Semester-V, BBA, 2012-15

Automation
Prof. Biranchi Prasad Panda
KSOM, KIIT University

Concept
AUTOMATION is a technology concerned with the
application of mechanical, electronic, and computerbased systems to operate and control production.
Manual Mechanical (motorized, pneumatic, hydraulic) Electromechanical Computerized/Digital Automatic

Example (Automatic Plant) :

Processing of parts by automatic machines (Pharmacy-tablet

Mfg.)

Automatic assembly machines

Operation with the use of robots

Automatic material handling and storage systems

Automatic (Computerized) inspection and quality control

Reasons for Automation

Increase in productivity
Increasing labor cost
Shortage of labor
Shifting trend of labor towards service
sector
Safety
Repeatability, accuracy, customization
Consistent quality
Reducing Mfr. lead time
Time and cost of material handling in
processes
Cost of manual (non-automatic) work

Automation
Advantages

Disadvantages

Timely and faster

Safe working condition
Lower cost of production

intelligence (transfer)

Better (consistent) quality

Talent suppression

Indirect jobs (less in no. but,

highly paid ones)
Systems Engineers,
Programmers, Computer
Operators

Increased productivity

Machines own the human

Reduced labor force

Unemployment
Reduced purchasing power

Automation Strategies
(to improve productivity through manufacturing operation technologies)

Specialization of operations
Combined operations (sequential)
Concurrent operations (parallel)
Integration of (above) operations
Higher flexibility
Better material handling and storage (systems)
On-line inspection
Better process control (optimization)
Better plant operations and maintenance
Computer-Integrated Manufacturing (CIM)

Types of Automation
Fixed automation
Integration and coordination of sequential operations
High investment for custom-engineered product/equips.
High production rates

Programmable automation
Capable to accommodate changes
Accurately repetitive products, processes or services
Suitable for batch-production

Flexible automation
Capability of producing variety of parts
Easy to alter the physical set-up (tools, fixtures,
machine setting)
Capable to handle product-mix continuously
Easy to redesign/ reengineer a product or process
design

Production
Automation

Number of
Different
Parts

Product Variety

High

Flexible
Automation

Programmable
Automation

Middle

Low

Manual
Methods
Low

Fixed Automation

Middle

High

Product Volume

Parts per
year

Computer Integrated
Manufacturing (CIM)
CAD (Computer-Aided Design)
CAD for design automation

CAM (Computer-Aided
Manufacturing)
CAM for manufacturing automation

CAE (Computer-Aided Engineering)

CAE for automatic inspection and QC

CIM - for complete automation

Automated Flow Lines

Manual Mechanical (motorized, pneumatic, hydraulic)
Electro-mechanical Computerized/Digital Automatic

Several machines or workstations linked by workhandling devices or transfer mechanisms

Reduce labor cost
Increase production rate
Reduce WIP (work-in-progress or in-process inventory)
Minimum movements of parts and people
Specialization of operations
Integration of operations

Work flow can be

In-line type
Rotary type

Automated Guided Vehicle

Systems (AGVS)
These are material handling systems (MHS)
independently operated, self-propelled,
guided by defined paths and programs
Use of
On-board batteries-operated
Cabled or Embedded wiring
Reflective painting
Sensory devices

Types of AGVS
Driverless trains
Pallet trucks
Unit load carriers

Automated Storage/ Retrieval

Systems (AS/RS)
A combination of equipments and controls for storage and
retrieval purpose
Customized or defined
Accurate and precise
Timely

Components of the AS/RS system

Storage structure
Storage module (e.g. pallets and bins)
P&D (pick and drop/deposit)
Robots and manipulators

Types of AS/RS
Unit load AS/RS
Miniload AS/RS
Man-on-board AS/RS
Automated item-retrieval (using bar code)
Deep-lane AS/RS

Carousel Storage Systems

It is a series of bins or baskets fastened to carrier that are connected
together and revolve around a long, oval track system to perform cyclic
operations.
Suitable for medium to large industry.

Usually mechanized where loading and unloading are

done manually or activated (powered) to deliver at the a
workstation
Size ranges in 10-100ft.
When the size is long, the storage density is high
Transaction time can be managed by carousel size or load
Offers relatively high throughput rate
Often applied to mini-load AS/RS for
Storage and retrieval (e.g. pick and load in a tool room)
Transportation and accumulation (e.g. distribution or sorted storage)
Unique applications (for a specific period/ project)

Sample Questions
(Assignment - 3 , Due Date: 8 September-2014)

1. What do you mean by automation?

Explain.
2. Give five examples of automation
and explain what type of automation
is involved there.
3. Do a self-study on Levels of