Automation in Manufacturing

(MEPD-4014)
Mechanical/Mechatronics Engineering
Unit 1: Production systems By
(with course introduction)
Varun Pratap Singh
 Disclaimer

This document does not claim any originality and cannot be used as a substitute for prescribed textbooks. The information
presented here is merely a collection by the subject faculty members for their respective teaching assignments, research
articles, subject books, and any other sources of information. Various sources, as mentioned on each slides or at the end of the
document as well as freely available material from the internet, were consulted for preparing this document. The ownership of
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use of this document. The subject faculty members make no representations or warranties concerning the accuracy or
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including but not limited to special, incidental, consequential, or other damages.
 Content
1. Course Objective 16. The USA principle
2. Course Outcomes 17. Ten strategies for automation
3. Course Description and Outline 18. Automation migration strategy
19. Case Studies
4. Course Content
20. Useful Links
5. Suggested Text/Reference Books
6. Modes of Evaluation: Quiz/Assignment/ Written
Examination Scheme
7. Categories of manufacturing systems
8. Manufacturing support systems,
9. Automation in production systems
10. Automated manufacturing systems
11. Opportunities for automation and computerization
12. Types of automation
13. Computerized manufacturing support systems
14. Reasons for automating
15. Automation principles and strategies
 Course Objective
Course objectives:
1. To understand and be able to complete the following charts with regard to a specific product, assembly chart,
route sheet, operations process chart, from-to chart, and activity relationship chart
2. To identify equipment requirements for a specific process
3. To understand the benefit of an efficient material handling system
4. Understand what effect process layout has on the material handling system
5. To describe and determine the effect of product, process, and schedule
6. To design parameters on plant layout and materials handling systems design.
7. To identify the characteristics of product and process layouts and their needs in terms of materials handling.
8. To develop and analyze plant layouts using manual and computer aided software methodologies.
 Course Outcomes
• On completion of this course, the students will be able to
• CO1. Understand the elements of automation and production systems
• CO2. Apply principles of automation for industrial applications
• CO3. Analyzed different types of automation.
• CO4. Interpret the different production systems, material handling systems and safety measures.
 Course Description and Outline
• Automation is the technology by which a process or procedure is performed without human
• Assistance. Automation is the use of various control systems for operating equipment such as
• Machinery, processes in factories, boilers and heat treating ovens, switching on telephone
• Networks, steering and stabilization of ships, aircraft and other applications and vehicles with
• Minimal or reduced human intervention. Some processes have been completely automated.
• Automation has been achieved by various means including mechanical, hydraulic, pneumatic,
• Electrical, electronic devices and computers, usually in combination. The benefits of automation include
labour savings, savings in electricity costs, savings in material costs, and improvements to quality, accuracy
and precision. This subject is concerned with the use of automation in production systems. This involves use
of various control strategies in production, group technology, assembly and transfer lines, cellular
manufacturing and flexible manufacturing systems. The subject will enhance knowledge about why, when
and where to use automation
 Course Content
Unit 1: Production systems Lectures
Categories of manufacturing systems, manufacturing support systems, automation in production systems, automated
manufacturing systems, opportunities for automation and computerization, types of automation, computerized manufacturing
8
support systems, reasons for automating, automation principles and strategies, the USA principle, ten strategies for automation,
automation migration strategy.
Unit 2: Automation and control technologies in production system Lectures
Basic elements of an automated system, advanced automation functions, levels of automation, continuous and discrete control
systems, computer process control, common measuring devices used in automation, desirable features for selection of measuring 8
devices.
Unit 3: Material handling system Lectures
Material handling equipment, design considerations for material handling system, material transport equipment, analysis of
material transport systems, storage systems and their performance and location strategies, conventional and automated storage 8
systems, overview of automatic identification and data capture, bar code technology, RFID, other AIDC technologies.
Unit 4: Production and assembly systems Lectures
Automated production lines- fundamentals, system configurations, work part transfer mechanisms, storage buffers, control of
production line, applications. Automated assembly systems- fundamentals, system configurations, parts delivery at work 8
stations, applications.
Unit 5: Cellular manufacturing Lectures
Group technology, part families, parts classification and coding, production flow analysis, Opitz coding system, composite part
7
concept, machine cell design, applications of GT
Unit 6: Flexible manufacturing systems Lectures
Introduction to FMS, types of FMS, FMS components, applications and benefits, planning and implementation issues in FMS,
6
quantitative analysis of FMS.
 Suggested Text/Reference Books
Text Book:
1. Mikell P. Groover, Automation, Production Systems, and Computer-integrated
Manufacturing, prentice Hall.
Reference Book:
1. Theory of Automation of Production Planning and of Tooling: Algorithms for Designing
Machine Tools in Automated Industrial Plants, By G. K. Goranskiĭ"
2. Serope Kalpakjian and Steven R. Schmid, Manufacturing – Engineering and
Technology, 7th Edition, Pearson.
3. Yoram Koren, Computer control of manufacturing system, 1st edition.
4. Ibrahim Zeid , CAD/CAM : Theory & Practice, 2nd edition.
MOOC:
Automation in Manufacturing - NPTEL Online Courses:
1. https://onlinecourses.nptel.ac.in/noc21_me120/preview
2. https://nptel.ac.in/courses/112103293
3. https://elearn.nptel.ac.in/shop/nptel/automation-in-manufacturing/
Modes of Evaluation: Quiz/Assignment/ presentation/
extempore/ Written Examination Scheme

Internal
Components MSE ESE
Assessment

Weightage (%) 30 20 50
 Introduction
• Automation is the technology by which a process or procedure is performed with
minimal human interference through the use of technological or mechanical devices. It
is the technique of making a process or a system operate automatically.
The 1970s ->The
The 1800s ->Time when
introduction of the
the revolution came in
computer and IT, and
the machine production
industrial robotics result in
with the help of the
the advance automation in
steam and water
the production process.

The 1900s ->It was the

time when the industries The 2015s + -> The era can be termed as the
industrial revolution 4.0 aka industry 4.0 .
got the booster of the
The time of the introduction of the IOT in
mass production with the with the advanced computer system and
machine powered by the industrial robotics has resulted in the huge
electricity and growth. Digitalization in the supply chain
combustion engine. management, Manufacturing automation.
https://heliconia.io/blog/industry-2/what-is-industry-4-0-1
 Significance of Automation
• What is Automation?
Automation enables processes to occur automatically — i.e., immediately and
without human labor. In many cases, monitoring of processes can be
automated, as well. Monitoring will often include summary statistics for key
measurements, and can even be integrated with automated recommendation
systems. Automation will transform a wide variety of vital job functions across
industries such as robotics, cyber security, wireless applications and banking.
Automation experts are already helping various industries navigate complicated
problems in their workflow processes; the revolution is here.
 Significance of Automation
• Every industry stands to benefit from intelligent transformation, and with the seemingly
endless array of automation applications, it is unlikely that the spread of automation will
slow any time soon. To keep up, thoughtful implementation of automated systems is
necessary. In the technology sector, the impact of automation is soaring and evolving at a
rapid pace, covering both hardware and software segments. Similarly, in the healthcare
industry, automation is making huge waves improving treatment, patient experience and
provider well-being. Automation provides benefits across all industries. While the
following list is by no means exhaustive, it provides a sense the benefits.
• Over the decades, automation has become widespread with the advent of Artificial
Intelligence (AI) and Machine Learning (ML). While it will disrupt industries, it is
neither a magic pill, nor a portent of doomsday scenarios. Automation will create new jobs
and push some to obsolescence.
• Automation doesn’t simply replace human labor, however. It augments human labor
by offloading simple, repetitive tasks to computers.
 Benefits of Automation
• Automation provides benefits across all industries. While the following list is by no
means exhaustive, it provides a sense the benefits.
• Improved quality
• Consistency
• Time savings
• Metric visibility
• Enhanced operational efficiency
• Better governance
• Reliability
• Reduced turnaround times
• Reduced costs of operations
 Manufacturing support systems
• This is the set of procedures used by the company to manage production and to solve the technical and
logistics problems encountered in ordering materials, moving work through the factory. and ensuring that
products meet quality standards. Product design and certain business functions are included among the
manufacturing support systems.
• To operate the production facilities efficiently, a company must organize itself to design the processes and
equipment. Plan and control the production orders, and satisfy product quality requirement. These functions
are accomplished by manufacturing support systems-people and procedures by which a company manages its
production operations. Most of these support systems do not directly contact the product, but they plan and
control its progress through the factory.
• Manufacturing support involves a cycle of information-processing activities.
The information-processing cycle, represented by the outer ring, can be described
as consisting of four functions: (1) business functions, (2) product design, (3)
manufacturing planning. and (4) manufacturing control.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Manufacturing support systems
• The most important factors that determine the type of manufacturing is the type of
products that are made.
• The quantity produced by a factory has a very significant influence on its facilities and
the way manufacturing is organized. Production quantity refers to the number of units of a
given part or product produced annually by the plant. The annual part or product quantities
produced in a given factory can be classified into Three ranges:
1. Low production: Quantities in the range of 1 to l00 units per year.
2 Medium production: Quantities in the range of 100 to 10,000 units annually.
3 High production: Production quantities are 10,000 to millions of units.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Manufacturing support systems
Business Functions: The business functions are the principal means of communicating
with the customer. They arc. therefore, the beginning and the end of the information-
processing cycle. Included in this category are sales and marketing, sales forecasting.
order entry, cost accounting, and customer billing.
The production order will be in one of the following forms: (l) an order to manufacture
an item to the customer's specifications, (2) a customer order to buy one or more of the
manufacturer's proprietary products, or (3) an internal company order based on a
forecast of future demand
fora proprietary product.
Product Design: If the product is 10 be manufactured to customer design, the design
will have been provided by the customer. The manufacturer's product design
department will not be involved. lf the product is to be produced to customer
specifications, the manufacturer's product design department maybe contracted to do
the design work for the product as well as to manufacture it.
Manufacturing Planning: The information and documentation that constitute the product design flows into the manufacturing planning function.
The information-processing activities in manufacturing planning include process planning. master scheduling, requirements planning, and
capacity planning. Process planning consists of determining the sequence of individual processing and assembly operations needed to produce the
part. The manufacturing engineering and industrial engineering departments are responsible for planning the processes and related technical
derails.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
Manufacturing support systems
Manufacturing Control: Manufacturing control is concerned with managing and
controlling the physical operations in the factory to implement the manufacturing plans
The flow of information is from planning to control as indicated in Figure 1.5.
Information also flows back and forth between manufacturing control and the factory
operations. Included in the manufacturing control function are shop floor control,
inventory control, and quality control.

Shop floor control deals with the problem of monitoring the progress of the product a~
it is being processed, assembled, moved and inspected in the factory. Shop floor control
is concerned with inventory in the sense that the materials being processed in the
factory are work-in-process inventory. Thus. shop floor control and inventory control
overlap to some extent.
Inventory control attempts to strike a proper balance between the danger of too little
inventory (with possible stock-outs of materials) and the carrying cost of too much
inventory. It deals with such issues as deciding the right quantities of materials to order
and “when to reorder a given item when stock is low.
The mission of quality control is to ensure that the quality of the product and its
components meet the standards specified by the product designer.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Automation in production systems
The automated elements of the production system can be separated into two categories:
(1) Automation of the manufacturing systems in the factory.
(2) Computerization of the manufacturing support systems.
In modern production systems, the two categories overlap to some extent. because the automated
manufacturing systems operating on the factory floor are themselves often implemented by computer systems
and connected to the computerized manufacturing support systems and management information system
operating at the plant and enterprise levels. The term computer-integrated manufacturing is used to indicate
this extensive use of computers in production systems.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Automated manufacturing systems
Automated manufacturing systems operate in the factory on the physical product. They perform operations such
as processing, assembly, inspection, or material handling, in some cases accomplishing more than one of these
operations in the same system. They are called automated because they perform their operations with a reduced
level of human participation compared with the corresponding manual process. In some highly automated
systems, there is virtually no human participation. Examples of automated manufacturing systems include:
• Automated machine tools that process parts
• Transfer lines that perform a series of machining operations
• Automated assembly systems
• Manufacturing systems that use industrial robots to perform processing or assembly operations
• Automatic material handling and storage systems to integrate manufacturing operations
• Automatic inspection systems for quality control
Automated manufacturing systems can be classified into three basic types:
(1) Fixed automation.
(2) Programmable automation, and
(3) Flexible automation.
Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
Main Categories of Automation
Main Categories of Automation
Main Categories of Automation

https://www.youtube.com/watch?v=WAXnftiVGko
 Main Categories of Automation
1.Fixed Automation
Also known as Hard Automation, Fixed Automation involves the employment of specific-purpose equipment
to automate a repetitive sequence of tasks, processing or assembly operations. Generally, the operational
sequence is not complex, involves fundamental functionalities like rotational or plain linear motion, or an
amalgamation of both. The advantages of fixed automation are improved rate of production, low cost of the
unit, and the automation of the material handling process. If the automation repeats the same tasks with
identical units, it is Fixed Automation. The most notable limitation, here, is that Hard Automation units must
be replaced when new tasks need to be completed.
Typical features of fixed automation are:
• high initial investment for custom-engineered equipment
• high production rates
• relatively inflexible in accommodating product variety
Advantages of Fixed Automation are:
• Fixed automation has high production rates.
• Manufacturing cost per unit is lower.
• Uniform quality output.
Limitations of Fixed automation are:
• High Initial investment is required.
• Difficult to adapt to changes.
 Main Categories of Automation
2. Programmable Automation
Programmable Automation allows for fresh programs to be designed and deployed to the system to implement
new processes. Programmable Automation allows for reprogramming for different tasks after a batch of one
type is complete. The main advantage of the programmable automation is greater flexibility to deal with the
variation of designs. While it is the best-fit for batch production of a variety of designs, it produces fewer units
than both Fixed and Flexible Automation because of the changeover-time between functions.
Some of the feature, that characterize programmable automation includes:
• high investment in general purpose equipment
• lower production rates than fixed automation
• flexibility to deal with variations and changes in product configuration
• most suitable for batch production
Advantages of Programmable Automation are:
•Programmable automation is best suited for batch production.
•There is flexibility to accommodate product change.
Limitations of Programmable automation are:
•Initial cost is high.
•Lower production level as compared to fixed automation.
•Reprogramming is time consuming.
 Main Categories of Automation
3.Flexible Automation
This automation type is an extension of programmable automation that has the capacity to produce a spectrum
of products with next-to-zero downtime and no complicated change-over manual procedure, which means
greater production rate. Because there is no need for complex reprogramming, Flexible Automation can switch
between tasks. In manufacturing, because there is no need for batch production, tasks can be completed on
demand. Flexible Automation enables automatic and rapid changes to programmed sequences, such as production
of design variations, with virtually no down-time. In short, Flexible Automation allows for a variety of procedure
outcomes and high output.
The features of flexible automation can be summarized as follows:
• High investment for a custom-engineered system
• Continuous production of variable mixtures of products
• Medium production rate,
• Flexibility to deal with product design variations
Advantages of Flexible Automation are:
•No time is lost while changes are made.
•Easier to adapt to changes in product.
•It is faster than programmable automation as no time is past in
making the changes.
Limitations of Flexible automation are:
•Higher cost of equipment/machinery.
•Manufacturing cost per unit is higher.
 Computerized manufacturing support systems
• Automation of the manufacturing support systems is aimed to reducing the amount of manual and clerical
effort in product design, manufacturing planning and control, find the business functions of the firm.
• Nearly all modem manufacturing support systems are implemented using computer systems. Indeed,
computer technology is used to implement automation of the manufacturing systems in the factory as well.
• The term computer integrated manufacturing (CIM) denotes the pervasive use of computer systems to
design the products, plan the production, control the operations, and perform the various business-related
functions needed in a manufacturing firm.
• True CIM involves integrating all of these functions in one system that operates throughout the enterprise.
• Other terms are used to identify specific elements of the CIM system. For example, computer-aided design
(CAD) denotes the use of computer systems to support the product design function. Computer-aided
manufacturing (CAM) denotes the use of computer systems to perform functions related to manufacturing
engineering, such as process planning and numerical control part programming.
• Some computer systems perform both CAD and CAM, and so the term CAD/CAM is used to indicate the
integration of the two into one system. Computer-integrated manufacturing includes CAD/CAM, but it also
includes the firm's business functions that are related to manufacturing.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Computerized manufacturing support systems
• In a manufacturing firm, the physical production activities that take place in the factory can be distinguished
from the information-processing activities, such as product design and production planning, that usually occur in
an office environment. The physical activities include all of the processing, assembly, material handling, and
inspection operations that are performed on the product in the factory.
• These operations come in direct contact with the product during manufacture. The relationship between the
physical activities and the information-processing activities in our model is depicted in Figure. Raw materials
flow into one end of the factory and finished products flow out the other end. The physical activities take place
inside the factory. The information-processing activities form a ring that surrounds the factory, proved the data
and knowledge required to successfully produce the product.
The information-processing activities arc accomplished to implement the
four basic manufacturing support functions identified earlier:
(I) Business functions.
(II) Product design,
(III)Manufacturing planning. and
(IV)Manufacturing control.

These four functions form a cycle of events that must accompany the
physical production activities but do not directly touch the product.
Model of manufacturing showing factory operations and the
information-processing activities for manufacturing support.
 Global and Specific Automation Approaches
All automated systems will fall into either Fixed, Programmable or Flexible, but
there are many other global and specific applications of automation. Here we will
explore some additional forms of automation, beginning with a global, integrative
approach and then moving onto more specific types.
 Global and Specific Automation Approaches
1. Integrated Automation
Integrated Automation is a comprehensive automation framework. Integrated automation seeks
to reduce the complexity of independently automated work processes by streamlining
communication between automated processes. Rather than allowing five automated systems to
operate separately, integrated automation unifies them under one system. This automation type
can include technologies such as Flexible Machining Systems, Automated Material Handling,
and Computer-Aided Manufacturing.
 Global and Specific Automation Approaches
2. Industrial Automation
Industrial automation involves the use of technology to manage the repetitive tasks, including those that are
hazardous for human laborers. Common implementation examples include Numerically Controlled Equipment,
Flexible Manufacturing Systems and Computer-Aided Manufacturing. Industrial automation can increase the
accuracy of production and improve industry safety.
 Global and Specific Automation Approaches
3. Computer-Aided Manufacturing
Computer-Aided Manufacturing (CAM) uses computers and machines in concert to automate manufacturing.
CAM is often integrated with Computer Aided Design (CAD) to improve manufacturing processes. Some benefits
of CAM include increased material and production consistency, increased production output, and increased
component quality. CAD designs verified by engineer oversight is then automatically reproduced using CAM.
 Global and Specific Automation Approaches
4. Robotics Process Automation (RPA)
• In RPA, developers write code that automates tasks and the interface at the back end by using Application
Programming Interfaces (APIs). The robotic automation interacts with the available IT infrastructure, and
there is no requirement of the complicated system integration. RPA is programmed to automate many back-
office operations, workflow and infrastructure. These processes are generally labor-intensive, and they can
easily integrate with user portals, websites, and the many in-house applications.

• RPA is a set of commands executed by bots, adhering to the pre-defined set of rules.

• The main aim of RPA is to get rid of the repetitive and monotonous tasks performed by humans.
 Global and Specific Automation Approaches
5. Cognitive Intelligence
Cognitive Intelligence relies on dedicated software to automate information-intensive processes. Cognitive
Intelligence generally uses RPA for automation. This form of automation has a range of benefits, which includes
reduced operational costs, improved customer satisfaction, and many other perks such as the bringing precision to
complicated business processes based on unstructured data.
 Global and Specific Automation Approaches
6. Conversational Automation
Conversational automation rapidly changing approaches to customer service. Messaging is the preferred customer
service channel in the US, South Korea, Singapore and India. Conversational Automation is a step forward from
traditional chat-bots. Through its use of Natural Language Processing, it is free-flowing and unstructured. Because
it is not dependent upon fixed responses like traditional chat-bots, it allows for more human-like interactions.
Conversational Automation yields better customer experience than traditional chat-bots. Intelligent bots
significantly reduce labor costs and improve customer service because of their 24/7 availability and rapid
responses.
 Reasons for automating
• Companies undertake projects in manufacturing automation and computer-integrated manufacturing for a variety of good
reasons. Some of the reasons used to justify automaton are the following'
1. To increase tat-or productivity, Automating a manufacturing operation usually in labor productivity This means greater
output per hour
2. To reduce labor cost, Ever-increasing tabor cost has been and continues to be the trend in the world's industrialized
societies. Consequently, higher investment in automation has become economically justifiable to replace manual
operations. Machines are increasingly being substituted for human lahar to reduce unit product cost.
3. To mitigate (the effects of labor shortages). There is a general shortage of labor in many advanced nations. and this has
stimulated the development of automated operations as a substitute tor labor
4. To reduce or eliminate routine manual and clerical/asks. An argument can be put forth that there IS social value in
automating operations that are routine. boring, fatiguing. and possibly irksome. Automating such tasks serves a purpose
of improving the general level of working condition.
5. To improve worker safety. By automating a given operation and transferring the worker from active participation in the
process to a supervisory role, the work is made safer. The safety and physical well-being of the worker has become a
national objective with the' enactment of the Occupational Safety and Health Act (OSHA) in 1970.This has provided an
impetus for automation.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Reasons for automating
6. To improve product quality. Automation not only results in higher production rates than manual operations; it also
preform the manufacturing process with greater uniformity and conformity to quality specifications. Reduction attraction
defect rate IS one of the chief benefits of automation
7. To reduce manufacturing lead lime. Automation helps to reduce the elapsed time between customer order and product
delivery, providing a competitive advantage 10 the manufacturer for future orders. By reducing manufacturing lead time,
the manufacturer also reduces work-in-process inventory
8. To accomplish. processes that cannot be done manually; Certain operations cannot be accomplished without the aid of
a machine, These processes have requirements for precision, miniaturization. or complexity of geometry, that cannot be
achieved manually. Examples include certain integrated circuit fabrication operations, rapid prototyping processes based
on computer graphics (CAD) models, and the machining of complex, mathematically defined surfaces using computer
numerical control. These processes can only be realized by computer controlled systems.
9. To avoid the high cast of not automating. There is a significant competitive advantage gained in automating a
manufacturing plant. The advantage cannot easily be demonstrated on a company's project authorization form. The
benefits of automation often show up in unexpected and intangible ways, such as in improved quality, higher sales, better
labor relations, and better company image. Companies that do not automate are likely to find themselves at a competitive
disadvantage with their customers, their employees, and the general public.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Manual Labor in Factory Operations
There is no denying that the long-term trend in manufacturing is toward greater use of automated machines to
substitute for manual labor. This has been true throughout human history, and there is every reason to believe the
trend will continue. It has been made possible by applying advances in technology to factory operations. In
parallel, and sometimes in conflict. with this technologically driven trend are issues of economics that continue to
find reasons for employing manual labor in manufacturing operations.
In addition to the labor rate issue. there are other reasons, ultimately based on economics, that make the me of
manual labor a feasible alternative to automation. Humans possess certain attributes that give them an advantage
over machines in certain situations and certain kinds of tasks.
A number of situations can be listed in which manual labor is usually preferred over automation:
• Task is too technologically difficult to automate.
(1) problems with physical access to the work location,
(2) adjustments required in the task.
(3) manual dexterity requirements, and
(4) demands on hand-eye coordination.
• Short product life cycle.
• Customized product.
• To cope with ups and down in demand.
DOI: 10.1007/s12599-019-00595-2
Project: Hybrid Intelligence | Powered by human intuition. Augmented by AI.
 Automation principles and strategies
• The preceding discussion leads us to conclude that automation is not always the right
answer for a given production situation.
• A certain caution and respect must be observed in applying automation technologies.
Three approaches for dealing with automation projects
1. The USA Principle
2. Ten Strategies for Automation and Production Systems
3. Automation Migration Strategy

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 The USA principle
USA Principle
The USA Principle is a common sense approach to automation projects. Similar procedures
have been suggested in the manufacturing and automation trade literature, but none has a
more captivating title than this one. USA stands for:
1. Understand the existing process
2. Simplify the process
3. Automate the process
The USA approach is applicable to nearly any automation project.

Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 The USA principle
Understand the existing process (Charting techniques and mathematical modeling)
The first step in the USA approach is to comprehend the current process in all of its details.
• What are the inputs? What are the outputs ?
• What exactly happens to the work unit between input and output?
• What is the function of process?
• How does it add value to the product?
• What are the upstream and downstream operations in the product sequence, and can they be combined with
the process under consideration?.

Simplify the process (Reduce unnecessary steps and moves)

• Once the existing process is understood, then the search can began for ways to simplify. This often involves a checklist
of questions about the existing process.
• Unnecessary steps can be eliminated without detracting from the function.

Automate the process

• Once the process has been reduced to its simplest form then automation considered. The possible form of automation
include those listed in the ten strategies.
Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Ten strategies for automation
Automation seems a feasible solution to improving productivity, quality, or other measure of performance then the
following ten strategies for these improvements discussed.
1) Specialization of operations: The first strategy involves the use of special-purpose equipment designed to
perform one operation with the greatest possible efficiency. This is analogous to the concept of labor
specialization. Which is employed to improve labor productivity.
2) Combined operations: Production occurs as a sequence of operations. Complex parts may require dozens,
or even hundreds, of processing steps. The strategy of combined operations involves reducing the number of
distinct production machines or work stations.
3) Simultaneous operations: A logical extension of the combined operations strategy is to simultaneously
perform the operations that are combined at one work-stations. In effect two or more processing (assembly)
operations are being performed simultaneously on the same work part.
4) Integration of operations: Another strategy is to link several work stations together into a single
mechanism, using automated work handling devices to transfer parts between stations.
5) Increased flexibility: This strategy attempts to achieve maximum utilization of equipment for job shop and
medium value situations by using the same equipment for a variety of parts or products.
“Prime objectives are to reduce setup time and programming time for the production machine. This normally
translates into lower manufacturing lead time and less work-in-process.”
Portion of this section are based on M.P. Groover; Fundamentals of manufacturing: Materials, processes and systems
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by M.P. Groover.
 Ten strategies for automation
6) Improved material handling and storage: A great opportunity for reducing non-productive time exists in the
use of automated material handling and storage systems.
7) On-line inspection: Inspection for quality of work is traditionally performed after the process is completed.
This means that any poor-quality product has already been produced by the time it is inspected.
This reduces scrap and brings the overall quality of product closer to the nominal specifications intended by the
designer.
8) Process control and optimization: This includes a wide range of control schemes intended to operate the
individual processes and associated equipment more efficiently. By this strategy, the individual process times can
be reduced and product quality improved.
9) Plant operation control: Whereas the previous strategy was concerned with the control of the individual
manufacturing process, this strategy is concerned with control at the plant level. It attempts to manage and
coordinate the aggregate operations in the plant more efficiently.
Its implementation usually involves a high level of computer networking within the factory.
10) Computer-integrated manufacturing (CIM): Taking the previous strategy one level higher, we have the
integration of factory operations with engineering design and the business functions of the firm.

Reference: Industrial Automation / Course Notes – David O’Sullivan

https://electrical-engineering-portal.com/10-strategies-for-automation-and-production-systems
 Ten strategies for automation
CIM involves extensive use of:
Computer applications,
Computer data bases, and
Computer networking throughout the enterprise.

Conclusion
The ten strategies constitute a checklist of the possibilities for improving the production system through
automation or simplification. They should not be considered as mutually exclusive.
For most situations, multiple strategies can be implemented in one improvement project.

Reference: Industrial Automation / Course Notes – David O’Sullivan

https://electrical-engineering-portal.com/10-strategies-for-automation-and-production-systems
 Automation migration strategy
• The improvements are often carried out in phases. Many companies have an automation migration strategy, that is, a
formalized plan for evolving the manufacturing systems used to produce new products as demand grows.
• A typical automation migration strategy is the following:
Phase 1 – Manual production
Manual production using single station manned cells operating
independently. This is used for introduction of the new product for
reasons already mentioned: quick and low cost tooling to get
started.

Phase 2 – Automated production

Automated production using single station automated cells operating
independently. As demand for the product grows, and it becomes clear
that automation can be justified, then the single stations are automated
to reduce labor and increase production rate.

Phase 3 – Automated integrated production

Automated integrated production using a multi-station automated
system with serial operations and automated transfer of work units
between stations.

https://electrical-engineering-portal.com/automation-migration-strategy-in-3-phases#:~:text=A%20typical%20automation%20migration%20strategy%20is%20the%20following%3A&text=(1)%20Phase%201%3A%20manual,with%20automated%20handling%20between%20stations.
 Advantages of automated integrated production
• When the company is certain that the product will be produced in mass quantities and for
several years, then integration of the single station automated cells is warranted to further
reduce labor and increase production rate.
• Advantages of such a strategy include:
• It allows introduction of the new product in the shortest possible time, since production
cells based on manual workstations are the easiest to design and implement.
• It allows automation to be introduced gradually (in planned phases), as demand for the
product grows, engineering changes in the product are made, and time is allowed to do a
thorough design job on the automated manufacturing system.
• It avoids the commitment to a high level of automation from the start, since there is
always a risk that demand for the product will not justify it.

Reference: Industrial Automation Course Notes – David O’Sullivan, Universidade do Minho, May 2009

https://electrical-engineering-portal.com/automation-migration-strategy-in-3-
phases#:~:text=A%20typical%20automation%20migration%20strategy%20is%20the%20following%3A&text=(1)%20Phase%201%3A%20manual,with%20automated%20handling%20between%20stations.
CASE STUDIES
SMI solutions for Industry 4.0

http://www.smidobrasil.com.br/profilo/smart-factory-iot
http://www.smidobrasil.com.br/profilo/smart-factory-iot
Delta Smart Manufacturing

https://www.youtube.com/watch?v=Fb6rkHYnPLE
Audi Smart Factory - Future of Audi Production

https://www.youtube.com/watch?v=sqCbYd8O8MU
Amazon Warehouse Robots

https://www.youtube.com/watch?v=IMPbKVb8y8s
Amazon Warehouse Order Picking Robots

https://www.youtube.com/watch?v=Ox05Bks2Q3s
 How many robots does it take to run a grocery store?
Inside A Warehouse Where Thousands Of Robots Pack Groceries

https://www.youtube.com/watch?v=ssZ_8cqfBlE
https://www.youtube.com/watch?v=4DKrcpa8Z_E
Automation in Manufacturing
The Smart Factory

https://slcontrols.com/en/solutions/smart-factory/
The Smart Factory

http://www.totaleng.net/index.php?hCode=SMART_05_01
 USEFUL LINKS
What Is Automation Control System - Types of Automation In The Industry
https://www.youtube.com/watch?v=HHsjSEdb_HE
OHP: Automation of Hydraulic And Pneumatic System
3 videos2
https://www.youtube.com/playlist?list=PLdoIhVhbPQV7PI6NaUlIxF2Fne5biVRZl
Industry 4.0 Deep Dive. Part 4: Evolving Industrial Robots
https://www.wevolver.com/article/industrie.40.deep.dive.part.4.evolving.industrial.robots