II- Automation in Production system ????? ???? ???????

1
II- Automation in Production system????? ????
???????
IE 469 Manufacturing Systems 469 ??? ??? ???????
2
1a- Automation Defined ????? ???????

• It is the technologies concerned with the
  application of mechanical, electrical, and
  computer based systems to carry the following
  function
• ???? ????? ??????? ????? ??????? ????????
  ???????-
• Operation and control of production activities
  without interference of people
• ??????? ??????? ??????? ?? ???????? ????????? ???
  ???? ?? ???????
• Adjusting and controlling operating condition as
  requested
• ?????? ?????? ???? ???? ????? ???????? ????
  ???????? ???????.
• These technologies include hardware and software
  such as
• ??? ????? ??? ???????? ?????? ?? ???? ?????? ???
• Motor actuators and mechanisms ????? ???????
  ?????? ?????????????-
• Computer and processing units ????? ??????
  ?????????? ?????? ???????-
• Measuring and monitoring equipment and
  programmable controller ????? ?????? ??????????
  ???????-
• Operating and analysis Programming????? ???????
  ????????? ????????-
• ETC. ??????

3
1b- Automation Functions in Manufacturing ?????
??????? ?? ???????

• Two Basic main functions for automation in
  manufacturing
• ???? ??????? ???????? ???
• Manufacturing Facility Automation Equipments
• ????? ????? ???????
• Manufacturing Support Automation Information
• ????? ??????? ???????

These two function are developed to build a self
operating manufacturing system using computer as
standard to operate all activities in integrated
form. ??????? ????? ???????? ??? ???? ???????????
????? ???? ????? ???? ??????? ?????? ????????
?????? ?????? ?????? ???? ???? ????? ?????? ?????
??????? ????? ??????? ??? ????? ???????? ????
??????? .
4
1c- Automation Functions in Manufacturing ?????
??????? ?? ???????
5
2a- Mfg Systems Automation history ???? ????? ???
???????
??? ?????? ?????? ???? ??????? ?? ????
???????????
6
2b- Mfg Systems Automation history ???? ????? ???
???????
??? ?????? ?????? ???? ??????? ?? ????
???????????
7
2c- Automation Generations ????? ????? ???
???????
8
2d- Automation Generations ????? ????? ??? ???????
9
2e- Automation Generations ????? ????? ??? ???????
10
2f- Automation Generations ????? ????? ??? ???????
11
2g- Automation Generations ????? ????? ??? ???????
12
3a- Automation Stages ????? ????? ??? ???????
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3b- Machinery Automation Levels ??????? ?????
???????
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3c- Automation Requirements ??????? ???????

• Process Automation (shaping, handling, Packaging,
  storing, inspection)
• ????? ??????? ??????? (??????? ???????? ??????
  ??????? ????????? ????????)
• Information Automation
• ????? ????????? ?????? ??????? ????????.
• Integration of operation and control
• ????? ???????? ???????? ????????? ???????
  ?????????? ???.
• Monitoring and adjusting
• ?????? ?????? ????????.
• Analysis and reporting
• ????? ?????? ??????

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3d- Automation for Production Type ??????? ??
????? ???????
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4a- Types of Automation ????? ????? ???????
1- Fixed Automation ??????? ??????? ?? ???? ??
?????? ?????? ?????? ??????? ??? ???? ??????
?????? ???? ?????? ???? ????.
2- Soft Automation ??????? ???????? ?? ???? ??
?????? ?????? ?????? ??????? ??? ?????? ?????
?????? ?????? ?????? ??? ?????- A- Programmable
Automation ??????? ???????? ?? ???? ???? ???????
?? ??????? ???? ?? ???????? ???????? ??????
??????? ?? ???? ????. B- Flexible Automation
??????? ?????? ?? ???? ?? ?????? ?????? ??????
??????? ??? ???? ?????? ?????? ??? ?????? ??????
???? ?????? ?????? ????? ???????.
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4b-Type of Automation Characteristics ????? ?????
???????
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4c-Type of Automation related to quantity
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4d-Type of Automation related to quantity
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4e- Flexibility in Automation ????? ????? ???
???????
Flexibility and Productivity of Various
Manufacturing Systems Overlapping between Systems
due to the Possibility of application of various
levels of Automation to the systems.
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5-Reason for Automation ????? ???????

• Why to automate?
• Increase productivity ????? ?????????
• Reduce Cost of labor ??? ??????? ???????
• Mitigate the effect of labor shortage ????? ?????
  ??? ???????
• Reduce or eliminate routine manual and clerical
  task????? ?? ????? ????? ??????
• Improve worker safety????? ????? ?????
• Improve product quality ????? ???? ????????
• Reduce manufacturing lead time????? ??? ???????
  ???????
• Accomplish a process difficult to be done
  manually????? ????? ???? ?????
• Avoid the high cost of not automating??????
  ??????? ??????? ???? ???????

• Why to be manual?
• Task is too difficult technologically ?????
  ???????
• Short product life cycle ??? ??? ????
• Customized product ???? ????
• To meet high variation of demand?????? ?????
  ??????
• To reduce risk of product failure in market?????
  ???????? ???? ?????? ?? ?????

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6- Dealing with Automation Projects

• Approaches when dealing with automation
• Automation visibility strategies ??????????
  ????? ???????
• Automation Strategies ?????????? ????? ??????
• Automation Migration strategies ?????????? ??????
  ???????
• Automating principle ???? ???????

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6-1- Automation Visibility Strategy ??????????
????? ???????
Automatic Analysis as a Function of Product
Variety, Production Volume, and Value of applying
automation
Candidate Value Analysis for applying automation Candidate Value Analysis for applying automation Candidate Value Analysis for applying automation
Factor Good Candidate Poor Candidate
Relative Market Share High (gt60) Low (lt25)
Sale from New Services Low (lt1 ) High (gt10)
Unionization Low (lt20) High (gt65)
Capacity Utilization High (gt85) Low (lt70)
Real Market Growth High (gt6 ) Low (lt-1 )
Type of Service Made to Order Standardized
Grade H L
Volume Candidate Value Factory Automation Possibility Factory Automation Possibility Factory Automation Possibility
High High H H H
High Medium H H M
High Low H M M
Medium High H H M
Medium Medium H M L
Medium Low M L L
Low High H M M
Low Medium M L L
Low Low L L L
Product Variety Product Variety Low Medium High
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6-2- Automation Strategies ??????????? ???????
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6-3a- Automation Migration Strategy ??????????
?????? ???????

• Formulating plans with phases for automation
• Phase 1 manual production used when
  introducing new product and testing the market
  quick start.
• Phase 2- automate Facility components
  independent cell automation (reduce labor cost
  and increase production.
• Phase 3- automate integrated production
  multi-cell and handling automation 9production
  for several years)

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6-3b- Automation Migration Strategy ??????????
?????? ???????
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6-3b- USA Automating Principle ???? ???????

• Deal with implementation of automation
• Step 1 Understand exiting process Comprehend
  current process in details. Use work design
  principles (charts modeling indicating
  relations and operation conditions and process
  considerations
• Step 2- Simplify the process use work design
  principles to simplify and eliminate unnecessary
  steps.
• Phase 3- automate the process consider possible
  forms of automation including the above
  strategies.

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7b-Automation Structure for information ??????
????? ?????????
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7c-Automation Structure for Hardware ??????
????? ??????
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8a- Automation tasks ???? ???????
First Automating the process equipment ????
????? ??????? Three element of automation are
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8a1 -1st step process Automating element

• 1- ?????? Power ??? ?????? ???????? ??????
  ?????? -
• ???? ??????? (??????? ????????)Power of Process
• ???? ?????? ?????????? Power of Automation

???? ???? ??????? Power of Process ????? ???
???????-
??????? ?????? ????????? ????? ??????
??????? Casting ????? Thermal ??? ?????? ???? ?? ?????
?????? ?????? Heat Treatment ????? ???? ???? ?????????? ????? ??????
????? ??? ?????? Cold Forging ???????? Mechanical ????? ?????? ?? ?????? ??????
????? ??? ?????? Hot Forging ???????? ? ????? ????? ?????? ?? ?????? ?????? ??????
????? Extrusion ???????? ? ????? ????? ?????? ?? ?????? ?????? ??????
????? Injection molding ???????? ? ????? ????? ?????? ?? ?????? ?????? ??????
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8a2 -1st step process Automating element
???? ???? ??????? Power of Process ????? ???
???????-
??????? ?????? ????????? ????? ??????
????? ??????? ???????? Forming ???????? ????? ?????? ???????? ????????
??????? Machining ???????? ????? ???? ?????? ??????? ??????? ??? ???????? ????? ?????
??? ??????? Laser beam cutting ????? ????? ????? ????? ????? ???? ???? ??????
??? ???????? ??????? Electric Discharge ????? Electrical ????? ?????? ???????? ??????? ?? ????? ??????? ?????? ?????
?????? Welding ?????/?????/????????? ????? ????? ????? ?????? ????? ???? ??????

• ???? ???? ????? ???????? Power of Handling
  Process-
• ??????? ????? ???? ??????? ??????????? ??
  ???????? ???? ??????
• ????? ?????? ????????? (Loading and Unloading of
  work unit) ?????? ??????? ??? ?????????.
• ??? ????????? ??? ???????? (Material Transport
  between Operation) .

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8a3 -1st step process Automating element

• ???? ???? ??????? Power for Automation ???
  ?????? ??? ????? ????? ????? ??????? ??? ????
  ?????? ?????? ???????? ??????-
• ????? ?????? Controller Unit ??? ????? ???
  ??????? ??????? ?????? ??????? ?????????.
• ????? ??????? Actuators ??? ????? ????? ???????
  (??????-??????)?????? ?????? ?????? ???? ?????
  ??? ???????.
• ????? ??? ???? ???????? ??????? ????????? Data
  Acquisition and Information Processing ??? ???
  ??????? ??????? ?? ??? ???????? ?? ????? ???????
  ????????? ?????? ?????????? ?????? ?????????? ??
  ???????? ???????.

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8a4 -2nd step process Automating element

• 2- ?????? ????????? Program of Instruction
• ??? ?????? ??? ???? ????? ?????? ????????(??????
  ????????) , ???? ????
• ??? ????? ???????? ???? ??? ?????? ? ????
  ???????? ??????? ??? ????? ??????.
• ??????? ???????? ?????? ???????.
• ???????? ??????? ?? ???????.
• ????? ??? ?? ???? ????? ????? ?? ??? ????? ??
  ?????? ??????? ???????

• ?????? Output ??????? Variables
• ??????? ???? ????? ?????? ??????? ???
• ???? ??????? ???????
• ??? ?????? ??????? ???????
• ???? ?????? ?? ??????
• ????? ??? ???????
• ??? ????? Discrete
• ?? ?????? Gradual (Continuous)

• ?????? Input ????? Parameters
• ????? ????? ?????? ??? ???
• ??? ????? ???
• ????? ???????? ????? ??? ?? ??? ????
• ??? ?? ??? ????
• ????? ?? ????? ????

???? ??????? Process (i)
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8a5 - 2nd step process Automating element

• ????? ?????? ?????? ?? ?????? ?????????
• ?????? ???? ??? ????? ???????? ???? ????
  ???????? ?? ???? ??? ???? ????? ???? ??? ??
  ????????? ?????? ???? ???? ?? ???????? ????
  ?????? ??? ??? ??????? ?? ???????? ????? ????
• ?????? ?????? Manual Interface ?? ???? ????
  ?????? ????? ?????? ????? (??????) ?? ?????
  ?????.
• ????? ????? ???????? ???????? Steps change.
• ?????? ?? ????? ????? Start changing.
• ?????? ?????? ??????? Input parameters changes.
• ?????? ???????? ?????? ?????? ??????.

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8a5 - 2nd step process Automating element
????? ??????? ????????? Program of Instruction

• ???? 1 ?????? ??? ?????? ???????? ????
• ?? ???? ???? ????? ????? ???? ???
• ?????? ????? ????? ??? ??????? ????? ??? ????
  ????? ????? ???? (?????? ??? ???????)
• ???? ??? ???? ???? (?????? ??? ??????)

• ???? 2 ?????? ??? ?? ???? ??? ????? ???
• ????? ???????? ??? ???????? (???? ?????? ?? ???
  ??? ??? )
• ???? ????? ??? ( ???? ????? ????? ??? ???? ?????)
• ????? ???????? ?? ????????(???? ?????? ?? ??? ???
  ??? )

37
8a7 - 2nd step process Automating element
????? ?????? ????????? Program of Instruction
Automation
????? ??????? ????? ??????? (?????) ????? ????????? (?????)
????? ??????? ??????? ????? ????????? ???????? Cams/ ?????? ?????????Relays ????????? Switches . ??????? ????? ??? ???????? ???????? Sensors ????????? ???????? CPU ?????????? ??????? ????????? ???????? ?????? Networks.
??????? ????? ??? ???? ??????? ???????? ???? ???? ???? ????? ??? ??????? ??? ??????? ????? ???????? ????????? ?????? ??????? ???? ????? ???? ????? ???????? ???????? ????? ???? ????? ????? ????? ??? ????????? ???????? ??????.
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8a8 - 3rd step process Automating element
3- ???? ?????? Control System ??? ??????
???????? ?????? ????? ???? ??????? ????? (??????
???? ?????) ?????? ????? ??? ???? ???????. ????
????? ?????? ?????? ??????? ?????? ??????
????????.
?- ???? ???? ????? Open loop control system
??????? Process
?- ???? ???? ???? Closed loop control system
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8b- Automation tasks ???? ???????
Second Automation of information ???? ?????
????????? ???? ?????? ?? ??????? ???? ?? ??????
??? ??????? ??????? ???????? ??????? ????????
?????? ??? ????? ???????. ??? ?? ???? ???? ???
?????? ????? ??????? ???? ?????? ?????? ???????
Safety Monitoring ????? ?????? ??????? ????????
???????? ?????? ?????? ?? ??????? ????????
????. ????? ??????? ???????? Maintenance and
Repair Diagnostics ????? ??????? ??????? ????
??????? ???? ?????? ??????? ???????. ?????? ?????
??????? Error Detection and Recovery ??????
????? ?????? ????? ????? (?????? ?? ????? ??
?????) , ?????? ?????? ???????? ?????? ?????
???????? ???. ???? ???? Groover ???????.