Automation in Controlling Processing Equipment

Automation is also used to control activities that are a part of the various stages of a manufacturing process.  It offers a set of procedures and equipment that automatically performs those activities that were traditionally considered to be activities that can be performed only by humans, such as process control. For example, in the steel industry, a computer process control system monitors the process of rolling the hot metal ingots into final shapes such as coils and strips. The rolling process involves the forming of large, hot metal billets by passing the ingots through a rolling mill consisting of one or more sets of large cylindrical rolls that squeeze the metal. In order to get the desired thickness, several passes are required. Sensors and automatic instruments measure the dimensions and temperature of the ingot after each pass through the rolls, and the computer controlling the activities calculates and regulates the roll setting for the next process. This monitoring ensures that the each ingot's dimension matches the specified standards.              

Computer Aided Manufacturing (CAM)

In Computer Aided Manufacturing (CAM), computers are used either directly to control the processing equipment or indirectly to support manufacturing operations. Automated machines usually perform a variety of operations, depending on the instructions received from the computer with respect to the sequence and operational specifications of a process. Computer programs can be stored in a database and can be retrieved, updated, and revised as components are added/redesigned. They can also be transmitted electronically in-house or externally by satellite to other divisions and facilities. 

The use of computers to indirectly support manufacturing operations is often referred to as indirect CAM. It involves capturing data regarding the flow of items through automatic means such as bar coding, and using this information in planning and scheduling production activities. Operations managers generally apply indirect CAM for activities such as capacity planning, purchasing, inventory control, quality reporting and so on. Direct CAM links computers directly to one or more machines such that the production processes are monitored and controlled by computer signals.  It is widely used in several kinds of manufacturing activities. CNC machines are one of the key elements of CAM.

Computer Numeric Controlled (CNC) machines store operational instructions on their on-board computers which control their operations. These machines can perform variety of tasks on the basis of instructions embedded in them. They can even change the type of operation to be performed based on the process requirements without any human intervention. All information regarding the new operation is fed to the computers by input devices such as keyboards and video scanners.

Benefits of using CAM:

1. Reliable information inputs

2. Consistent product quality

3. Reduction in labor costs

4. Better control and management of equipment and materials

5. Improvement in production rate

The high costs involved in implementing CAM deter many companies from using it. Moreover, any error in the computer program can result in the production of many erroneous parts. Hence managers use CAM only under the close supervision of a skilled machine operator.              

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