Industrial Automation and Manufacturing Systems: Concepts and Applications Abdul Sattar 1,a, Qadir Bakhsh 1,b, Muhammad Sharif 2,c

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1 Advanced Materials Research Online: ISSN: , Vol. 903, pp doi: / Trans Tech Publications, Switzerland Industrial Automation and Manufacturing Systems: Concepts and Applications Abdul Sattar 1,a, Qadir Bakhsh 1,b, Muhammad Sharif 2,c 1 Department of Mechanical Engineering, Quaid-e-Awam University of Engineering, Science and Technology Nawabshah Pakistan 2 Department of Mechanical Engineering, Mehran University of Engineering and Technology Jamshoro Pakistan jamali_sattar@yahoo.com a, qadirquest@gmail.com b, sharifjamali@hotmail.com c Keywords. Automation, Manufacturing system, Flexible manufacturing, Production Abstract. Manufacturing comprises an effective and efficient integration of automation tools and advanced technologies for the industrial production. Automation is an advanced technique used in the manufacturing industry for integrating the machine tools to automatically perform different tasks. This paper presents the study about industrial automation and manufacturing system. The research and development in the area of automation includes programmable logic control (PLC), robotics, distributed control system (DCS), computerized numerical control machine (CNC), radio frequency identification (RFID). The intelligent systems for scheduling and manufacturing the product such as flexible manufacturing systems (FMS), computer aided manufacturing (CAM), computer integrated manufacturing (CIM), lean manufacturing and green manufacturing. Introduction Manufacturing is the production of finish goods using man power and machines, tools, chemical and biological processing, or formulation. It may refer to the human activities from manual work to advanced technology, but it is commonly used in the industries by convert raw material into finish goods, shown in Fig. 1. Such product of one industry can be used as a raw material for manufacturing other, more complex products. Advanced manufacturing system covers number of intermediate processes, which has been used for the production and integration of a product's component. Fig. 1 Manufacturing process This aim of the paper is to contribute to a better understanding of industrial automation and manufacturing systems. The scope covers the conceptual study of industrial automation methods mostly used in the industries, such as Robotics, CNC machines, RFID, DCS and PLC system, the manufacturing systems such as flexible manufacturing, agile manufacturing, re-entrant manufacturing, and reconfigurable manufacturing system. All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of Trans Tech Publications, (# , Pennsylvania State University, University Park, USA-19/09/16,00:31:56)

2 292 Manufacturing Engineering Industrial Automation It is a technology used to optimize the rate of production and product dispatch system by the help of machines, control systems and information technologies. The major benefits for introduction of automation in the industries, is to enhance the rate of production and quality of product as compared to possibilities with manual labour. The automation is stood as second after mechanization system, whereas mechanization provides human manual operators with machinery. It highly reduces the requirement of human skill and mental approach, while increase in workload, speed and repeatability. The types of automation mostly used in the industry are shown in Fig. 2. The advantages and disadvantages are given in Table 1. Fig. 2 Industrial automation In the industries, the automatic control system enables a safe, profitable and high production process [1]. In industries, an established system must trade off between the involved fixed costs for advanced equipments and the reduction of the variable costs for energy consumption [2]. Generally, the commands used by CNC system are G codes, which contain incremental or absolute position data of each axis, spindle speed, feed rate and other information [3]. PLC system has been used to coordinate in the monitoring, management and control of various complex processes in manufacturing industries [4]. New control device based on microprocessor, automation and communication technology with high characteristics of reliability and very convenient to use in industries [5]. Industrial robots work like scouts, to complete task within specific environment in a proper behaviour to avoid time delay and production stoppage, it also can be automatic or manual operated system [6]. RFID technology collects data about a certain item or product by the use of electromagnetic waves without any physical interaction with the data label [7]. Table 1. Advantages and disadvantages of industrial automation Advantages Disadvantages Increase rate of productivity Less secure Improved quality or improve predictability of High installation cost quality Enhanced the robustness of product High maintenance and running cost Reduced the time consumption in product Increase unemployment manufacturing Reduced the time for finished goods dispatch Need more skilled workers or technicians Increased customer satisfaction

3 Advanced Materials Research Vol Manufacturing Systems A manufacturing system can be defined as the arrangement and operation of machines, tools, material, man power and information to produce finish goods, informational or service product. It can be classified in various types; few of them are shown in Fig. 3. The advances in the industries carried out by the manufacturing systems used and implemented for all production line and documentations. The design of a manufacturing system comprises many parameters, from machine tools used for production to the communication and documentation of product, the system design flow is shown in Fig. 4 [8]. The capabilities of manufacturing system contain the resources, skills and operations of a firm. It consist process modularity, integration and automation [9]. Based on the various product demands, the manufacturing system adjusted to the fast market change such as, cost benefit, economical and makes manufacturing process quickly. It accomplished by itself in terms of organizing, liberalization, study and maintenance for the whole manufacturing process [10]. Fig. 3 Manufacturing systems Fig. 4 Manufacturing System design [8]

4 294 Manufacturing Engineering Flexible manufacturing. It is defined as a system in which, the group of numerical control machines and all other material handling machines or tools integrated each other and work together under one computer control unit. This system gives advantages to manufacturing firms in quickly changing manufacturing environments. FMS integrated with computer application systems such as Group technology, computer aided process planning, material requirement planning. It is used to interlink between the high production line efficiency and job shop flexibility, which covers the mid volume batch production and various type of products. The flexible manufacturing system comprises flexible machining cell, machining system, transfer line and flexible transfer multi line [11]. A distinctive FM system can process continuous operation for the groups of one or more part families without any human intercession. It is flexible enough to fit for all market changes and product types without need of any other equipment or system [12]. A closed FMS environment shown in Fig. 5, the system consist three different machines are connected each other for process of buffering the product by machine buffer, pre- processed part buffer and finished parts buffer [13]. Fig. 5 FMS environment [13] Agile manufacturing. This manufacturing system closely related to the same approach as lean manufacturing system, its goal is to minimize the product waste. It mainly covers; process control, function, information, process communication, distribution, development, process implementation, requires high number of the customers and co-operation with market competitors [14]. Reconfigurable manufacturing. This system driven by smart sensing parameters such as vibration, temperature, finish quality and control, which are effective for the enhancement of production efficiency and rate of production processes in industries [15]. Re-entrant manufacturing system. This manufacturing system defines the work in process (WIP), the work piece or raw material repeatedly passes through the same machine or workstation at different stages of the process flows, shown in Fig. 6. The semiconductor manufacturing system is a best example of this manufacturing system [16]. Fig. 6 Re-entrant manufacturing model [16] Sustainable manufacturing: The system approach is to minimize the impact of environment and enhance the sustainability performance of a manufacturing system by implementation of

5 Advanced Materials Research Vol pollution control strategies shown in Fig. 7. It comprises three correlated components, which all are environmentally sustainable such as, material, technology and energy of a manufacturing system [17]. Fig. 7 Sustainable manufacturing system scheme [17] Conclusion It is concluded through our study that, many research was already has been done by researchers, scientist and engineers in the field of automation and manufacturing systems. The main focus of research was for better development of industrial environment by enhancing the rate of production, product quality, minimize production runtime, to reduce man power and energy consumption. Based on the current development on both eras, still need more effective and efficient method, coordination and advanced technology to improve the industrial environment. As this type of research is more important and still needed, we expect that in future the research and development work will focus on the more advancement on current techniques and systems used in industries. References [1] R. Bayindir and Y. Cetinceviz, A water pumping control system with a programmable logic controller (PLC ) and industrial wireless modules for industrial plants, An experimental setup, ISA Transactions, vol. 50, no. 2, pp , [2] M. Pellicciari, G. Berselli, F. Leali, and A. Vergnano, A method for reducing the energy consumption of pick-and-place industrial robots, MECHATRONICS, pp. 1 9, [3] B. U. Ping, L. I. Jiangang, and H. Liang, A General Motion Simulation Description of Multiaxis CNC Machine Tools, in proceeding of 31st chinese control conference, 2012, pp [4] Xiaomei Chen, Hongyi Gao, A Remote PLC Laboratory Design and Realization in proceeding 31 st of International Conference on Advances in Computational Modelling and Simulation 2012, pp [5] Q. Dongkai, Y. Xiangyu, and J. Jinxin, The Application of PLC to CNC Machine Tools Development, IEE 2nd international conference on digital manufacturing and automation pp , [6] R. Vidoni, F. García-sánchez, A. Gasparetto, and R. Martínez-béjar, An intelligent framework to manage robotic autonomous agents, Expert Systems With Applications, vol. 38, no. 6, pp , [7] T. Abinaya and M. Bharathi, Enhancement of RFID through ZigBee Networks, in International Conference on Computing and Control Engineering (ICCCE 2012), April, 2012.

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