Unit-2:

Automation in Manufacturin

Dr.A.SASIKUMAr
Assistant Professor
Government college of technology, Coimbatore

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 Automation in machine tools
Mechanical feeding and tool changing - machine
tool control transfer automaton, automated flow
lines - Methods of work part transport transfer -
Line efficiency. Simulation in assembly line -
Analysis of Automated flow lines - General
terminology and analysis of transfer lines -
without and with buffer storage, partial
automation, Implementation of automated flow
lines. Buffer stock - Mechanical buffer storage
control function.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 2

 Automated Production Lines
 Automated production lines are used for high production
of parts that require multiple processing operations.
 Each processing operation is performed at a workstation,
and the stations are physically integrated by means of a
mechanized work transport system to form an
automated production line.
 Machining (milling, drilling, and similar rotating cutter
operations) is a common process performed on these
production lines, in which case the term transfer line or
transfer machine is used.
 Automated production lines require a significant capital
investment.
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Features and Applications of Automated transfer lines

• High production of parts requiring multiple processing

operations.
• Fixed automation
• Applications:
– Machining transfer lines
– Robotic spot welding lines
– Sheet metal stamping
– Electroplating of metals
– Electronics assembly

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 Where to Use
Automated Production Lines?
• High product demand
– Requires large production quantities
• Stable product design
– Difficult to change the sequence and content of processing
operations once the line is built
• Long product life
– At least several years
• Multiple operations required on product
– The different operations are assigned to different
workstations in the line

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 Benefits of
Automated Production Lines
• Low amount of direct labor
• Low product cost
-because cost of fixed equipment is spread over many units.
• High production rates.
• Manufacturing lead time and work-in-process are
minimized.
• Factory floor space is minimized.

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 Fundamentals of
Automated Production Line
 An automated production line consists of multiple
workstations that are linked together by a work
handling system that transfers parts from one station
to the next.

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 Fundamentals of Automated Production Line
 A raw workpart enters one end of the line, and the
processing steps are performed sequentially as the part
progresses forward.
 The line may include inspection stations to perform
intermediate quality checks.
 Manual stations may also be located along the line to
perform certain operations that are difficult or
uneconomical to automate.
 Each station performs a different operation, so that the sum
total of all the operations is required to complete one unit
of work.
 Multiple parts are processed simultaneously on the line,
one part at each workstation.
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 Fundamentals of Automated Production Line
 In the simplest form of production line, the number of parts
on the line at any moment is equal to the number of
workstations.
 In more complicated lines, provision is made for temporary
parts storage between stations, in which case there is on
average more than one part per station.
• Workpart transfer:
– Palletized transfer line
• Uses pallet fixtures to hold and move workparts
between stations
– Free transfer line
• Part geometry allows transfer without pallet fixtures

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 System Configurations
Depending upon the workflow, the automated transfer
lines are classified as below.
1) In-line (straight line) arrangement of workstations
2) Segmented in-line – two or more straight line
segments, usually perpendicular to each other
3) Rotary indexing machine (e.g., dial indexing
machine)

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 In-line (straight line) arrangement of
workstations

This configuration is common for machining big work pieces, such

as automotive engine blocks, engine heads and transmission cases.
Because these parts require a large number of operations, a
production line with many stations is needed.
The in-line configuration can accommodate a large number of
stations.
 In-line systems can also be designed with integrated storage
buffers along the flow path.
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 Segmented In-Line Configurations

L-shaped layout

U-shaped layout

Rectangular configuration
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 Segmented in-line arrangement of
workstations
The segmented in-line configuration consists of two or more
straight-line transfer sections, where the segments are
usually perpendicular to each other.
There are a number of reasons for designing a production
line in these configurations rather than in a pure straight line,
including:
1) Available floor space may limit the length of the line.
2) It allows reorientation of the work piece to present
different surfaces for machining.
3) The rectangular layout provides for return of work holding
fixtures to the front of the line for reuse.
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 Two Machining Transfer Lines

Figure: Line drawing of two machining transfer lines: At bottom right, the first is a 12-
station segmented in-line configuration that uses pallet fixtures to locate the work
parts. The return loop brings the pallets back to the front of the line.
The second transfer line (upper left) is a seven-station in-line configuration.
The manual station between the lines is used to reorient the parts.
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 Rotary configuration
 The work parts are attached to fixtures around the
periphery of a circular worktable, and the table is
indexed (rotated in fixed angular amounts) to present
the parts to workstations for processing.
 The worktable is often referred to as a dial, and the
equipment is called a dial indexing machine, or
simply, indexing machine.

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 Rotary configuration
 Although the rotary configuration does not seem to belong
to the class of production systems called "lines," their
operation is nevertheless very similar.
 Compared with the in-line and segmented in-line
configurations, rotary indexing systems are commonly
limited to smaller work parts and fewer workstations
 This configuration cannot accommodate buffer storage
capacity.
 The rotary system usually involves a less expensive piece of
equipment and typically requires less floor space.

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 Rotary Indexing Machine

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 Work Transport Systems
There are two basic ways to accomplish the
movement of work units along a manual
assembly line:
(1) manually or
(2) by a mechanized system.

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 Manual Methods of Work Transport
• In manual work transport, the units of product are passed
from station-to-station by hand.
• Two problems result from this mode of operation are
starving and blocking.
• Starving is the situation in which the assembly operator has
completed the assigned task on the current work unit, but
the next unit has not yet arrived at the station. The worker is
thus starved for work.
• When a station is blocked, it means that, operator has
completed the assigned task on the current work unit but
cannot pass the unit to the downstream station because that
worker is not yet ready to receive it. The operator is
therefore blocked from working.
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• To mitigate the effects of these problems, storage buffers are
sometimes used between stations.
• The work units made at each station are collected in batches
and then moved to the next station. In other cases, work
units are moved individually along a flat table or unpowered
conveyor. When the task is finished at each station, the
worker simply pushes the unit toward the downstream
station.
• Space is often allowed for one or more work units in front of
each workstation. Hence, starving and blocking are
minimized.
• It can result in significant work-in-process.
• Production rates tend to be lower.
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 Mechanized Work Transport
Three major categories of work transport
systems in production lines are:
(a) continuous transport,
(b) synchronous transport, and
(c) asynchronous transport.

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 continuous transport, synchronous transport,

asynchronous transport
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 Continuous Transport System
• A continuous transport system uses a continuously
moving conveyor that operates at constant velocity,
This method is common on manual assembly lines.
• The conveyor usually runs the entire length of the
line. However, if the line is very long, such as the case
of an automobile final assembly plant, it is divided
into segments with a separate conveyor for each
segment.
• Examples of this kind are overhead trolley conveyor,
Belt conveyor, Roller conveyor, Drag chain conveyor.
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• Continuous transport can be implemented in two ways:
(1) Work units are fixed to the conveyor, and (2) work
units are removable from the conveyor.
• In the first case, the product is large and heavy (e.g.,
automobile, washing machine) and cannot be removed
from the conveyor. The worker must therefore walk
along with the product at the speed of the conveyor to
accomplish the assigned task.
• In the case where work units are small and lightweight,
they can be removed from the conveyor for the physical
convenience of the operator at each station.
• Another convenience for the worker is that the assigned
task at the station does not need to be completed within
a fixed cycle time.
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 Overhead Trolley Conveyor
• A trolley is a wheeled
carriage running on an
overhead track from which
loads can be suspended.
• Trolleys are connected and
moved by a chain or cable
that forms a complete loop.
• Often used to move parts
and assemblies between
major production areas.

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 Belt Conveyor
• Continuous loop with
forward path to move
loads.
• Belt is made of
reinforced elastomer.
• Support slider or rollers (Support frame not shown)
used to support forward
loop.
• Two common forms:
– Flat belt (shown)
– V-shaped for bulk
materials
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 Roller Conveyor
• Pathway consists of a
series of rollers that are
perpendicular to
direction of travel.
• Loads must possess a
flat bottom to span
several rollers.
• Powered rollers rotate to
drive the loads forward.
• Un-powered roller
conveyors also available.
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 Skate-Wheel Conveyor
• Similar in operation to
roller conveyor but use
skate wheels instead of
rollers.
• Lighter weight and
unpowered.
• Sometimes built as
portable units that can be
used for loading and
unloading truck trailers in
shipping and receiving.
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 Synchronous Transport Systems
• In synchronous transport systems, all work units are moved
simultaneously between stations with a quick, discontinuous
motion, and then positioned at their respective stations. This type
of system is also known as intermittent transport, which describes
the motion experienced by the work units.
• Synchronous transport is not common for manual lines, due to the
requirement that the task must be completed within a certain
time limit. This can result in incomplete units and excessive stress
on the assembly workers.
• Despite its disadvantages for manual assembly lines, synchronous
transport is often ideal for automated production lines.
• Examples of this kind are Walking beam transport equipment and
Rotary indexing mechanisms.
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 Asynchronous Transport System
• In an asynchronous transport system, a work unit
leaves a given station when the assigned task has
been completed and the worker releases the unit.
• Work units move independently rather than
synchronously.
• Examples of this kind are Power-and-free overhead
conveyor, Cart-on-track conveyor, Powered roller
conveyors, automated guided vehicle system,
Monorail systems, and Chain-driven carousel systems.

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 Workpart Transfer Mechanisms

• Linear transfer systems:

– Continuous motion – not common for
automated systems
– Synchronous motion – intermittent motion, all
parts move simultaneously
– Asynchronous motion – intermittent motion,
parts move independently
• Rotary indexing mechanisms:
– Geneva mechanism
– Others
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 Belt-Driven Linear Transfer System

Side view of chain or steel belt-driven conveyor (over and

under type) for linear transfer using work carriers

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 Belt-Driven Linear Transfer System
• Chain or belt driven conveyor provides continuous or
intermittent movement of parts between stations.
• Either a chain or flexible steel belt is used to transport
parts using work carriers attached to the conveyor.
• The chain is driven by pulleys in either an "over-and-
under" configuration, in which the pulleys turn about a
horizontal axis, or an "around-the corner“ configuration,
in which the pulleys rotate about a vertical axis.

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 Walking Beam Transfer System

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• Many transfer lines utilize various walking beam transfer
systems, in which the parts are synchronously lifted up from
their respective stations by a transfer beam and moved one
position ahead to the next station. The transfer beam then
lowers the parts into nests that position them for processing at
their stations. The beam then retracts to make ready for the
next transfer cycle.
The action sequence is
(1) work parts at station positions on fixed station beam
(2) transfer beam is raised to lift work-parts from nests
(3) Elevated transfer beam moves parts to next station positions.
(4) Transfer beam lowers to drop work parts into nests at new
station positions. Transfer beam then retracts to original
position.
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 Geneva Mechanism with Six Slots

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• The Geneva mechanism uses a continuously rotating driver to index the
table through a partial rotation.
• If the driven member has six slots for a six-station dial indexing table,
each turn of the driver results in 1/6 rotation of the worktable, or 60o.
• The driver only causes motion of the table through a portion of its own
rotation. For a six-slotted Geneva, 120° of driver rotation is used to index
the table. The remaining 240° of driver rotation is dwell time for the
table, during which the processing operation must be completed on the
work unit.
In general,
Where θ= angle of rotation of worktable during indexing (degrees of
rotation), and ns = number of slots in the Geneva.
• The angle of driver rotation during indexing = 2θ , and the angle of driver
rotation during which the work table experiences dwell time is (360-2θ).
• Geneva mechanisms usually have four, five, six, or eight slots, which
establishes the maximum number of workstation positions that can be
placed around the periphery of the table.
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 Cam Mechanism to Drive Dial Indexing Table

• Various forms of cam drive mechanisms, are used to provide an accurate

and reliable method of indexing a rotary dial table.
• Although a relatively expensive drive mechanism, its advantage is that the
cam can be designed to provide a variety of velocity and dwell
characteristics.
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 Ratchet and pawl mechanism
• A ratchet is a device that allows linear or rotary motion
in only one direction, while preventing motion in the
opposite direction.
• Ratchets are used in many other mechanisms, including
clocks, jacks, and hoists.

• Ratchets consist of a gearwheel and a pivoting spring

loaded finger called a pawl that engages the teeth.
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• Either the teeth, or the pawl, are slanted at an angle, so
that when the teeth are moving in one direction, the
pawl slides up and over each tooth in turn, with the
spring forcing it back with a 'click' into the depression
before the next tooth.
• When the teeth are moving in the other direction, the
angle of the pawl causes it to catch against a tooth and
stop further motion in that direction.
• Because the ratchet's teeth can only stop 'backward'
motion at discrete points, a ratchet does allow a limited
amount of 'backward' motion, or backlash, to a
maximum of the spacing between its teeth.
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 Rack and pinion mechanism
• A rack and pinion is a pair of gears which convert rotational motion
into linear motion.
• The circular pinion engages teeth on a flat bar - the rack.
Rotational motion applied to the pinion will cause the rack to
move to the side, up to the limit of its travel.
• The rack and pinion arrangement is commonly found in the
steering mechanism of cars or other wheeled, steered vehicles.

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 Storage Buffers in Production Lines
A location in the sequence of workstations where parts
can be collected and temporarily stored before
proceeding to subsequent downstream stations
• Reasons for using storage buffers:
– To reduce effect of station breakdowns
– To provide a bank of parts to supply the line
– To provide a place to put the output of the line
– To allow curing time or other required delay
– To smooth cycle time variations
– To store parts between stages with different
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 Storage Buffer

Storage buffer between two stages of a production line

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 Control Functions in an
Automated Production Line
• Sequence control
– To coordinate the sequence of actions of the
transfer system and workstations.
• Safety monitoring
– To avoid hazardous operation for workers and
equipment.
• Quality control
– To detect and possibly reject defective work units
produced on the line.
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 Applications of
Automated Production Lines

• Transfer lines for machining

– Synchronous or asynchronous workpart transport .
– Transport with or without pallet fixtures, depending
on part geometry.
– Various monitoring and control features available.
• Rotary transfer machines for machining
– Variations include center column machine and
trunnion machine.

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Rotary Indexing Machine (Plan View)
 Trunnion machine

05/24/2025 Dr.P.Ilamathi, GCT, CBE 70

Center Column Machine (Plan View )
 Design and Fabrication
Considerations
• Link line: uses standard machine tools connected by
specialized handling system
• Specialized processes often engineered by the user
company

• Building block approach: machine tool companies

specialize in transfer lines and indexing machines
– User contracts for custom-engineered line
– Standard modules such as workheads, feed units,
transfer mechanisms, and bases
– Called a unitized production line
 Standard Feed Units used with
In-Line or Rotary Transfer Machines

(a) Horizontal feed drive unit, (b) angular feed drive unit,
and (c) vertical column feed drive unit
 Standard Milling Head

Milling head unit that attached to one of the feed drive units
in the previous slide
 ANALYSIS OF TRANSFER LINES

05/24/2025 Dr.P.Ilamathi, GCT, CBE 75

 Analysis of Transfer Lines
• Three problem areas must be considered:
1. Line balancing
• To divide the total work load among workstations as
evenly as possible
2. Processing technology
• Theory and principles about the manufacturing or
assembly processes used on the line
3. System reliability - two cases:
• Transfer lines with no internal parts storage
• Transfer lines with internal storage buffers
 Transfer lines without buffer
storage

05/24/2025 Dr.P.Ilamathi, GCT, CBE 77

 GENERAL TERMINOLOGY AND ANALYSIS

Flow line performance can be analyzed by

means of three basic measures :
• average production rate,
• proportion of time the line is operating (line
efficiency), and
• cost per item produced on the line.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 78

 GENERAL TERMINOLOGY AND ANALYSIS
• A synchronous transfer system is assumed.
• Parts are introduced into the first workstation and are
processed and transported at regular intervals to
succeeding stations.
• This interval defines the ideal or theoretical cycle time Tc
of the flow line.
• It is equal to the time required for parts to transfer plus
the processing time at the longest workstation.

Tr repositioning time or transfer time

Tsi the service time at station i
05/24/2025 Dr.P.Ilamathi, GCT, CBE 79
 Common reasons for downtime on an
Automated Production line
• 1. Tool failures at workstations.
• 2. Tool adjustments at workstations
• 3. Scheduled tool charges
• 4. Limit switch or other electrical malfunctions.
• 5. Mechanical failure of a workstation.
• 6. Mechanical failure of a transfer line.
• 7. Stock outs of starting work parts.
• 8. Insufficient space for completed parts.
• 9. Preventive maintenance on the line worker breaks.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 80

 GENERAL TERMINOLOGY AND ANALYSIS
• Because of breakdowns of the line, the actual average
production time Tp will be longer than the ideal cycle
time.
• When a breakdown occurs at any one station, we assume
that the entire line is shut down.
• Let Td represent the average downtime to diagnose the
problem and make repairs when a breakdown occurs.
• The frequency with which line stops per cycle occur is
denoted by F.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 81

 GENERAL TERMINOLOGY AND ANALYSIS

• Average production time Tp

05/24/2025 Dr.P.Ilamathi, GCT, CBE 82

 GENERAL TERMINOLOGY AND ANALYSIS
• One of the important measures of performance for a
transfer line is the average production rate Rp.
• The actual average production rate is based on the
average production time Tp :

• The theoretical production rate of the flow line,

rarely achieved in practice, is computed as

05/24/2025 Dr.P.Ilamathi, GCT, CBE 83

 GENERAL TERMINOLOGY AND ANALYSIS
• The line efficiency E is simply the proportion of time
the line is up and operating.

• An alternative measure of performance is the

proportion of downtime D on the line :

• Certainly, the downtime proportion and the uptime

proportion must add to 1 :

05/24/2025 Dr.P.Ilamathi, GCT, CBE 84

 GENERAL TERMINOLOGY AND ANALYSIS
• The third measure of flow line performance is the
cost per item produced.
• Let Cm equal the cost of raw materials per product.
• Let Co represent the cost per minute to operate the
line.
• Let Ct represent cost of tooling per workpiece .
• The cost per workpiece Cpc, is

05/24/2025 Dr.P.Ilamathi, GCT, CBE 85

 What the Equations Tell Us –
Lines with No Storage Buffers
• As the number of workstations increases
– Line efficiency and production rate are adversely
affected
• As reliability of individual workstations decreases
– Line efficiency and production rate are adversely
affected
 Transfer lines with buffer storage

05/24/2025 Dr.P.Ilamathi, GCT, CBE 87

 ANALYSIS WITH BUFFER STORAGE
• The other workstations will be forced to stop
production for one of two reasons :
– Starving of stations.
– Blocking of stations.
• One of the methods by which flow lines can be made
to operate more efficiently is to add one or more
parts storage buffers between workstations along the
line.
• The presence of these in-process inventories allows
each stage to operate somewhat independently.
05/24/2025 Dr.P.Ilamathi, GCT, CBE 88
 ANALYSIS WITH BUFFER STORAGE
• The two extreme cases of storage buffer
effectiveness can be identified as
• No buffer storage capacity at all

• Storage buffers with infinite capacity

• Efficiency at any stage

• Overall efficiency
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 ANALYSIS WITH BUFFER STORAGE
• Buffer stock effectiveness in practice

05/24/2025 Dr.P.Ilamathi, GCT, CBE 90

 ANALYSIS OF TWO STAGE LINE
• The two-stage line is separated by a storage buffer of
capacity b.
• Let F1 and F2 represent, respectively, the breakdown
rates of stages 1 and 2.
• ratio of breakdown rates

• average downtimes of stages 1 and 2 are Td1 and Td2.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 91

 ANALYSIS OF TWO STAGE LINE
• Over the long run, both stages must have equal
efficiencies.
• overall line efficiency for the two stages

• D1’h(b)E2 represents the improvement in efficiency

that results from adding buffer capacity (b > 0).
• Two-stage system efficiency when b = 0

05/24/2025 Dr.P.Ilamathi, GCT, CBE 92

 ANALYSIS OF TWO STAGE LINE
• D’1 is the proportion of total time that stage 1 is down.

• h(b) is the ideal proportion of the downtime D1 (when stage 1

is down) that stage 2 could be up and operating within the
limits of buffer capacity b.
• E2 corrects the assumption in the calculation of h(b) that both
stages are never down at the same time.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 93

 What the Equations Tell Us –
Lines with Storage Buffers
• If E0 and E are nearly equal
– Then little advantage is gained by adding a storage buffer

• If E is much greater than E0

– Then adding a storage buffer may improve line performance
significantly

• Storage buffers should be located so that production

rates of the stages are about equal.
• During operation, if any buffers are always empty or
always full, then the buffer is serving little purpose.
 What the Equations Tell Us -
Lines with Storage Buffers
• The maximum possible efficiency is achieved by:
– Setting the number of stages = number of stations
– Using large buffer capacities

• The “law of diminishing returns” operates in multi-

stage automated lines:
– As the number of storage buffers is increased, line efficiency
improves at an ever-decreasing rate
– As storage buffer capacity is increased, line efficiency
improves at an ever-decreasing rate
Automated Assembly Systems
 Automated Assembly - Defined
The use of mechanized and automated devices to
perform the various assembly tasks in an assembly
line or cell.
• Fixed automation
– Most automated assembly systems are designed
to perform a fixed sequence of assembly steps on
a specific product that is produced in very large
quantities.
 Automated Assembly -
Application Characteristics
• Where is automated assembly appropriate:
– High product demand
– Stable product design
– The assembly consists of a limited number of
components
– The product is designed for automated assembly
 Typical Products
Alarm clocks Light bulbs
Ball bearings Locks
Ball point pens Mechanical pencils
Cigarette lighters PCB assemblies
Door mechanisms Small electric motors
Gear boxes Wrist watches
 Assembly Processes in
Automated Assembly
Adhesive bonding Snap fitting
Insertion of components Soldering
Placement of components Spot welding
Riveting Stapling
Screw fastening Stitching
 System Configurations

1. In-line assembly machine

2. Dial indexing machine
3. Carousel assembly system
4. Single-station assembly cell
 In-Line Assembly Machine
A series of automatic workstations located along and
in-line transfer system.
• Either synchronous or asynchronous work transfer
used.
 Dial Indexing Machine
Base parts are loaded
onto fixtures or nests
attached to a circular
dial table, and
components are added
at workstations located
around the periphery of
the dial as it indexes
from station to station.
Dial indexing
assembly
machine
(Bodine Corp.)
 Carousel Assembly System
A hybrid between circular work flow of dial indexing
machine and straight work flow of in-line system.
 Single-Station Assembly Cell
Assembly operations are performed on a base part at
a single location.
• A robot is sometimes used as the assembly machine.
 Multi-Station vs. Single-Station
• Multi-station assembly machine or line
– Faster cycle rate
– High production quantities
– More operations possible
– More components per assembly

• Single-station assembly cell

– Suited to robotic assembly
– Intended for lower production quantities
 Parts Delivery at Workstations
• Typical parts delivery system at a workstation
consists of the following hardware components:
1. Hopper - container for parts
2. Parts feeder - removes parts from hopper
3. Selector and/or orientor - to assure part is in
proper orientation for assembly at workhead
4. Feed track - moves parts to assembly workhead
5. Escapement and placement device - removes parts
from feed track and places them at station
Parts Delivery System at Station
 Vibratory Bowl Feeder
• Most versatile of hopper feeders for small parts
• Consists of bowl and helical track
– Parts are poured into bowl
– Helical track moves part from bottom of bowl to outlet

• Vibration applied by electromagnetic base

– Oscillation of bowl is constrained so that parts climb
upward along helical track
Vibratory Bowl Feeder
 Selector and/or Orientor
• Purpose - to establish the proper orientation of the
components for the assembly workhead.
• Selector
– Acts as a filter
– Only parts in proper orientation are allowed to pass
through to feed track
• Orientor
– Allows properly oriented parts to pass
– Reorients parts that are not properly oriented
 Parts Selection and Orientation

(a) Selector

(b) Orientor
 Feed Track
• Moves parts from hopper to assembly
workhead
• Categories:
1. Gravity - hopper and feeder are located at higher
elevation than workhead
2. Powered - uses air or vibration to move parts
toward workhead
 Escapement and Placement Devices
• Escapement device
– Removes parts from feed track at time intervals that
are consistent with the cycle time of the assembly
workhead
• Placement device
– Physically places the parts in the correct location at
the assembly workstation
• Escapement and placement devices are sometimes
the same device, sometimes different devices.
Escapement and Placement Devices

(a) Horizontal and (b) vertical devices for

placement of parts onto dial-indexing table
Escapement and Placement Devices

Escapement of rivet-shaped parts actuated by work

carriers
Escapement and Placement Devices

Two types of pick-and-place mechanisms for

transferring base parts from feeders to work carriers
 Partial Automation
Partial automated production lines occur for two main
reasons:
1. Automation is introduced gradually on an existing
manual line.
2. Certain operations are too difficult or too costly to
automate.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 119

 Partial Automation
• Assumptions:
1. Workstations perform either processing or assembly
operations.
2. Processing and assembly times at automated systems
are constant , though not necessarily equal at all stations.
3. System uses synchronous transfer of parts.
4. System has no internal buffer storage.
5. Station breakdowns occur only at automated stations.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 120

 Partial Automation
• Average production time, Tp

• na – No of automated stations
• Total cost to operate partially automated line, Co

• nw – No of manual stations
• Casi – Cost to operate automated station
• Cwi – Cost to operate manual station
• Cat – Cost to operate automatic transfer mechanism
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 Partial Automation
• For all Casi = Cas and all Cwi = Cw , then

• Total cost per unit produced, Cpc

• Where, Pap- Portion of good assemblies

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 Partial Automation with storage buffers

• When the automated portion of the system breaks

down, the manual station must also stop to either
starving or blocking.
• Performance would be improved if the manual stations
could continue to operate even when the automated
station stops.
• Storage buffers located before and after the manual
stations would reduce forced downtime at these stations.

05/24/2025 Dr.P.Ilamathi, GCT, CBE 123

 THANK YOU

05/24/2025 Dr.P.Ilamathi, GCT, CBE 124