Module 1: Introduction

Basic Concepts of Automation

Definition:
In an Industrial Context, we can define Automation as a technology that is concerned with the use of
mechanical, electronic, and computer based systems in the operation and control of production.
e.g. Transfer lines, mechanized assembly machines, feedback control systems (Applied to industrial
processes), numerically controlled machine tools and robots.
Accordingly Robotics is a form of Industrial Automation.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
Types of Industrial Automation
1. Fixed Automation (Hard Automation)
2. Programmable Automation
3. Flexible Automation (Soft Automation)

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
1. Fixed Automation
• It is used when the volume of production is very high.
• It is therefore appropriate to design specialized equipment to
process the product (or a component of a product) very
efficiently and at high production rates.
• Automotive Industry is a good example of fixed automation.
• Highly integrated transfer lines consisting of several dozen
workstations are used to perform machining operations on
engine and transmission components.
• The cost of the special equipment can be divided over a large no
of units, and the resulting unit costs are low relative to
alternative methods of production.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
Problems with Fixed Automation
• Since the initial investment cost is high, if the volume of
production turns out to be lower than anticipated, then the unit
costs become greater than anticipated.
• Equipment is specially designed to produce the one product, and
after the product’s life cycle is finished, the equipment is likely
to becomes obsolete.

Note: For products with short life cycles,

the use of fixed automation represents a
big gamble.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
2. Programmable Automation
• It is used when volume of production is relatively low and there are a
variety of products to be made.
• The production equipment is designed to be adaptable to variations in
product configurations.
• The adaptability feature is accomplished by operating the equipment
under the control of a ‘program’ of instructions which has been prepared
specially for the given product.
• The program is read into the production equipment, and the equipment
performs the particular sequence of processing (or assembly) operations
to make that product.
• Cost of the programmable equipment can be spread over a large no of
product even though the products are different.
• Because of the programming feature, the resulting adaptability of the
equipment, many different and unique products can be made
economically in small batches.
Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by
Groover
 Module 1: Introduction
Basic Concepts of Automation
3. Flexible Automation
• Most suitable for Mid Volume production range.
• Flexible systems possess some of the features of both fixed and
programmable automation.
• It must be programmed for different product configurations, but the
variety of configurations is usually more limited than for programmable
automation.
• Flexible automation systems typically consist of a series of workstations
that are interconnected by a materials handling and storage system.
• A central computer is used to control the various activities that occur in
the system, routing the various parts to the appropriate stations and
controlling the programmed operations at the different stations.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
3. Flexible Automation

• One of the features that distinguishes programmable automation from flexible

automation is that with programmable automation, the products are made in
batches. When one batch is completed, the equipment is reprogrammed to
process the next batch.
• With flexible automation, different products can be made at the same time on
the same manufacturing system. This feature allows a level of versatility that is
not available in pure programmable automation.
• This means that products can be produced on a flexible system in batches if
desirable or several different product styles can be mixed on the system.
• The computational power of the control computer is what makes this versatility
possible.
Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by
Groover
 Module 1: Introduction
Basic Concepts of Automation

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics by

Groover
 Module 1: Introduction
Basic Concepts of Automation
Reasons for Automation:
1. Increase in Productivity: Automation of an operation usually increases production rate and output per labor
hour.
2. Reduction of Labor Cost: As labor cost increases, economics tends to force a substitution of automated
equipment for labor. Because production rate is usually increased and labor cost is reduced by use of
automated equipment, the unit cost of product is reduced.
3. Labor Shortages: In many industrialized nations, there is a labor shortage (e.g., Japan and Germany), forcing
these countries to increase production by seeking alternatives to the use of labor. Automation is such an
alternative.
4. Trend of Labor Toward the Service Sector: In the United States, labor shortages have not been a problem as
in other industrialized countries. However, in the United States, there is a general trend toward employment in
the service sector and lower employment levels in manufacturing. The growth of government employment as
well as insurance, personal services, entertainment, legal, sales, etc. has resulted in a largely service economy
in the United States. One of the reasons is that people tend to view factory work as demeaning and desirable.
Implementation of automation in manufacturing has contributed to this trend.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Basic Concepts of Automation
Reasons for Automation:
5. Safety: Automation of a production operation tends to remove the human from direct participation in the
operation. This improves safety in potentially dangerous production situations. The Occupational Safety and
Health Agency (OSHA) has motivated the automation of unsafe jobs.

6. High Cost of Materials: Higher levels of efficiency in processing of raw materials requires tighter controls in
manufacturing, which can often be achieved through automation.

7. Improved Quality: Automated production usually achieves greater consistency in processing. Consistency is one
measure of product quality. Automobile companies have achieved significant gains in product quality through the
automation of certain critical assembly processes such as robotic spot welding of car bodies.

8. Reduction of Manufacturing Lead Time: Manufacturing lead time is the time between customer order and
delivery of the finished product. Automation usually means less time to produce the product, leading to greater
customer satisfaction and a competitive advantage in manufacturing.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Basic Concepts of Automation
Reasons for Automation:
9. Reduction of Work-in-Process: Work-in-process is product in the factory either being processed or between
processing operations. It is inventory that represents an investment cost to the manufacturer that cannot be
recovered until the product is shipped. Automation tends to reduce work-in-process by reducing the time the
product spends in the factory. Reducing manufacturing lead time reduces work-in-process.

10. Increase in Flexibility: The increase of flexibility is of growing concern to manufacturers: flexibility to
change quickly over from one product to another and flexibility to accommodate new products. With
programmable automation, these flexibilities can be achieved.

11. High Cost of Not Automating: There is a competitive advantage in automating a manufacturing plant. The
advantage often shows up in sometimes intangible ways, such as improved quality, higher sales, better labor
relations, and better company image. Companies that do not automate often find themselves at a competitive
disadvantage with their customers, their employees, and the general public.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Basic Concepts of Automation
Advantages of Automation:
1. Increased productivity.
2. Reduced overall production cost.
3. Less floor area required.
4. Increased overall profits of the manufacturing concern.
5. Human fatigue is greatly minimized.
6. Reduced maintenance requirements.
7. The workers avail better working conditions.
8. Owing to the use of standardized parts and assemblies, the inventory requirement is minimized.
9. Uniform components are produced.
10. There is an effective control over the production process.
11. The work piece is tidy and safe.
12. With the use of group technology a considerable saving is effected in terms of design cost, material cost,
tooling cost etc.
13. There is a great improvement in the quality and reliability of products.
14. Human safety is fully ensured.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics and Industrial
Automation by R K Rajput
 Module 1: Introduction
Basic Concepts of Automation
Limitations of Automation:
1. Initial Investment: The considerations of cash flow may make an investment in automation difficult even if
estimated rate of return is high.
2. Labor resistance: Although the use of robots increases productivity, makes the firm more competitive and
preserves jobs, yet some jobs are lost. Therefore people look at robots and manufacturing automation as a
cause of unemployment.
3. Cost of upgraded labor: It is very easy to automate routine monotonous tasks. But skill is required to automate
the difficult tasks, this requires the upgradation of manufacturing labor, which involves cost.

Prepared by: Mr. Rajendra Soni Ref: Industrial Robotics and Industrial
Automation by R K Rajput
 Module 1: Introduction
Basic Concepts of Automation
Applications of Automation:
1. Automatic machine tools to process parts.
2. Automated transfer lines and similar sequential production systems.
3. Automatic assembly machines.
4. Automated production lines.
5. Industrial Robots.
6. Automatic material handling and storage systems.
7. Automated inspection system for quality control.
8. Feedback control computer process control.
9. Computer Systems that automate procedures for planning, data collection, and decision making to
support manufacturing activities.
10. Building Automation System. (BAS)
11. CAD/CAM and Computer Integrated Manufacturing (CIM).

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Components of Automated System

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Components of Automated System
1. Power to accomplish the process
• An automated system performs some action to accomplish its function, and the action requires
power.
• Most power sources used in automated manufacturing systems are based on electrical energy.
• Use of electric power has the following benefits in the operation of an automated system:
(1) It can be readily converted to other forms of power-mechanical, hydraulic, pneumatic;
(2) Low level electric power can be used for signal transmission, information processing, and data
storage; and
(3) Electrical energy can be conveniently stored in long-life batteries.
• The actions performed by an automated system can be divided into two categories: processing and
movement or positioning.
• These categories are especially appropriate in a manufacturing system, in which processing refers to
the operation performed on the work part (e.g., machining, forming, molding); and movement or
positioning refers to the transport and placement of the part before, during, and after the
manufacturing process.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Components of Automated System
2. Machine Programming
• The actions performed by an automated system are determined by a program of instructions.
• The program operates the system without human intervention, although the automated process or procedure m
involve human interaction (e.g., an automated teller machine).
• The instructions contained in the program specify the details of each action that must be accomplished,
the sequence in which the actions must be performed, and variations in the sequence that may be required
depending on circumstances.
• The decision-making capability of the system is included in the program in the form of instructions that execute
different actions depending on conditions and circumstances. Under one set of conditions, the system responds o
way, but under a different set of conditions, it responds in another way.
• Decision making also allows an automated system to cope with unanticipated events in the work cycle, such as a
broken tool or a part not positioned correctly in a fixture or other malfunction in the process.
• Process optimization is another aspect of programming in the operation and control of a production process.
Optimization is applicable in situations where there is a well-defined economic performance criterion, such as
product cost, production rate, or process yield, and the relationships between the process variables and the
performance criterion are known.
Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Components of Automated System
Feedback controls:
• These are widely used in automated systems to ensure that the programmed commands have been prope
executed.
• A feedback control system consists of five basic components:
(1) Input signal,
(2) Process,
(3) Output,
(4) Feedback sensing elements, and
(5) Controller and actuators.
• The input signal represents the desired value of the process output.
• The output is some variable that is being measured and compared with the input. The output value is a function
the process.
• Sensing elements close the loop between output and input. Finally, the controller and actuators compare the outp
with the desired input and make adjustments in the process to reduce the difference between them.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Components of Automated System
Feedback controls:
• An important example of feedback control in manufacturing is a positioning system.
• A typical purpose of the positioning system in production operations is to move a work part to a desired location relative
to a tool or work head.
• Examples of positioning systems include numerical control machine tools, spot welding robots, electronic component
insertion machines, and coordinate measuring machines.
• In operation, a programmed instruction directs the positioning system to move the worktable to a certain location defined
by coordinate values in an axis system (e.g., x and y values in a Cartesian coordinate system).

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
• Most manufacturing operations can be automated.
• Given the large number of manufacturing processes and assembly operations used
in Industry (the number is in thousands) and the many possible ways in which any
given operation can be automated, the variety of automated system would seem to
be unlimited.
• However although the number of specific automation solutions may be limitless,
they can be classified into a limited number of categories.
• Some of the principle categories and examples of automation in manufacturing are.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
1. Automated Production Lines
• It is a production system consisting of a series of automated workstations connected by an automatic parts
transfer mechanism.
• A raw work part begins at one end of the line and passes through each station, where an operation is
accomplished.
• The stations perform processing or assembly operations such as machining. press working, and spot welding.
• Examples include transfer lines (associated primarily with machining), dial indexing machines, integrated sheet
metal press lines, and certain automated assembly machines.
• Transfer lines and similar systems are often cited as examples of fixed automation.
• Although their control system is programmable, the configuration of the production hardware limits these
systems in adapting to changes in product configuration.
• They are, therefore, best suited to high production.
Video link: https://
www.google.com/search?q=automated+production+lines&rlz=1C1GCEU_enIN944IN949&source=lnms&tbm=vid&sa=X&ved
=2ahUKEwidkJb91cP8AhXMaGwGHWHvCt4Q_AUoA3oECAEQBQ&biw=1517&bih=730&dpr=0.9#fpstate=ive&vld=cid:5
b4901b5,vid:NGR7-rBmi_E
Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
1. Automated Production Lines
• One of the biggest problems in managing an automated production line is system reliability.
• When one component in the system malfunctions (e.g., one workstation fails), it often means that the entire line
must be shut down to make repairs.
• As the equipment becomes increasingly complex (as the number of stations on the line is increased), the reliability
decreases.
• This translates into more frequent malfunctions and a higher proportion of downtime during operation.
• Various means are available to reduce the effect of these problems, such as the
1. Use of computer monitoring and diagnostic systems,
2. Scheduling cutting tool changes instead of waiting for each individual tool to fail, and using storage buffers
between stations along the line to allow sections of the line to operate independently.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
2. Position and Motion Control Systems
• Many manufacturing operations require the positioning of a work head or tool relative to a work part to accomplish
a process.
• In some cases, the positioning is required before the process is performed.
• For example, in a drilling operation, the part must be moved to the proper location, and then the hole is drilled at
that location. This type of positioning is often called point-to-point control.
• In other applications, the tool is moved while the process is being carried out. Milling is an example of this.
• The work part is fed past a rapidly rotating cutting tool, which removes material from the part to achieve the desired
geometry. This type of motion control is called continuous path control.
• In drilling, milling, and other machining operations, position and motion control systems of the type described here
are called numerical control (NC) systems.
• NC is a form of programmable automation in which a machine tool is controlled by a program consisting of
properly coded numeric symbols (hence the name numerical control).
• The applications can be divided into two categories:
(1) Machine tool applications and (2) Non-machine tool applications.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
Machine Tool Applications:
• In this category, NC is widely used for machining and other metal working processes.
• In these applications, NC is used to control the position of a tool relative to a work part.
• Without NC, a human worker would manually have to position the part and the tool.
• Some of the principal machine tool applications of numerical control are described below.
1. Machining Centers: These machines are NC machine tools with additional automatic features beyond
conventional position and motion control. Some of the additional features include automatic tool changing, automatic
work part positioning to present more than one surface to the cutting tool, and automatic pallet shuttles to change work
parts.
2. Grinding Machines: NC can be used to control the grinding of parts with irregular geometries (e.g., nonflat,
noncylindrical).
3. Pressworking Machines: NC presses equipped with multiple punch and die sets are capable of punching holes of
different size and shape on flat sheet stock. Special NC presses can also perform bending operations and laser cutting.
4. NC Tube-bending Machines: These machines can be programmed to bend tube stock to specified angles under
numerical control.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
Machine Tool Applications:
5. Flame-cutting Processes. These processes include flame cutting, laser cutting, electron- beam cutting, and plasma-
arc cutting. They share a common feature in that they all cut a narrow kerf in metal sheet or plate stock by melting the
metal to separate the parts. The cutting path is controlled by NC.
Video Link: https://www.youtube.com/watch?v=AFmgQ3kc6kA

6. Wire EDM. Wire EDM is a form of electric discharge machining in which a thin wire is the electrode used to cut a
thin kerf in a metal plate, in some respects similar to the way an electric bandsaw works. The cutting path is guided by
NC. The process can produce parts with complex two-dimensional outlines.
Video Link: https://www.youtube.com/watch?v=pBueWfzb7P0

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation in Production System
Non Machine Tool Applications:
This category includes operations such as assembly and inspection. The list includes
1. Welding Machines. Spot welding and continuous arc welding are automated by NC. Spot welding is programmed
as a point-to-point operation, whereas arc welding is a continuous path operation.

2. Component Insertion Machines. These machines are used extensively in electronics to insert components into
printed circuit boards (PCBs) to form an electronic assembly. The NC program defines the x-y positions on the PCB
where components are to be placed.
3. Coordinate Measuring Machines. A coordinate measuring machine (CMM) is an inspection machine possessing a
contact probe that can be moved to measure x-y-z locations on the surface of work part. CMMs can be programmed to
move the probe from one location to the next, recording the coordinates of the contact position, and automatically
inspecting the part.
Video Link: https://www.youtube.com/watch?v=xgDpq4orAFM

Benefits usually cited for numerical control in these applications include (1) reduced nonproductive time, (2) less time
to complete a production order, (3) simpler fixtures, (4) greater flexibility to alter the production schedule and deal
with engineering changes, (5) better accuracy, and (6) reduced human error.
Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
A number of fundamental strategies exist for improving productivity in manufacturing operations. These strategies
often involve the use of automation technology and are, therefore, called automation strategies.
1. Specialization of Operations:
• Specialization of operations is analogous to "labor specialization" or "division of labor" which is used to improve
labor productivity.
• As applied in automation, the principle involves the use of special-purpose equipment designed to perform one
operation with maximum efficiency.
• Examples include automatic screw machines, tube-seam welding machines, and other special high production
machines.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
2. Combined Operations:
• Production usually consists of a sequence of processing steps.
• Complex parts may require many individual operations during their fabrication, each operation requiring a different
machine.
• The objective in combining operations is to reduce the number of separate production machines through which the part
must be processed.
• This is implemented by combining more than one operation at a given machine, thereby reducing the number of machines
needed to complete the part.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
3. Simultaneous Operations
• The strategy of combined operations can be extended by not only performing multiple processing operations at the same
workstation but also performing the operations simultaneously.
• In effect, two or more processing (or assembly) steps are carried out at the same time on the part, thereby reducing total
cycle time at the machine.
• A good example of simultaneous operations is the use of multiple-spindle drills that perform a large number of hole-
drilling operations simultaneously.
4. Integration of Operations.
• A related but alternative strategy is to connect multiple workstations together into a single integrated system, using
automated part transfer devices to move parts between stations.
• The system can be viewed as a single machine, and thus the number of separate machines through which the product must
be scheduled is reduced.
• However, because the system consists of multiple workstations, each capable of processing a separate workpart, several
parts can be processed simultaneously.
• This results in a high production rate, the rate being limited by the slowest workstation in the sequence.
• Systems of this type are sometimes referred to as a serial production system.
• Examples of these production systems include transfer lines, dial indexing machines, and automatic assembly machines.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
5. Increased Flexibility
• While most of the strategies described above are intended principally for high production, there is a need to automate job
shop and medium volume production by increasing the flexibility of the processing equipment.
• Increased flexibility can be achieved in several ways, according to the flexible automation concepts discussed earlier.
• Primary objectives are to reduce setup time and machine programming time.
• Achieving these objectives reduces nonproductive time, manufacturing lead time, and work in process.
• Flexible manufacturing systems (FMSs) and flexible manufacturing cells (FMCs), usually designed to accomplish
machining on part families, illustrate this strategy.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
6. Automated Material Handling and Storage
• Opportunities exist to reduce nonproductive time by using automated material handling and storage systems.
• Mechanized or automated part handling systems are employed in transfer lines, flexible manufacturing cells, and similar
production systems.
• The obvious advantage is reduction in labor cost.
• Other benefits include reduced work-in-process and shorter manufacturing lead times.
• Examples of automated material handling systems include mechanized and automated conveyor systems and automated
guided vehicle systems.
• The tremendous advantage of an automated storage system is that it provides control over the inventory stored in it.
• Raw materials, parts, tools and fixtures, and finished products can be put into storage and retrieved rapidly and accurately.
• Lost materials are minimized.
• Examples of automated storage systems include automated storage-retrieval systems and carousels.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
7. Automated Inspection
• Inspection procedures are traditionally accomplished by manual methods after the part has been processed, which means
that the quality level has already been established by the time the part is inspected.
• Manual inspection is a time-consuming activity, and inspection costs can be significant.
• Automating the inspection function can result in substantial labor savings.
• Including automated inspection into the manufacturing process allows the process to be corrected as the product is being
made.
• This reduces scrap and improves the overall quality level of the product.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
8. Process Control and Optimization
• Control is one of the fundamental building blocks of automation.
• Process control includes various control schemes and optimization strategies designed to operate the individual
manufacturing processes and equipment so as to achieve certain objectives related to the specific process.
• Common objectives in process control and optimization, sometimes called objective functions in the language of control
theory, include (1) minimum product cost, (2) maximum production rate, (3) maximum yield, and (4) various objectives
that attempt to minimize variations in process and product parameters.
• The last objective might be considered a quality improvement goal.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
9. Plant Operations Control
The previous strategy is concerned with controlling individual manufacturing processes. Plant operations control is
concerned with controlling the entire factory. In pursuing this strategy, one attempts to manage and coordinate the aggregate
plant operations more efficiently. Areas that lie within the scope of aggregate plant operations include process planning,
production scheduling, shop floor control, and quality control. Implementation of the plant operations control strategy
usually requires use of local area networks in the factory.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Automation Principles and Strategies
10. Computer Integrated Manufacturing
• Computer technology has had a dramatic effect on the development of automation.
• Virtually all production systems installed today use computer systems. The term computer integrated manufacturing
(CIM) denotes the use of computers to design the products, plan the production. control the operations, and accomplish
many of the business related functions in a manufacturing firm.
• Computer integrated manufacturing suggests a bringing together of the various diverse functions of manufacturing by
means of computer systems. It is in the data processing and information flow within a firm that this integration primarily
occurs.
• The control of production equipment by computers facilitates integration in a CIM system.
• Implementing CIM involves taking the previous strategy of plant operations control one step further by connecting the
factory operations with the engineering and business functions of the firm.
• This requires extensive use of the computer and associated databases, and it also requires a high level of local and long-
distance computer networking in the company.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Levels of Automation
Level 0 – Sensors and Signals
• This is the first and lowest level of industrial automation. It consists of field devices like sensors,
actuators, instruments, motors, valves, actuators, switches, and other equipment. You can also
define it as a field layer.
• These devices send and receive data with respect to the next level. The data transfer can be
digital, analog, or in communication form.

Level 1-Manipulation and Control

• This is the stage from where controlling starts. It comprises PLCs and PIDs. You have got the data
from a sensor and you now want to control a motor according to it.
• For that, a program needs to be written in a controller that will accept the hardware sensor input
and control the hardware motor output accordingly.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf
 Module 1: Introduction
Levels of Automation
Level 2 – Supervisory Control
• Suppose there are 10 PLC’s in a plant. You want to monitor and control them by sitting in a
single remote location office. This requires networking and communication among all these
PLCs.
• Basically, the role of this level is to integrate all the controllers of a plant into one single
platform. This helps to supervise and control the whole system in one go.
• This is done by SCADA. You can visualize the whole process, see alarms, generate reports,
run batches, and control the operator’s action through the audit trail.
Level 3 – Planning and Operations
• This level is used for planning and operations in a plant. It is a computer management
system and can monitor and control multiple SCADA systems.
• So, suppose there are multiple processes in a plant and it is required to supervise the entire
manufacturing process from start to end. This can be done by MES (Manufacturing Execution
System). With this, the user can plan his activities and control manufacturing data and
processes.
• Multiple plants (right from start to end), various vendor data information, equipment
information, and planning and manufacturing daily chart can be viewed and controlled
Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
through MES. Automation by R C Dorf
 Module 1: Introduction
Levels of Automation
Level 4 – Business Planning, Logistics, and Enterprise Level Operations
• There are multiple departments in a company – like sales, purchase, HR, finance,
logistics, production, inventory control, etc. If all the processes after manufacturing
(MES) are not linked and are done manually, it will give the desired outputs; but will be
very slow.
• The production rate will decrease; because many persons will have to wait for other
department personnel to wait for their next step. So, ERP (Enterprise Resource
Planning) comes into the picture here.
• ERP is an automation process that works on computer technology and automates all
the processes of an office in an easy way.
• Data has been communicated automatically in a transparent way between the
departments. This reduces time and increases efficiency.

Prepared by: Mr. Rajendra Soni Ref: Handbook of Design, Manufacturing, and
Automation by R C Dorf