Automation in Manufacturing

Answer

Automation is the technology by which manufacturing processes are performed with minimum or no direct human intervention using control systems, computers, sensors, machines and other automatic equipment.

Answer

Need for automation in manufacturing

Automation is needed to increase productivity, maintain consistent quality, reduce manufacturing time and cost, improve worker safety, and manufacture complex products accurately. It is especially useful for repetitive, hazardous and high-volume operations.

Advantages

1. Higher production rate and productivity.
2. Better and more consistent product quality.
3. Reduced manufacturing time and labour cost per unit.
4. Improved dimensional accuracy and repeatability.
5. Better utilization of machines and materials.
6. Improved safety by removing workers from hazardous operations.
7. Reduced human error and fatigue.
8. Enables manufacture of complex products and integration with CAD/CAM.

Disadvantages

1. High initial investment and installation cost.
2. Skilled personnel are required for programming, operation and maintenance.
3. Maintenance and troubleshooting can be complex.
4. Automation may be uneconomical for low-volume or frequently changing production.
5. Failure of an automated system can interrupt a large part of production.
6. Workers may require retraining and some conventional jobs may be reduced.

Conclusion: Automation is most economical when its productivity, quality and safety benefits justify the initial investment and operating complexity.

Answer

CIM wheel

The CIM (Computer Integrated Manufacturing) wheel represents the integration of the major computer-based functions involved in manufacturing. At its centre is the manufacturing information/database and communication system, while engineering, planning, production and business functions are interconnected around it.

A simplified representation is:

Marketing & Sales → Product Design/CAD → Process Planning/CAPP → Production Planning → Scheduling → CNC/Manufacturing → Material Handling & Storage → Inspection/Quality → Feedback

All these functions exchange information through a common computer and communication infrastructure.

Major elements of CIM

1. CAD: Computer-aided product design and engineering analysis.
2. CAPP: Computer-aided process planning and generation of manufacturing instructions.
3. CAM/CNC: Computer-based control and execution of manufacturing operations.
4. Production planning and control: Planning, scheduling, inventory and shop-floor control.
5. Material handling and storage: Automated movement and storage of parts/materials.
6. Robotics/automation: Automatic handling, assembly and processing.
7. Inspection and quality control: Computer-assisted measurement and quality monitoring.
8. Database and communication: Central/shared manufacturing data and communication networks.
9. Business functions: Order processing, purchasing, costing and other enterprise activities.

Benefit: CIM reduces information delays and manual data transfer, improves coordination and enables integrated, flexible and efficient manufacturing.