AKGEC/IQAC/QP/03

AJAY KUMAR GARG ENGINEERING COLLEGE, GHAZIABAD

DEPARTMENT OF MECHANICAL ENGINEERING

Sessional Test – 1 - Solution

Section-A

A. Attempt all the parts. (3x2 = 6)

1. Automation vs Industrial Automation

Aspect Automation Industrial Automation

Definition Technology for task automation. Automation in industrial processes.
Scope All sectors Focused on industries.
Examples Smart homes, AI, robotics. PLCs, SCADA, CNC machines.
Objective Efficiency and convenience. Productivity and quality in industries.
Technology AI, IoT, Robotics, etc. PLCs, SCADA, DCS, Robotics.
Cost Low to high. High initial investment.
Human Involvement Low to Moderate. Minimal in operations.

2. Identify the key components of a typical automated system.

The key component of a typical automated system includes:

i. Sensors - to collect data from the environment
ii. Controllers - like PLCs or microcontrollers, to process the data and make decisions
iii. Actuators - to perform physical actions, such as motors or valves), and
iv. Human-Machine Interface (HMI) - to monitor and control the system.

These components are interconnected through communication networks and work together to ensure
efficient and precise operation.

3. Explain the difference between an open-loop and a closed-loop system.

Aspect Open-Loop System Closed-Loop System

A system where the output has no effect on A system where the output is fed back to influence
Definition
the control action. the control action.
Feedback is present to compare output with the
Feedback No feedback is present.
desired input.
Accuracy Less accurate as it cannot correct deviations. More accurate due to self-correction via feedback.
Complexity Simple in design and implementation. More complex in design and implementation.
Electric toaster, washing machine (timed), Air conditioner (thermostat-based), automatic
Examples
traffic lights. cruise control.
 Section-B

B. Attempt all the parts. (3x4 = 12)

4. Describe the various levels of automation in industrial processes.

5. Analyze how Industry 4.0 has influenced the role of automation in modern manufacturing.

 Industry 4.0 has revolutionized the role of automation in modern manufacturing by integrating
cutting-edge technologies such as the Internet of Things (IoT), Artificial Intelligence (AI), and
Cyber-Physical Systems (CPS).
 Automation is no longer limited to repetitive tasks but has evolved into an intelligent,
interconnected system that drives real-time decision-making and process optimization. Smart
factories leverage IoT-enabled devices to enable seamless communication between machines,
enhancing operational efficiency and flexibility.
 AI-powered systems and big data analytics are now used to predict machine failures, optimize
workflows, and enable mass customization, aligning manufacturing with dynamic customer
demands.
 Additionally, advanced robotics, including collaborative robots (cobots), are improving
productivity while fostering safe human-machine collaboration. Automation also supports
remote monitoring and control via cloud computing, ensuring uninterrupted production.
Moreover, it promotes sustainability by reducing energy consumption and waste.
 Overall, Industry 4.0 has transformed automation into a cornerstone of smart, efficient, and
adaptive manufacturing processes, bridging the gap between technology and human-centric
innovation.
 Aspect Impact of Industry 4.0 on Automation
Automation now includes CPS, where physical manufacturing processes are
Integration of Cyber-
integrated with computational algorithms, enabling real-time monitoring and
Physical Systems (CPS)
control.
Automation systems are now equipped with IoT-enabled devices, allowing
Smart Factories seamless data exchange and interconnected machinery for higher efficiency and
flexibility.
Industry 4.0 has driven the adoption of advanced robotics, such as collaborative
Increased Use of Robotics
robots (cobots), that work alongside humans, enhancing productivity and safety.
Automation systems now use big data analytics to predict machine failures,
Big Data and Predictive
optimize operations, and minimize downtime, leading to more proactive
Analytics
maintenance practices.
AI-powered automation enables decision-making and adaptability in
Artificial Intelligence (AI) manufacturing processes, allowing systems to learn and optimize based on
historical data.
Automation is now geared toward flexible manufacturing, allowing mass
Personalization and
Customization
customization of products tailored to individual customer demands without
slowing production.
Automated systems integrated with IoT and blockchain improve supply chain
Supply Chain Automation
transparency, inventory management, and logistics.
Automation technologies now focus on minimizing energy consumption and
Energy Efficiency and
Sustainability
reducing waste, aligning with Industry 4.0's emphasis on sustainable
manufacturing practices.
Automation has shifted to include human-centric design, where systems assist
Human-Machine
Collaboration
workers rather than replace them, enhancing roles through augmented reality
(AR) and AI tools.
Industry 4.0 enables automation systems to be controlled and monitored remotely
Remote Monitoring and
via cloud computing, ensuring uninterrupted production and operational
Control
visibility.

6. Describe the differences between fixed, flexible and programable automation.

Automation of production systems can be classified into three basic types:

1. Fixed automation (Hard Automation)
2. Programmable automation (Soft Automation)
3. Flexible automation.

1. Fixed automation (Hard automation): Fixed

automation refers to the use of special purpose
equipment to automate a fixed sequence of
processing or assembly operations. Each of the
operations in the sequence is usually simple,
involving perhaps a plain linear or rotational
motion or an uncomplicated combination of two. It
is relatively difficult to accommodate changes in
the product design. This is called hard automation.
Advantages:
1. Low unit cost
2. Automated material handling
3. High production rate.

2. Programmable automation (Soft Automation): In programmable automation, the production equipment is

designed with the capability to change the sequence of operations to accommodate different product
configurations. The operation sequence is controlled by a program, which is a set of instructions coded. So that
they can be read and interpreted by the system. New programs can be prepared and entered into the equipment
to produce new products.

Advantages:
1. Flexible to deal with design variations.
2. Suitable for batch production.

Disadvantages:
1. High investment in general purpose equipment
2. Lower production rate than fixed automation.
Example: Numerical controlled machine tools, industrial robots and programmable logic controller.

3. Flexible automation: Flexible automation is an extension of programmable automation. A flexible

automation system can produce a variety of parts with virtually no time lost for changeovers from one-part style
to the next. There is no lost production time while reprogramming the system and altering the physical set up.

Advantages:
1. Continuous production of variable mixtures of product.
2. Flexible to deal with product design variation.
 Section-C

C. Attempt all the parts. (1x7 = 7)

7. Explain three situations in which manual labor is preferred over automation. write the benefits of
industrial automation
Situations Where Manual Labor is Preferred Over Automation
1. High Customization or Artistic Work:
In industries like fine arts, handcrafted furniture, or luxury goods production, manual labor is essential
for tasks that require creativity, intricate detailing, and personalization. Automation lacks the flexibility
to replicate the uniqueness and emotional touch of handcrafted products.
2. Low Production Volume:
When manufacturing involves small batch sizes or one-off production, manual labor is more cost-
effective. Automating such processes can require significant investment in machinery and programming,
which may not justify the limited production output.
3. Dynamic or Unstructured Environments:
In scenarios like construction sites or disaster recovery operations, where the environment is
unpredictable and constantly changing, human workers are preferred due to their ability to adapt, think
critically, and make real-time decisions that automated systems cannot yet handle effectively .
Benefits of Industrial Automation
1. Increased Productivity:
Automation enables continuous, 24/7 operation, eliminating downtime associated with human labor,
thereby boosting production capacity.
2. Improved Quality and Consistency:
Automated systems maintain precision and reduce errors, ensuring consistent product quality, which is
challenging to achieve with manual labor.
3. Cost Efficiency:
Although initial investment in automation is high, it significantly reduces long-term operational costs by
minimizing waste, errors, and reliance on manual labor.
4. Enhanced Worker Safety:
By automating hazardous tasks, such as handling toxic chemicals or working in extreme environments,
automation reduces the risk of workplace injuries.
5. Scalability and Flexibility:
Automation allows manufacturers to scale up production quickly and adapt to changing market demands
by reprogramming machines rather than hiring or training new workers.
6. Data-Driven Decision Making:
With the integration of IoT and AI, industrial automation systems provide real-time data analytics,
enabling predictive maintenance, performance monitoring, and process optimization.