The University of Jordan
Mechatronics Engineering Department
Automation
Chapter 1
Introduction
Dr. Osama Al-Habahbah
The economic realities of the modern world that affect manufacturing
enterprises are:
 Globalization.
 International outsourcing .
 Local outsourcing .
 Contract manufacturing .
 Trend towards the service sector in developed economies.
 Quality expectations.
 Operational efficiency.
Globalization
More countries are becoming industrialized, such as China and India, due to
their high population and low labor cost .
International outsourcing
More parts and products are outsourced to companies outside
the USA .
Local outsourcing
Within the same country . Due to specialty of the suppliers, cheaper
rate in smaller companies, lack of in-house manufacturing capability
Contract manufacturing
The customer designs product while the supplier makes the
product .
Trend towards the service sector in developed economies
Erosion of direct manufacturing .
Quality expectations
Perfect quality is expected
Operational efficiency
Used to offset the high labor cost
Some modern manufacturing technologies that help to compete :
• Automation
• Material handling technologies
• Manufacturing system
• Flexible manufacturing
• Quality programs
• Computer Integrated Manufacturing (CIM)
• Lean production
Reduces labor cost, decreases production cycle time, and
improves quality.
Include transportation, storage, tracking .
Production line, manufacturing cells.
Helps to compete in the low-volume/hig-mix product categories .
Such as statistical quality control and six sigma.
Includes (CAD) : Computer Aided Design,(CAM): Computer
Aided Manufacturing, and integrating computer networks .
Accomplish more with less resources  increases productivity
 It is a collection of people, equipment, and procedures to
perform the manufacturing operation they are two categories
Factory
Equipment
Layout
The set of procedures
used by the company
to manage production
,such as product
design.
Facilities
Manual
work system
Using
unpowered
hand too;
Worker
machine
Automated
Using power
equipment
Automated facility
branches out-to:
Semi-automated
machines and fully
automated machines
Business
function
Functions of
Manufacturing
support system
Communicating with customer
Product design
Either provided by customer or in
house if it’s proprietary
Manufacturing
planning
Scheduling, Capacity, planning and
process planning
Manufacturing
planning control
Shop floor
control
Product progress
Inventory
control
Balancing too little and
too much inventory
Quality control
Product quality meets
standard
Examples include :Automated machine tool that process parts ,
Automated assembly , Industrial robots , Automatic material
handling storage , Automatic quality control (inspection).
Minimal change
High initial
investment , high
production rate,
inflexibility
Fixed automation
High initial
investment ,
high production
rate,
inflexibility
Types of automated
manufacturing
systems
flexible
programmable
High
investment ,
low production
rate, flexibility
Computer Integrated Manufacturing (CIM) :
Such as CAD / CAM
 Increase labor productivity .
 Reduce labor cost .
 Mitigate the effect of labor shortages
 Reduce manufacturing lead time
 Accomplish processes that can’t be done manual .
 To avoid the high cost of not automating (competition)
 Eliminate routine tasks
 Improve safety
 Improve quality
It is still needed .
It can be preferred to automation in some cases :
1- Task is technologically or economically too difficult to
automate . < E.g: hand-eye coordination >.
2- Short product life cycle <Automation takes time>.
3- Customized product .
4- Ups and downs in demand .
5- To reduce risk of products failure < In the market>.
6- Lack of capital to invest in automation.
Equipment
maintenance
Engineering
project work
Programming
and computer
operation
Plant
management.
Stand for
1- Specialization of operations: Use of special-purpose equipment
for greatest efficiency.
2- Combined operations: Perform more than one operation at a
given machine.
3- Simultaneous operations:To reduce processing time.
4- Integration of operations: Linking work-stations together →
increasing output
5- Increased flexibility: Maximum utilization of equipment → Use
the same equipment for a variety of products.
6- Improved material handling and storage: reduce work in
process and shorter manufacturing lead times.
7- On-line inspection: (of quality) reduce scrap and improves
quality.
8- Process control and optimization: process time decrease
,quality increase.
9- Plant operations control (of the factory)
10-Computer-integrated manufacturing CIM:
( Design → Operations → Business ) Computer Network
Moving from manual
to automated.
Phase 1
Manual production.
Phase 2
Automated production → single-station
system.
Phase 3
Automated integrated production
→ multi-station system.
 Short product introduction time.
 Gradual automation.
 Lower risk at the start.