or most of the humankind.

DISADVANTAGES
1. Technology limits- nowadays technology is not able to automatize all desired task. 2. Initial costs are relative high.

Document Automation:
Automatically Produce Personalized Documents: Organizations can produce fully personalized documents quickly and efficiently. Using database publishing methods provides the ability to automatically generate documents using computer databases and programmed documents or templates. Benefits of Document Automation:
y y y y y y y

Produce documents in high volume Create fully customized documents Increase productivity and lower cost Eliminate errors Improve document consistency Simplify the production process Focus more on your business and not documents

Automation in Different Departments

Production Dept. Real time production status: manufacturing status is updated in real time in direct communication to operator and control device Production schedules: production schedules can be viewed and updated directly Production information management: production specific information is distributed to all Quality Dept. Data integrity and quality control is improved by using a common interface It is an open platform for statistical analysis

Consolidation of manufacturing and lab data Maintenance Dept. Improved troubleshooting and de-bugging: direct connection to wide variety of devices, displays improves troubleshooting reduces diagnostic/debugging time Plant can be viewed remotely. Notification can include pagers, e-mails and phones. Co-ordination between maintenance and management reduces unscheduled downtime. Enterprise Information Corporate information and real time production data can be gathered and viewed from anywhere within operations User specific information ensures better informed decisions Data exchange with standard databases and enterprise systems provides integrated information solutions Engineering Dept. Integrated automation solutions reduce design and configuration time Common configuration platform offers flexibility for constant configuration in all areas

Capable of connecting to wide variety of systems. Reduces start up time and system training with industry proven open interfaces Manufacturing Dept. Unscheduled down time is reduced due to swift alarm detection and event driven information Makes operations easier and more repeatable with its real time functionality Secured real time operation are maintained with windows

Analysis:
Our company have forty-eight factory workers on three different shifts and closes on weekends, for example, can save thousands of dollars with industrial automation. This is particularly true if weekend work is necessary, which means overtime pay of time and a half must be paid for Saturday work and double-time for Sunday. This equates to an additional twelve hours of pay per employee. Of course, life insurance, 401K benefits, dental insurance, health insurance, pension coverage, and disability also contribute to the expense. Industrial automation can eliminate the need for all forty-eight jobs. The robotic machinery used for industrial automation may only involve a monthly payment until the machinery is paid for, a couple technicians to keep the robotic machinery running, and electricity costs. Unfortunately for workers, industrial automation can eliminate thousands of jobs. As the workforce decreases and the cost of living increases, many families struggle to make ends meet as their jobs are replaced by high-tech machines.

Implementation
Phase 1 - Unit Automation The first step in integration requires that some level of plant automation has taken place. It is important to build your automation system using highly reliable industry-hardened PLC's and automation equipment. The automation system should be based on non-proprietary based controllers/software and the PLC's and HMIs should be Ethernet capable devices. The data received at the Business Information Systems is only as good as the devices wired to the PLCs, in other words, if the transmitter of a particular parameter is faulty, then there is no use sending that particular parameter since it is not accurate. So we have to eliminate all possible sources of error in the field devices and automation equipment Phase 2 Process Cell Automation Once the basic automation is in place, the next step is to install PLCs/HMIs to control different process cells. Each cell would be a logical or geographical grouping of equipment or area of the plant. For example, a typical flour mill may be broken into the follow process cells: Elevators/Storage Cleaning House Flour Mill Flour Storage/Loadout By-Products Storage/Loadout Each process cell shares information with one another over the Ethernet Network. The different process cells work together over the common network as

one automated production system. This is a network of PLCs communicating through Ethernet.

Conclusion:
Automation (industrial automation, numerical control) is the use of control systems such as computers to control industrial machinery and processes, reducing the need for human intervention. By automation we can control our documentation machinery. All data of employees and inventory is stored by software. Reports bills are generated by computer.