Rapid improvements in both computer software and hardware have made possible a dramatic shift towards automation in the industrial manufacturing system. Now complete operation in factories can be done with limited human involvement, such automated industrial manufacturing systems rely on effective procedures for controlling their operation.
There are three major categories of manufacturing which are batch manufacture, Jobbing manufacture, and flow or mass production. The aim of automation in manufacturing systems is to raise the efficiency level of batch manufacture to flow manufacture, this can be greatly eased by using effective production planning and control system.
In automated manufacturing systems, integrated equipment is used and arranged in a manufacturing cell, this can range from material handling and work positioning devices, production machines, and tools, to the use of computer systems that can facilitate automation in the production environment of industries. The various types of manufacturing systems are as given below:
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Single station cell: It is a system in which one worker tends to work on one production machine that operates on a semi-automatic cycle.
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Machine cell or cellular manufacturing: It is a system in which a series of manually operated production machines and workstations are often arranged in a U-shaped configuration, which performs a sequence of operations on parts and products that are similar but not identical.
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Machine cluster: It is a system in which one worker tends to work on a group of semi-automated machines.
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Automated transfer line: It is a production line consisting of a series of automated workstations that perform operations such as machining, including automation of transfer of parts between workstations.
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Automated assembly station: It performs a sequence of mechanized or automated assembly operations.
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Flexible manufacturing system or FMS: It is a highly automated machine cell that often consists of workstations comprising machine tools that produce parts or products.
An automated manufacturing system consists of a group of processing workstations (usually NC machines) and is connected by an automated work part handling system. Under the control of the computer, it operates as an integrated system. It is capable of processing a variety of different parts simultaneously at different workstations. The work parts are unloaded and loaded at the central location in the system.
By using pallets, work parts are transferred between machines. After loading of work part onto the handling system, it is automatically routed to the particular work station for further processing. The routing, operations, and tooling required at each work station are different for different work part types. The control and coordination of processing activities and parts handling is accomplished under computer command.
There is careful coordination between different sections of the automated manufacturing system to pass the parts from one section to another. Each part has a different route and planning and controlling the movement of each part through different routes may be a complex problem.
Automation in industrial manufacturing systems will achieve this by several features:
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Equipment usage levels can be increased.
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Reduction in lead times can be achieved.
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Downloading part programs to NC machines can be relatively easy.
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Depending on the provision of a production planning and control system can be adequate and effective
Currently, industries are shifting the focus of automation from increasing productivity and cost reduction to increasing the quality and flexibility of processes. Thus, the automation of industrial manufacturing systems serves broader goals.