1. The University of Jordan Mechatronics Engineering Department
Automation
Chapter 1
Introduction
Dr. Osama Al-Habahbah
2015

2. 1.0 Introduction
The economic realities of the modern world that affect manufacturing enterprises are:
Globalization.
International outsourcing .
Local outsourcing .
Contract manufacturing .
Trend towards the service sector in developed economies.
Quality expectations.
Operational efficiency.

3. International outsourcing
Globalization
More countries are becoming industrialized, such as China and India, due to their high population and low labor cost .
International outsourcing
More parts and products are outsourced to companies outside
the USA .
Local outsourcing
Within the same country . Due to specialty of the suppliers, cheaper rate in smaller companies, lack of in-house manufacturing capability

4. Contract manufacturing
The customer designs product while the supplier makes the product .
Trend towards the service sector in developed economies
Erosion of direct manufacturing .
Quality expectations
Perfect quality is expected
Operational efficiency
Used to offset the high labor cost

5. Some modern manufacturing technologies that help to compete :
Automation
Material handling technologies
Manufacturing system
Flexible manufacturing
Quality programs
Computer Integrated Manufacturing (CIM)
Lean production

6. Automation
Reduces labor cost, decreases production cycle time, and improves quality.
Material handling technology
Include transportation, storage, tracking .
Manufacturing system
Production line, manufacturing cells.
Flexible manufacturing
Helps to compete in the low-volume/hig-mix product categories .

7. Computer Integrated Manufacturing (CIM)
Quality programs
Such as statistical quality control and six sigma.
Computer Integrated Manufacturing (CIM)
Includes (CAD) : Computer Aided Design,(CAM): Computer Aided Manufacturing, and integrating computer networks .
Lean production
Accomplish more with less resources  increases productivity

8. 1.1 production system
It is a collection of people, equipment, and procedures to perform the manufacturing operation they are two categories
Facilities
Manual support system
Factory
Equipment
Layout
The set of procedures used by the company to manage production ,such as product design.

9. Facilities Manual work system Worker machine Automated
Using unpowered hand tool
Using power equipment
Automated facility branches out-to:
Semi-automated machines and fully automated machines

10. Functions of Manufacturing support system
Business function
Product design
Manufacturing planning
Manufacturing planning control
Communicating with customer
Either provided by customer or in house if it’s proprietary
Scheduling, Capacity, planning and process planning
Shop floor control
Product progress
Inventory control
Balancing too little and too much inventory
Quality control
Product quality meets standard

11. 1.2 Automation in production system
1.2.1 Automated Manufacturing System
Examples include :Automated machine tool that process parts , Automated assembly , Industrial robots , Automatic material handling storage , Automatic quality control (inspection).

12. Types of automated manufacturing systems Fixed automation programmable
flexible
Minimal change High initial investment , high production rate, inflexibility
High initial investment , high production rate, inflexibility
High investment , low production rate, flexibility

13. 1.2.2 Computerized Manufacturing Support System
Computer Integrated Manufacturing (CIM) : Such as CAD / CAM

14. 1.2.3 Reason for Automating Increase labor productivity .
Reduce labor cost .
Mitigate the effect of labor shortages
Reduce manufacturing lead time
Accomplish processes that can’t be done manual .
To avoid the high cost of not automating (competition)
Eliminate routine tasks
Improve safety
Improve quality

15. 1.3 Manual labor in production systems
It is still needed .
1.3.1 Manual labor in factory operations
It can be preferred to automation in some cases :

16. 1.3.1 Manual labor in factory operations
1- Task is technologically or economically too difficult to automate . < E.g: hand-eye coordination >.
2- Short product life cycle <Automation takes time>.
3- Customized product .
4- Ups and downs in demand .
5- To reduce risk of products failure < In the market>.
6- Lack of capital to invest in automation.

17. 1.3.2 Labor in manufacturing support system
Equipment maintenance
Programming and computer operation
Engineering project work
Plant management.

18. 1.4 Automation Principle And Strategies
The USA Principle
Stand for
Simplify the process.
Automate the process.
Understand the exiting process.

19. 1.4.2 Ten strategies for Automation and process improvement
1- Specialization of operations: Use of special-purpose equipment for greatest efficiency. 2- Combined operations: Perform more than one operation at a given machine. 3- Simultaneous operations: To reduce processing time. 4- Integration of operations: Linking work-stations together → increasing output 5- Increased flexibility: Maximum utilization of equipment → Use the same equipment for a variety of products.

20. 1.4.2 Ten strategies for Automation and process improvement
6- Improved material handling and storage: reduce work in process and shorter manufacturing lead times. 7- On-line inspection: (of quality) reduce scrap and improves quality. 8- Process control and optimization: process time decrease ,quality increase. 9- Plant operations control (of the factory) 10-Computer-integrated manufacturing CIM: ( Design → Operations → Business ) Computer Network

21. Moving from manual to automated.
Automation Migration Strategy
Moving from manual to automated.
Phase 1
Phase 2
Phase 3
Manual production.
Automated production → single-station system.
Automated integrated production
→ multi-station system.

22. 1.4.3 Automation Migration Strategy
Advantages of this strategy:
Short product introduction time.
Gradual automation.
Lower risk at the start.