low cost automation

LOW COST AUTOMATION

1. Introduction

In today's scenario it is mandatory to do some sort of automation in industry to survive in the competitive market due to increase in manpower cost, high expectations of customers, shorter product life, rapid development of new technologies, etc.

Automation is basically the delegation of human control function to equipments for increasing the productivity, increasing quality, meeting customer needs & expectations, cost reduction and increasing safety in working conditions. Also going for full automation in industry is a costly affair as rate of return on investment (ROI) will be long period and product cost will become high to match with competition. The full automation involves all sorts of machinery that will ease the overall manufacturing process. That's why, these days, small and medium industries employ low cost automation.

2. Why Automation?

Any machine/process that is automated definitely speeds up the productivity since no thinking is needed by the machine, there is better repeatability, and less human error.

(i) Quality improvement and repeatability in quality: When a machine/process is automated to perform certain task over and over again, the quality, accuracy & repeatability are improved (compared to an employee).

(ii) Cost reduction: Automating a machine/process to an operation, means less employees are needed to get the job done. Also lesser will be the rework and rejection; thus automation results in cost saving.

(iii) Improved sustainability: Automated equipment/process creates a valuable resource for large production volumes, which in turn, will increase profitability.

(iv) Improved safety: Automation of machines/process means creating safe working by automating tasks that can be dangerous and prone to injury, which make the work environment safer and motivate people to give more output.

(v) Reduced rejection: Automated machine/process that performs repeated tasks is less likely to make mistakes than an employee hence reduces rejection.

3. What is Low Cost Automation?

• Definition: Low Cost Automation (LCA) is defined as a technology that creates some degree of automation around the existing equipment, tools, methods and people, using mostly standard components available in the market.

• LCA is mainly used:

(i) To reduce machine investment cost

(ii) To reduce the process time

(iii) To increase productivity; and

(iv) To have consistent quality.

• Areas of applications of low cost automation: The low cost automation can be effectively used in many processes/functions in manufacturing industries and few of them are listed below:

• Material movement/handling operations

• Loading

• Feeding

• Pick and place functions

• Clamping

• Welding

• Forming

• Machining operations like drilling, riveting, broaching, shaping, etc.

• Painting

• Measurement and inspection functions such as marking, checking, gauging, etc.

• Assembly and packing

• LCA is very useful in processing industries for manufacturing chemicals, oils, pharmaceuticals.

• LCA is also used in areas like food industry, marketing, IT industry, etc.

4. Methods of Low Cost Automation

Low cost automation can be done by many methods. They include:

1. Using gravitational force

2. Using leverage systems

3. Using hydraulic systems

4.. Using compressed air pneumatic/electromagnetic systems

5. Using motor or PLC control systems

6. Using robots.