Automation

System Integration and

Implementing Automation
Successfully

By
Naresh Kantoor
Director, Encon Systems,
Gurgaon, Haryana.
EnconSystems
 Encon Systems

461, Pace City II, Sector 37,

Gurgaon – 122001, Haryana, India.
Tel. 91-124-4276461 to 4276463
Fax. 91-124-4276460
e-mail :- etpl@enconsystems.com
website :- http://www.enconsystems.com

EnconSystems
 Encon Systems

Systems Integrator
Rockwell
Automation

**
IAI - Intelligent Actuators, Japan
Cartesian & SCARA Robots.

EnconSystems
 WHAT DO WE DO ?

• Manufacturing Automation
• Low Cost Automation Solutions
• Lean Manufacturing, Poke-Yoke etc.
• Transfer Systems
• Control Systems
• e-Manufacturing Solutions
• Robotics

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 IN THIS PRESENTATION
WE WILL COVER -

1. Strategy for Automation

2. Level of Automation To Choose
3. A Roadmap For Automation Integration
4. Case Studies

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 1. Strategy for Automation

1.1 Why Automate?

1.2 Important characteristics to consider
1.3 Examine Options
1.4 Selection Of Mfg Automation Projects

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 1. Strategy for Automation

1.1 Why Automate?

1.1.1 Increase production

1.1.2 Better Use of Men, machine, Material,
Money
1.1.3 Increased Quality of Manufactured
Products
1.1.4 Increased Safety of Operation

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 1. Strategy for Automation

1.2 Important characteristics to

consider

1.2.1 Characteristics of Process

1.2.2 Characteristics of Components
1.2.3 Characteristics of Fixture

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 1. Strategy for Automation

1.3 Examine Options

1.3.1 If various operations can be combined

1.3.2 If non-value added operations can be
. eliminated e.g. operator moving the
components
1.3.3 Unloading of component by LCA
1.3.4 First make operation easier for operator,
then it becomes easy to automate.

EnconSystems
 1. Strategy for Automation

1.4 Selection Of Mfg Automation Projects

1.4.1 Consider Plant Requirements

1.4.2 Management Objectives
1.4.3 Adaptability to Change
1.4.4 In-house Technical Strength

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 2. Level of Automation To Choose

2.1 High End

2.2 Mid Level
2.3 Low Level

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 2. Level of Automation To Choose

2.1 High End (examples)

2.1.1 Robotics Control

2.1.2 Flexible Manufacturing Systems
2.1.3 e-Manufacturing

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 2. Level of Automation To Choose

2.2 Mid Level

2.2.1 Semi Automatic Controls

2.2.2 Sequence Controls
2.2.3 Pick and Place
2.2.4 Auto conveying and Transfer
2.2.5 Auto data capture and analyze

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 2. Level of Automation To Choose

2.3 Low Level (examples)

2.3.1 Use of Power Tools

2.3.2 Automated Mechanical Aids
2.3.3 Simple Sequence Controls
2.3.4 Fixtures to simplify work &
Operations

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 3. Roadmap For Automation
Integration

3.1 Advance Planning

3.2 Make a Detailed Document
3.3 Selection of Right Hardware
3.4 Implementation of Integration

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 3. Roadmap For Automation Integration

3.1 Advance Planning

3.1.1 Proper Planning will Prevent Poor Performance

3.1.2 Discuss the common and specialized benefits
each user would receive from the project.
3.1.3 Check if user and maintenance team will be
able to handle the complexities.
3.1.4 Plan for transition to automated system –
training the right people.
3.1.5 Plan Systems which can expand with Vision
for tomorrow

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 3. Roadmap For Automation Integration

3.2 Make a Detailed Document

3.2.1 Ideally, the basic design should be made by the

engineers who will be responsible for
implementing it - the user team, the integrator’s
engineers, or both.
3.2.2 Clearly indicate how the completed automated
system will work and objectives met.
3.2.3 Draw detailed specifications of all the
components to be used.
3.2.4 Identify right engineering resources.

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 SAMPLE DOCUMENTATION

Project identification
Concept definition
Requirements definition
Design specification
Implementation description
Final operation
Decommission definition
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- .
 3. Roadmap For Automation Integration

3.3 Selection of Right Hardware

3.3.1 Information – The Input Hardware

3.3.2 Interpretation – The Control Hardware
3.3.3 Instruction – The Output Hardware

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 Automation Elements
Input Devices

- Proximity Sensor - Photo Sensor

- Laser Sensor - Vision Sensor
- Ultrasonic Sensor - Limit Switches
- Push Switches - Transmitters
- Pressure - Temperature
- Humidity - level etc.

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 Automation Elements
Controllers

– Pneumatic Control
- Relay Logic
- Hardwired
- PLC, SCADA
- PC Based
- Embedded Microcontrollers
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EnconSystems
 Automation Elements
Output Devices

- Pneumatic Actuators, cylinders, valves

- Hydraulic Actuators, cylinders
- Electrical actuators, motors, magnets
- VFDs, Servo, Stepper motors,
- Indication Lamps etc.

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 Automation Elements
Advanced Systems
- Bar Code Reader / Writer
- RFID Reader / Writer
- Vision System
- LVDT measuring tools
- Laser Systems

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 4. Case Study

4.1 Automation of Auto Lathes & Broaching

Operation.

4.2 Automation of Unloading of Railway

Bearing after machining / Assembly

4.3 Automation of Production Data / OEE

from Machines.

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 4. Case Study

4.1 Auto-component manufacturer

Objective of LCA on a Turning &

Broaching Line-

* To reduce WIP
* Automate Loading Unloading
* Single Piece flow
* Reduce manual handling

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WIP - Before LCA

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 Case Study
Introduced conveyor in between 4 lathes

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 Case Study
Introduced Poke-Yoke

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 Case Study
Introduced Automatic Transfer

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 Case Study
Second transfer Conveyor

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 Case Study
Automatic Loading Pick N Place

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 Case Study
Automatic Discharge

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4. Case Study - Video 1

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 4. Case Study
4.1 Auto-component manufacturer

After Automation -

* WIP reduced to almost Nil

* On – Line inspection
* Single Piece flow
* Manpower reduced from 4 to 1
per shift

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 4. Case Study
4.2 Automation of Unloading of
Railway Bearing after
machining / Assembly

Objective of Automation-

* To reduce Operator Fatigue

* Automate Palletization
* Operator Safety
* Relocate Manpower

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 4. Case Study
4.2 Automation of Unloading of Railway
Bearing after machining / Assembly
Before Automation

EnconSystems
 4. Case Study
4.2 Automation of Unloading of Railway
Bearing after machining / Assembly
Before Automation

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4. Case Study

Video 2

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 4. Case Study
4.3 Automation of Production
Data / OEE from Machines.

Objective of Automation-

* To get on-line production data

* To check machine efficiency
* To upload information on MIS

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 Present Methodology

SHOP

DATA

OFFICE OFF LINE

Report Generation

EXCEL

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Automated Methodology

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Control System Architecture For Data Collection & Display

Data concentrator Line ABC

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Signals from Machine and Processes
 ANDON ARCHITECTURE

42” SONY LCD

DISPLAY

FT Metrics
Server

Ethernet Layer

Controller

It can be expanded in future

up to Multiple workstations

1 2 3 4 5

Input 6 Input 6 Input 6 Input 6 Input 6

Output
Output Output Output Output
5 5 5 5 5

Workstations 1 - 5 EnconSystems
Daily Production Summary of Line 1

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Hourly Production Data of Line 1

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OEE Report of Line 1
Weekly Report For Product ABC Line

Product ABC

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Andon-Board For Line Supervisor And operators

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Current Status Indication

Current Status Indication

Production Line # 1

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FIFO Racks Status of Empty Bins

PRODUCTION LINE 1

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 4. Case Study
4.3 Automation of Production
Data / OEE from Machines.

Observations -

* OEE Measured is much lower

than calculated OEE
* OEE Measured is more than
112%
* Production capacity calculation
for negotiation

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QUESTIONS ?

EnconSystems