|
The obvious advantage here is that since no
hardware assembly is required, assembly time is low. The system
also becomes very compact and the chances of malfunctioning are
reduced as there are no hardware elements connected through wires.
In the case where a PC is also available, much more complex
decision-making can be done by the system. Further, by installing
a diagnostic module, identifying the fault, in case of
malfunctioning or breakdown becomes very easy. For example, if the
system indicates "fault in pneumatic system", or "defect in
clamping system", the maintenance people will find it much easier
to rectify the problem quickly.
The foregoing discussion
highlights the fact that the phase of actual LCA system
development is very crucial since many characteristics like cost
(and hence pay back period), ruggedness, easy maintainability,
running cost, reliability etc. need to be built into the system.
The experience and capability of the designer can make the system
either "just O.K" or "very good" or "excellent." A good designer
will usually conceptualize more than one system, make a
comparative evaluation and finally choose the one that appears to
be the most appropriate under the specific circumstances.
Concluding Remarks
While implementing an LCA system, one has to
understand the need to overcome "the learning curve" problem. The
productivity may temporarily even decrease when a manual operation
is automated by LCA, since the person is in the learning phase.
Teething troubles also create
problems. However, this need not spell rejection of the LCA
system. Instead it is necessary to accord time
|
|
|
for integrating the
system. Obviously, this is quite contrary to installing a CNC machine where, if the program is
correct, there is hardly any learning time and the increase in
output will be sudden.
|
LCA
Implementation : Main Issues |
|
1.
Assessment of the Current Productivity Level
- There are some simple procedures for this. Work Sampling
(activity sampling) is one of them. It needs no equipment and
only very little time to collect the data. If the data is
processed, considerable information will come out about the
current productivity level.
2.
PMTS -
Predetermined Motion and Time Studies is a very useful
tool to check whether an existing manual operation is
correctly pasted. If the time taken is more than desirable,
PMTS will help in identifying it and improving it.
3.
Design for Automation and Assembly
- When components are made and assembled manually one may not
have thought about the complexity of automation. For example
putting half a dozen nuts and bolts is very easy in a manual
assembly but very complex for a automatic system. |
|
|
With the pressures of liberalization and globalization
mounting, it is necessary that the local industry explores
methods of enhancing automation and productivity to
acquire greater competitiveness. In this regard, LCA is a
technology that promises to be very useful for any kind of
manufacturing organization. The rewards will be slow in
the beginning, but are expected to be very substantial
once a properly designed LCA system is in place. |
|
|
|
|
^Top |
<<Back |
|
Micro-Controller Based
Low Cost Automation,
D.
K. Sharma,
Electrical Engineering |
|
Modern techniques for
implementing automation schemes make heavy use of micro-computer
based design. Micro-computer based design brings flexibility,
re-configurability, compactness and economy to an automation
system. Because a great deal of processing power is available
through micro-controllers at very reasonable prices, it is
possible to perform quite sophisticated tasks in an automation
system, and yet remain in the "low cost" bracket.
The main hurdle for wide deployment of low cost electro-mechanical
automation systems has been the relatively high cost of devices
which interface the electrical and mechanical domains. However,
during the last few years, inexpensive high quality sensors and
actuators have become widely available through their use in the
automobile industry. For example, very sensitive accelerometers
have become standard components. Also, stepper motors are now
available with a wide range of specifications. |
|
|
Many systems which combine
low cost electronic and mechanical systems are being studied at
IIT Bombay. Examples include Interactive Inventory Control
Systems, Global Positioning Systems etc. Many systems using low
cost electronic systems to control and automate processes have
also been developed. These include range meters, flow control
units, controllers for pick and place units etc.
High technology, low cost automation implemented with Mechanical
systems controlled by micro-controllers and other electronic
devices is indeed poised for big growth and wide applications in
the Indian Industry. Such systems will be of particular interest
to manufacturing of engineering products, pharmaceuticals, food
processing etc., and for automating operations in hospitals,
libraries, retailing etc. Development effort for such systems is
going on through collaborative efforts between many departments of
IIT Bombay - such as the Mechanical, Electrical and Aerospace
Engineering departments.
|
|
|
|
|
|
>> LCA in Batch
Processing
Industries |
|
|
|
|
|
|
|
|
|
|
|
