AUTOMATION IN PRODUCTION SYSTEMS
Some components of the firm's production system are likely to be automated. Whereas others
will be operated manually or clerically. The automated clements of the production system can
be sepatated into two categories:
(1) automation of the manufacturing systems tn the factory
(2) computerization of the manufacturing support svstems
In modern production systems, the two categories overlap to some extent, because the
automated manulacturing systems operating on the lactory floor are themselves usually
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 computerintegrated manufacturing is used to indicate this extensive use of computers in
production systems.
1.1 Automated Manufacturing Systems
Automated manufacturing systems operate in the factory on the physical product. They perform
operations such as processing, assembly, inspection. and material handling. in some cases
accomplishing more than one of these operations in the same system. Thev 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. Thev generally operate as fully
automated systems although semi-automated systems are common in
Manufacturing Potential
support system computerization
applications
Production system Computer integrated
Facilities: Factory Potential Manufacturing
and Equipment automation
applications
, Fixed Automation. Fixed automation is a system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration. Each operation in the sequence ts
usually simple, involving perhaps a plain linear or rotational motion or an uncomplicated
combination of the two, such as the feeding of a rotating spindle. It is the integration and
coordination of many such operations into one piece of equipment that makes the system
complex. Typical features of fixed automation are (1) high initial investment for custom-
engineered equipment, (2) high production rates, and (3) relative inflexibility of the equipment to
accommodate product variety.
The economic justification for fixed automation is found in products that are produced in very
large quantities and at high production rates. The high initial cost of the equipment can be
spread over a very large number of units, thus making the unit cost attractive compared with
alternative methods of production. Examples of fixed automation include machining transfer
lines and automated assembly machines.
Programmable Automation. In programmable automation, the production equipment is
designed with the capability to change the sequence of operations to accom: modate different
product configurations. The operation sequence is controlled by 4 program, which is a set of
instructions coded so that they can be read and interpreted by the system. New programs can
be prepared and entered into the equipment to produce new products. Some of the features that
characterize programmable automation include :
(1) high investment in general purpose equipment
(2) lower production rates than fixed automation
(3) flexibility to deal with variations and changes in product configuration.
(4) high suitability for batch production.
Programmable automated production systems are used in low- and men volume production.
The parts or products are typically made in batches. To pre a cach new batch of a different
product, the system must be reprogrammed with the set of machine instruction that correspond
to the new product. The physical setup of the machine must also be changed Tools must he
loaded. fixtures must be attached to the machine table, aud ihe regutrcd machine settings must
be entered. This changeover procedure takes time. Consequently, the typical cycle for a given
product includes a period during which the setup and reprogramming takes place. followed by a
period in which the parts in the batch are produced. Examples of programmable automation
include numerically controlled (NC) machine tools, industrial robots, and programmable logic
controllers.
Flexible Automation. Flexible automation is an extension of programmable automation. A
flexible automated system is capable of producing a variety of parts (or products) with virtually
no time lost for changeovers from one part style to the next. There is no lost production time
Some components of the firm's production system are likely to be automated. Whereas others
will be operated manually or clerically. The automated clements of the production system can
be sepatated into two categories:
(1) automation of the manufacturing systems tn the factory
(2) computerization of the manufacturing support svstems
In modern production systems, the two categories overlap to some extent, because the
automated manulacturing systems operating on the lactory floor are themselves usually
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 computerintegrated manufacturing is used to indicate this extensive use of computers in
production systems.
1.1 Automated Manufacturing Systems
Automated manufacturing systems operate in the factory on the physical product. They perform
operations such as processing, assembly, inspection. and material handling. in some cases
accomplishing more than one of these operations in the same system. Thev 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. Thev generally operate as fully
automated systems although semi-automated systems are common in
Manufacturing Potential
support system computerization
applications
Production system Computer integrated
Facilities: Factory Potential Manufacturing
and Equipment automation
applications
, Fixed Automation. Fixed automation is a system in which the sequence of processing (or
assembly) operations is fixed by the equipment configuration. Each operation in the sequence ts
usually simple, involving perhaps a plain linear or rotational motion or an uncomplicated
combination of the two, such as the feeding of a rotating spindle. It is the integration and
coordination of many such operations into one piece of equipment that makes the system
complex. Typical features of fixed automation are (1) high initial investment for custom-
engineered equipment, (2) high production rates, and (3) relative inflexibility of the equipment to
accommodate product variety.
The economic justification for fixed automation is found in products that are produced in very
large quantities and at high production rates. The high initial cost of the equipment can be
spread over a very large number of units, thus making the unit cost attractive compared with
alternative methods of production. Examples of fixed automation include machining transfer
lines and automated assembly machines.
Programmable Automation. In programmable automation, the production equipment is
designed with the capability to change the sequence of operations to accom: modate different
product configurations. The operation sequence is controlled by 4 program, which is a set of
instructions coded so that they can be read and interpreted by the system. New programs can
be prepared and entered into the equipment to produce new products. Some of the features that
characterize programmable automation include :
(1) high investment in general purpose equipment
(2) lower production rates than fixed automation
(3) flexibility to deal with variations and changes in product configuration.
(4) high suitability for batch production.
Programmable automated production systems are used in low- and men volume production.
The parts or products are typically made in batches. To pre a cach new batch of a different
product, the system must be reprogrammed with the set of machine instruction that correspond
to the new product. The physical setup of the machine must also be changed Tools must he
loaded. fixtures must be attached to the machine table, aud ihe regutrcd machine settings must
be entered. This changeover procedure takes time. Consequently, the typical cycle for a given
product includes a period during which the setup and reprogramming takes place. followed by a
period in which the parts in the batch are produced. Examples of programmable automation
include numerically controlled (NC) machine tools, industrial robots, and programmable logic
controllers.
Flexible Automation. Flexible automation is an extension of programmable automation. A
flexible automated system is capable of producing a variety of parts (or products) with virtually
no time lost for changeovers from one part style to the next. There is no lost production time
