Lecture 1 - What Is Automation

WHAT IS AUTOMATION
PRESENTED BY
U AUNG NAING OO
DEFINITION OF AUTOMATION
• “the technique of making an

apparatus, a process, or a system
operate automatically.”
• "the creation and application of
technology to monitor and control the
production and delivery of products
and services.”
• “the use of self-regulating machinery,
electronic equipment, etc. to make a
manufacturing system or process
operate at greater speed and with little
or no human intervention.”
HISTORY OF AUTOMATION
• 1st Century BC: Water Wheels

• 9th Century: Mill Machinery
Advancements
• 17th to 18th Century: Industrial
Revolution
• 1900 to 1950s: Electrification &
Industrial Controllers
• 20th to 21st Century: Computers &
Robotics
TYPES OF CONTROL SYSTEMS
Open loop control systems (non- Closed loop control systems

feedback control systems) (feedback control systems)
• If in a physical system, there is no • A closed loop control system is a system
automatic correction of the variation in where the output has an effect upon the
its output, it is called an open loop input quantity in such a manner as to
control system. maintain the desired output value.
TYPES OF AUTOMATION
1. FIXED AUTOMATION
• high levels of production
• consistent quality in production
• low cost per unit produced
2. PROGRAMMABLE AUTOMATION
• flexibility to change products if needed
• suitable if batch production is required
3. FLEXIBLE AUTOMATION
• flexibility of products
• no time lost with new changes to production

PROS AND CONS OF AUTOMATION
The advantages The disadvantages

• Productivity is increased • The sensors or robots that is used in automation
can’t take any judgment calls
• Improved quality
• Cost is reduced
• It takes time to repair
• Safety in working conditions

• It could be hazardous and also can cause problems
• It replaces human operators in tedious tasks

• The initial cost will be high for installing machines
and equipment
• Accuracy
• High maintenance is required for automated
• Reliability machines
• Quality
• It can do tasks which is beyond human capability

AUTOMATION PYRAMID
• Level 5: Management level for the general production

planning and order management via the ERP system
• Level 4: Planning level (MES) serving as interfaces

for the detailed production planning, quality
management as well as data collection and material
management .
• Level 3: Supervisory level for the monitoring,

operational purposes as well as the recipe management
via SCADA and HMI.
• Level 2: Control level carrying the structure for

controlling the production process by means of PLC,
PID and DCS.
• Level 1: Field level with sensors and actuators for

collecting production data and executing commands.
FIELD LEVEL
The field level is made up of field devices such as
sensors and actuators.
• The field devices have a core task of transferring

machines and processes data to the next level for
monitoring and analysis.
• Sensors include; proximity sensors, flow meters,

thermocouple, RTDs among others. Real time process
parameters such as level, flow, temperature, and
pressure are converted into electrical signals by the
field level sensors.
• Actuators include; pneumatic actuators, flow control

valves, relays, solenoid valves, servo motors, and Dc
motors among others. Actuators are used to control the
process parameters
CONTROL LEVEL
• The control level is made up of

automation devices such as PLCs, PIDs
and DCS that derive ideal process
parameters from the different sensors.
• Industrial automated controllers trigger
the actuators as per the processed sensor
signals, control techniques, or programs.
• PLCs allow industrial automation
operators to program control functions
to execute automatic process operations.
SUPERVISORY LEVEL
• Automatic monitoring systems and devices are

used to facilitate the intervention and control
of functions such as; setting of production
targets, supervising different parameters,
supervisory control and data acquisition
(SCADA), setting machine start and stop
periods, and Human Machine Interface (HMI).
• Visualize the whole process, see alarms,
generate reports, run batches, and control the
operator’s action through the audit trail.
• To integrate the whole network with SCADA,
various communication topologies which are
used with the PLC systems.
PLANNING LEVEL
A Manufacturing Execution System (MES), is an information
system which monitors and tracks the process of producing
manufactured goods on the factory floor.
The overall goal of MES is to make certain that manufacturing
operations are effectively executed to improve production
output. That goal is achieved by tracking and gathering real-
time and accurate data about a complete production lifecycle.
MES’ core functions include:
• Data collection and acquisition
• Scheduling
• Staff and resource management
• Process management
• Performance analysis
• Document management
• Benefits of a Manufacturing
MANAGEMENT LEVEL
• Often referred to as Enterprise Resource Planning

(ERP), is tasked with management of the entire
industrial automation system.
• Tasked executed at this level include; market and

customer analysis, sales, orders, and production
planning just to mention a few.
• This level is geared towards supporting

commercial industrial activities as opposed to
technical industrial aspects.
• All industrial automation hierarchy levels comprise

of industrial communication networks that transfer
information from one hierarchy level to another.
QUESTIONS ARE WELCOME
THANK YOU

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WHAT IS AUTOMATION

• “the technique of making an

• 1st Century BC: Water Wheels

Open loop control systems (non- Closed loop control systems

• consistent quality in production

• low cost per unit produced

• suitable if batch production is required

• no time lost with new changes to production

The advantages The disadvantages

• Safety in working conditions

• It replaces human operators in tedious tasks

• It can do tasks which is beyond human capability

• Level 5: Management level for the general production

• Level 4: Planning level (MES) serving as interfaces

• Level 3: Supervisory level for the monitoring,

• Level 2: Control level carrying the structure for

• Level 1: Field level with sensors and actuators for

• The field devices have a core task of transferring

• Sensors include; proximity sensors, flow meters,

• Actuators include; pneumatic actuators, flow control

• The control level is made up of

• Automatic monitoring systems and devices are

• Often referred to as Enterprise Resource Planning

• Tasked executed at this level include; market and

• This level is geared towards supporting

• All industrial automation hierarchy levels comprise

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