First Bit
Automation of production: systems, their purpose and varieties
To achieve success in their activities, enterprises need to make significant adjustments to the previous production management system. Scientific and technological progress comes to the rescue. Modern developments make it possible to automate production. At the same time, people are freed from performing many functions, and they are assigned to special instruments, devices, and information systems. Automation of production can be complete, partial and complex. In the first option, the entire work process is carried out using machines. With less expensive partial automation, technical devices are only responsible for performing individual operations. An integrated approach involves the functioning of a workshop or site as a single whole consisting of interconnected parts. But in any case, the most responsible decisions are made by humans. He prepares the initial data, selects suitable algorithms, and analyzes the results.
Goals of production automation
The installation and maintenance of special technical equipment at an enterprise require considerable costs. But it helps to achieve the following:
- Free people from heavy manual labour and increase production safety;
- minimize product defects resulting from employee errors, improve the quality of products and expand their range – all this ensures an influx of customers
- increase labor productivity several times – devices help produce a large volume of products in a minimum period of time
- reduce the number of employees and thereby reduce wage costs.
Automation of production helps achieve the main goal – to increase the profit of the enterprise. However, there are also certain disadvantages to this approach. In particular, one of the problems is the emergence of so-called technological unemployment. In addition, the increasing complexity of the production system necessitates the selection of qualified personnel. However, it is not always easy to find specialists with the necessary experience and knowledge of modern standards. The list of problems associated with the introduction of automation can be supplemented by the fact that there is a risk of system hacking, the devices are technically vulnerable, and their operation depends on the power supply. However, the listed disadvantages can be minimized with the help of competent organization of production control, advanced training of workers, timely maintenance of equipment, and ensuring high-quality data protection. These measures need to be implemented since, in general, the advantages turn out to be much more significant than the disadvantages.
Types of Factory Automation
The replacement of human labour with machine labour is carried out in different directions. In this case, appropriate equipment is used – it can be relatively simple or represent entire software and hardware complexes. There are several types of automation.
We are talking about machines programmed to perform certain jobs. The entire technological process here is carried out under electronic control. Human intervention is kept to a minimum. It consists of setting up and checking equipment and installing and removing workpieces. One worker can handle this, and several machines can be under his control at once. Numerically controlled machines, operating virtually autonomously, are capable of producing high-quality products. They process parts very accurately within the required time and “do not get tired”, unlike craftsmen who work manually. Such machines cope with tasks that cannot be performed using conventional devices. They help to clearly plan activities due to the fact that the time for operating is set in advance. Another advantage of this technology is production flexibility. It lies in the fact that when working with parts of a different type, it is enough to change the program, and the previously used one can be stored on the drive and used again if necessary.
Robots Such machines are increasingly being included in production automation in order to facilitate human labour. They handle complex workflows with ease. Robots vary in appearance, size, and functionality. The range of tasks that they are capable of performing is very wide. This includes loading heavy or dangerous objects, packaging goods, finishing, welding, and many other tasks. There are robots whose every movement is controlled by an operator. Others related to automatic machines follow a given program. They are not able to correct the actions being performed, and here, too, the participation of the worker is required. Autonomous robots are the most independent. Such mechanisms perform programmed operations. Functioning according to given algorithms, they adjust actions if necessary. Such devices take on all the work on a certain section of the conveyor without the need for human labour. Information technology (IT) The use of computer equipment characterizes this vast area. Unlike other tools used in production automation, they primarily cover the sphere of intellectual labour. Such technologies are aimed at various ways of handling information – its creation, receipt and processing, storage, and distribution. In modern manufacturing, computers have become vital in data management. People get the opportunity to free themselves from performing routine and complex mental operations. Moreover, the speed of the human brain cannot be compared with the productivity of a machine. In addition, properly configured equipment works flawlessly and can cope with a colossal amount of work. Application of computer-aided design systems This refers to software that is divided into separate areas, such as CAD/CAM/CAE. Each of them helps solve highly specialized problems, and the most suitable system can be applied at a specific stage of production. With this kind of computer support, it is possible to produce complex parts and reduce their production cycle. Using application programs, algorithms for the operation of the machines used are created. It becomes possible to design products, predict their qualities and characteristics, and determine the optimal manufacturing technology. These systems help to implement ideas of any complexity. The speed and accuracy of computer programs contribute to obtaining high-quality products and reducing their cost. Flexible Manufacturing Systems (FMS) Such complexes help complete product manufacturing cycles in a changing production environment. The system responds in a timely manner to predictable and unforeseen circumstances and adapts to them. For example, if necessary, the order of work operations is changed, the design of the product is adjusted, and the assembly of parts is simplified. Automation of production carried out using this method cannot be called economical. The cost of the equipment itself, as well as its installation, is high. In addition, it requires qualified personnel capable of operating such equipment and carrying out complex pre-planning. However, these points are compensated by the high reliability of the system, a significant increase in labour productivity, and a reduction in production costs. Flexible systems help you avoid downtime and make the most of your work time. If conventional equipment stops working when a breakdown occurs, then FMS is able to adapt to the problems and continue manufacturing products during repairs.