Automation in manufacturing

Evolution of industrial automation and Industry 4.0

Prof. Abdollah Saboori

Politecnico di Torino
Department of Management and Production Engineering (DIGEP)

abdollah.saboori@polito.it
 What is manufacturing?
 The word manufacture is derived from two Latin words manus (hand) and factus (make), the combination
means made-by-hand.

 Made-by-hand accurately described the manual methods used when the English word manufacture was first
coined around 1567 A.D.

 Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or
appearance of a given starting material to make parts or products.

 Manufacturing also includes assembly of multiple parts to make products.

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 What is manufacturing?
 Manufacturing is almost always carried out as a sequence of operations.
 Manufacturing is the transformation of materials into items of greater value by means of one or more
processing and/or assembly operations.
 Manufacturing adds value to the material by changing its shape or properties or by combining it with
other materials that have been similarly altered

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 The importance of manufacturing
 Technological perspective
 Technology can be defined as the application of science to provide society and its members with those
things that are needed or desired

 Economic perspective
 Manufacturing is a means by which a nation creates material wealth

 Historical perspective
 Historically, the importance of manufacturing in the development of civilization is usually
underestimated

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 What is a manufacturing systems?
 A manufacturing system is defined as a collection of integrated equipment and human resources,
whose function is to perform one or more processing and/or assembly operations on a starting raw
material, part, or set of parts.
 Equipment includes

 Production machines and tools

 Material handling and work positioning devices

 Computer systems

 Human resources are required either full-time or periodically to keep the system running.

 Automation and material handling technologies, as well as human workers, are combined to create
manufacturing systems.
 The manufacturing system is where the value-added work is accomplished on the parts and products.

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 Components of a manufacturing system

Production machines

Material handling system

Computer system to coordinate and/or control

the preceding components

Human workers to operate and manage the system

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 Production machines
 In virtually all modern manufacturing systems, most of the actual processing or assembly work is
accomplished by machines or with the aid of tools

Manually operated machines are controlled or supervised

by a human worker. The machine provides the power for
the operation and the worker provides the control. The
entire work cycle is operator controlled.

A semi-automated machine performs a portion of the

work cycle under some form of program control, and a
worker tends to the machine for the remainder of the cycle.
Typical worker tasks include loading and unloading parts

Fully automated machine operates for extended periods

(longer than one work cycle) without worker attention
(periodic tending may be needed).

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 Material handling system
 In most manufacturing systems that process or assemble discrete parts and products, the following material
handling functions must be provided:
 Loading work units at each station
 Positioning work units at each station
 Unloading work units at each station
 Transporting work units between stations in multi-station systems
 Temporary storage of work units

Fixed routing
Work units always flow through the
same sequence of workstations

Variable routing
Work units are moved through a
variety of different station sequences

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 Computer control system

 Typical computer functions in a manufacturing system:

 Communicate instructions to workers
Receive processing or assembly instructions for the specific work unit
 Control material handling system
 Download part programs to computer-controlled machines
 Schedule production
 Failure diagnosis when malfunctions occur and preventive maintenance
 Safety monitoring
Protect both the human worker and equipment
 Quality control
Detect and reject defective work units produced by the system
 Operations management
Manage overall operations
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 Human resources
 In many manufacturing systems, humans perform some or all of the value-added work
on the parts or products. In these cases, the human workers are referred to as direct
labor. Through their physical efforts, they directly add to the value of the work unit by
performing manual work on it or by controlling the machines that perform the work.
 In fully automated systems, direct labor may still be needed to perform activities such as
periodically loading and unloading parts, changing tools, and resharpening tools.
 Human workers are also needed in automated manufacturing systems to manage or
support the system as computer programmers, computer operators, part programmers
for computer numerical control (CNC) machine, maintenance and repair personnel, and
similar indirect roles.
 In automated systems, the distinction between direct and indirect labor is not always
precise.

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 Manufacturing systems

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 What is automation?

 Automation is the conversion of a work process, a procedure, or equipment to automatic (with little to no
human assistance) rather than human operation or control.

 Automation does not simply transfer human functions to machines, but involves a deep reorganization of
the work process, during which both the human and the machine functions are redefined.

 Early automation relied on mechanical and electromechanical control devices.

 During the last 40 years, however, the computer gradually became the leading vehicle of automation. Now,
automation includes electronic and computer controls.

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 Automation of manufacturing processes
 Automation of manufacturing processes is achieved through:

 Observing all manufacturing operations

 Making decisions
 Controlling all operations

 Automation is an evolutionary rather than a revolutionary concept, and it has been implemented
successfully in the following basic areas of activity:
 Manufacturing processes and operations
 Material handling
 Inspection
 Assembly
 Packaging

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 Automation of manufacturing processes

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 The goals of automation
 Integrating various aspects of manufacturing operations to improve product quality and uniformity,
minimize cycle times and involved effort, and reduce labor costs.
 Improving productivity by reducing manufacturing costs through better control of production. Raw
materials and parts are loaded, fed, and unloaded on machines faster and more efficiently; machines are
used more effectively; and production is organized more efficiently.
 Improving quality by improving the repeatability of manufacturing processes.
 Reducing human involvement, boredom, and the possibility of human error.
 Reducing workpiece damage caused by manual handling of parts.
 Economizing on floor space by arranging machines, material handling and movement, and auxiliary
equipment more efficiently.
 Raising the level of safety for personnel, especially under hazardous working conditions.

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 The history of automation in industry
 The history of automated devices extends as far back as the ancient Greeks’ and Persians’ invention of
timekeeping mechanisms.
 Some experts trace the assembly line as far back as 1104 AD, to the Venetian Arsenal, when an estimated
16,000 workers laboured to build one ship per day for the Republic of Venice.

The internal workings of a water-clock. From ‘The Book of Archimedes on Venetian Arsenal, 1724 engraving by Joan Blaeu
the Construction of Water-Clocks’. Or. 14270, f. 16v

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 The first industrial revolution
 In the time period between 1760 and 1840, there
was the transition from skilled artisans making
goods by hand to (relatively) unskilled workers
using machines powered by a water wheel or
steam engine.

 The transition was most prevalent in the textile

industry, but the effects of the first industrial
revolution were eventually felt in almost every
aspect of daily life.

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 The second industrial revolution

 The second industrial revolution took place from about

1870 to 1914 and the beginning of World War I. Unlike
the first industrial revolution, which was characterized
by the advent of new technologies, the second industrial
revolution had more to do with improving existing
technologies and the synergies between them. For
example, electricity replaced water and steam as the
primary power source in factories.

 The second industrial revolution also marked the

beginning of the assembly line, interchangeable parts
and, with them, mass production.

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 Frederick Taylor scientific management

Integrated Manufacturing Systems | Industrial automation and Industry 4.0 https://youtu.be/vNfy_AHG-MU 1

 The third industrial revolution
 The third industrial revolution, saw the introduction of
disruptive new technologies, in this case, automation
and the computer.

 These advancements brought about monumental

changes to manufacturing, enabling levels of
precision (thanks to industrial robots) and accuracy
(thanks to Computer Numerical Controls (CNCs),
never before seen on the shop floor.

 The beginning can be traced to the early 1960s, which

saw the introduction of the first industrial robot and
first commercial CNCs.

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 The history of automation in industry
 Phase I: Mechanization and rationalization of labour

 The mechanization of machine tools for production began during the Industrial Revolution at the end of the 18th
century with the introduction of the Watt steam engine. Mechanization replaced human or animal power with
machine power; those mechanisms, however, were not automatic but controlled by factory workers.

 In the late 19th century Frederick W. Taylor rationalized the factory system by introducing the principles of scientific
management. Scientific management strictly separated mental work from manual labour: workers were not to think
but to follow detailed instructions prepared for them by managers.

 In 1913 the Ford Motor Company introduced a moving assembly line, drastically cutting assembly time. The
assembly line imposed a strict order on production by forcing workers to keep pace with the motion of the conveyor
belt. The Ford assembly line became a symbol of efficiency of American manufacturing; for workers and social
critics, however, it epitomized the monotony and relentless pressure of mechanized work.

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 The history of automation in industry

 Phase II: Automation of production

 In 1947 the Ford Company brought the term automation into wide circulation by establishing the first Automation
Department, charged with designing electromechanical, hydraulic, and pneumatic parts handling, work-feeding, and
work-removing mechanisms to connect standalone machines and increase the rate of production. In 1950 Ford put into
operation the first automated engine plant.
 To meet US Air Force demands for a high-performance fighter aircraft whose complex structural members could not
be manufactured by traditional machining methods, a technology of Numerical Control (NC) of machine tools was
developed in the early 1950s.
 Designed to military specifications, early NC equipment proved too complex and therefore unreliable, as well as
prohibitively expensive, and was applied mostly in the state-subsidized aircraft industry.
 NC technology allowed engineers and managers to exercise greater control over the production process.

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 The history of automation in industry

 Phase III: Computer-Aided Manufacturing (CAM)

 The first industrial applications of digital computers occurred in the electrical power, dairy, chemical, and petroleum
refinery industries for automatic process control. In 1959, TRW installed the first digital computer designed
specifically for plant process control at Texaco's Port Arthur refinery.
 In the late 1960s, with the development of time sharing on large mainframe computers standalone NC machines were
brought under Direct Numerical Control (DNC) of a central computer.
 With the introduction of microprocessors in the 1970s, centralized DNC systems in manufacturing were largely
replaced by Computer Numerical Control (CNC) systems with distributed control, in which each NC machine was
controlled by its own microcomputer.
 Robotics combined the techniques of NC and remote control to replace human workers with numerically controlled
mechanical manipulators. The first commercial robots appeared in the early 1960s.
 Flexible Manufacturing Systems (FMS) combined DNC equipment with machine for automated loading, unloading,
and transfer of workpieces. These systems permitted varying process routes and sequences of operations, allowing
automatic machining of different products in small batches in the same system.

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 The history of automation in industry
 Phase IV: Automated engineering

 In the 1960s large aerospace manufacturers, such as McDonnell-Douglas and Boeing, developed proprietary
computer-aided design (CAD) systems, which provided computer graphics tools for drafting, analysing, and
modifying aircraft designs.
 In 1970 Computer Vision Corporation introduced the first complete turnkey commercial CAD system for industrial
designers, which provided all the necessary hardware and software in one package.
 In the 1970s, combined CAD/CAM systems emerged which used the parameters of a geometrical model created
with the help of CAD to generate programs for CNC machine tools and develop manufacturing plans and
schedules. While CAD systems are often standardized, CAM (Computer-Aided Manufacturing) applications tend
to be industry-specific and proprietary.
 With the introduction of Computer-Aided Engineering (CAE) systems for standard techniques of engineering
analysis, the whole range of engineering tasks – from conceptual design to analysis to detailed design to drafting
and documentation to manufacturing design – became automated.

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 The history of automation in industry
 Phase V: Automated management

 Among the earliest applications of information technology was the automation of information-processing tasks.
The first stored-program digital computer purchased by a nongovernment customer was UNIVAC, installed by GE
in 1954 to automate basic transaction processing: payroll, inventory control and material scheduling, billing and
order service, and general cost accounting.
 In the mid-1960s the first management-information systems (MIS) appeared, providing management with data,
models of analysis, and algorithms for decision-making; eventually they became a standard tool for operation
control, management control, and strategic planning.

 Phase VI: Computer-Integrated Manufacturing (CIM)

 In the late 1980s an integration of the automated factory and the electronic office began. CIM combines flexible
automation (robots, numerically controlled machines, and flexible manufacturing systems), CAD/CAM systems,
and management-information systems to build integrated production systems that cover the complete
operations of a manufacturing firm, including purchasing, logistics, maintenance, engineering, and business
operations.

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 The history of automation in industry

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 The fourth industrial revolution
 All previous industrial revolutions have had both positive and
negative impacts on different stakeholders.

 Nations have become wealthier, and technologies have helped

pull entire societies out of poverty, but the inability to fairly
distribute the resulting benefits or anticipate externalities has
resulted in global challenges.

 This revolution is about much more than technology.

 It is an opportunity to unite global communities, to build

sustainable economies, to adapt and modernize governance
models, to reduce material and social inequalities, and to
commit to values-based leadership of emerging technologies.

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 The fourth industrial revolution
 The fourth industrial revolution is therefore not a prediction of the
future but a call to action.

 The fourth industrial revolution is a vision for developing,

diffusing, and governing technologies in ways that foster a more
empowering, collaborative, and sustainable foundation for social
and economic development, built around shared values of the
common good, human dignity, and intergenerational stewardship.

 Realizing this vision will be the core challenge and great

responsibility of the next 50 years.

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 What is the fourth industrial revolution?

Integrated Manufacturing Systems | Industrial automation and Industry 4.0 https://youtu.be/kpW9JcWxKq0

 Industry 4.0
 Industry 4.0 is “the comprehensive transformation of the whole sphere of industrial production
through the merging of digital technology and the internet with conventional industry” (Angela
Merkel, German Chancellor).

 In short, everything in and around a manufacturing operation (suppliers, the plant, distributors, even the
product itself) is digitally connected, providing a highly integrated value chain.

 The term Industry 4.0 originated in Germany, but the concept largely overlaps developments that, in other
European countries, may variously be labelled: Smart factories, the Industrial Internet of Things, Smart
industry, or Advanced manufacturing.

 Industry 4.0 is the digital transformation of manufacturing, leveraging third platform technologies
(Social, Mobile, Cloud & Analytics, possibly IoT) and innovation accelerators in the convergence of IT
(Information Technology) and OT (Operational Technology) to realize connected factories and industry,
smart decentralized and self-optimizing systems and the digital supply chain in the information-driven
cyber-physical environment of the 4th industrial revolution.

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 The nine pillars of technological advancement
 In Industry 4.0, digital technologies will interconnect to offer exceptional speed and communication along the
value chain.
 Following is a list of the nine pillars of technological advancement:

1. Additive Manufacturing
2. Augmented Reality
3. Autonomous Robots
4. Big Data and Analytics
5. The Cloud
6. Cybersecurity
7. Horizontal and Vertical System Integration
8. Internet of Things (IoT)
9. Simulation

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 The nine pillars of technological advancement

 Additive Manufacturing refers to the 3D technology that creates objects — and potentially organic parts
— by appending successive layers of material. This technology offers a strong application for prototype
work, small custom batches, and lightweight, locally produced parts.

 Augmented Reality offers benefits for training, troubleshooting, and repairs during service calls.

 Autonomous Robots. Autonomous capabilities increase the utility of robots, allowing them to adjust
actions based on a particular activity or on the product’s level of completeness. In addition to collaborating
safely with humans, robots can also work together with humans. In manufacturing, for example, an
application may include the portable assembly line. Using autonomous vehicles, you could ferry work in
progress between stations, rather than employ a fixed conveyor belt assembly line. Portable workstations
provide the convertibility that accelerates turnaround in manufacturing. Increased cognitive automation
can also aid robots in decision making. Moreover, sophisticated cognitive automation can improve
manufacturing’s clerical activities. Armed with lines and machines that connect to your company’s ERP,
you can generate products based on orders rather than projections, reducing costly lead time.

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 The nine pillars of technological advancement
 Big Data and Analytics. Huge volumes of data and advanced data analytics capabilities mean greater
quality and service. Companies can collect data at each stage of the chain to ultimately improve process
and save resources. Smart technologies enable predictive maintenance. Industry 4.0 combines predictive
maintenance with enhanced communication capabilities to increase efficiency and energy savings in smart
service lines and factories.

 The Cloud. Interconnectedness in manufacturing requires collaboration and contact beyond facility and
company boundaries. Fast cloud computing permits data collection, analysis, storage, and even
monitoring.

 Cybersecurity. The move away from closed systems and toward interconnectedness demands higher
levels of user-access security and cybersecurity for networks that relay precision data and control
machines.

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 The nine pillars of technological advancement

 Horizontal and Vertical System Integration. System integration signifies the complete coordination of
all departments and entities along the supply chain, beginning with machine-to-machine (M2M)
communication on the factory floor. For example, producers receive information from their supply chain
and sales organizations, and engineering departments maintain a connection to production. Cloud
computing enables much of these capabilities.

 Internet of Things (IoT). When they all contain IoT sensors, devices along the production line, in the
field, and in control centres can interact with one another to provide granular data and faster responses.
With IoT technology, these devices can also include the wired and wireless capability to communicate with
the cloud and to offer predictive maintenance.

 Simulation. 3D simulations of products, materials, and production processes can leverage real-time data to
present virtual models of entire production systems. With enhanced simulation, you can test and optimize
tool settings before lines change over.

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 Industry 4.0
 As businesses adopt Industry 4.0 approaches, experts expect productivity to increase, thereby propelling
economic growth.

 The nine pillars of technological advancement that comprise the foundation of Industry 4.0 are already
used in manufacturing.

 With Industry 4.0 approach, the nine pillars of technological advancement will transform production.

 Isolated, optimized cells will come together as a fully integrated, automated, and optimized production
flow, leading to greater efficiencies and changing traditional production relationships among suppliers,
producers, and customers as well as between human and machine.

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 From traditional manufacturing to Industry 4.0

https://www.bcg.com/it-it/publications/2015/engineered_products_project_business_industry_4_future_productivity_growth_manufacturing_industries

Integrated Manufacturing Systems | Industrial automation and Industry 4.0 36

 The vision of tomorrow's manufacturing

Integrated Manufacturing Systems | Industrial automation and Industry 4.0 https://youtu.be/HPRURtORnis

 Smart factory explained

Integrated Manufacturing Systems | Industrial automation and Industry 4.0 https://youtu.be/h9t06cyC7Es

 Automation in manufacturing
Evolution of industrial automation and
Industry 4.0

Question???

abdollah.saboori@polito.it
Integrated Manufacturing Systems | Industrial automation and Industry 4.0 39