The concept and principles of automation of production processes

 Automation of production processes lies in the fact that part of the functions of management, regulation and control of technological complexes is carried out not by people, but by robotic mechanisms and information systems. In fact, it can be called the main production idea of the 21st century.

Principles

At all levels of the enterprise, the principles of automation of production processes are the same and the same, although they differ in the scale of the approach to solving technological and management problems. These principles ensure that the required work is done efficiently automatically.

The principle of consistency and flexibility

All actions within a single computerized system must be coordinated with each other and with similar positions in related areas. Full automation of operational, production and process processes is achieved through a commonality of operations, formulations, schedule and optimal combination of techniques. Failure to do so would disrupt the flexibility of production and the integrated execution of the entire process.

Features of flexible automated technologies

The use of flexible production systems is a key trend in modern automation. As part of their action, technological optimization is carried out due to the coherence of all system elements and the ability to quickly replace the toolkit. The methods used allow to effectively redevelop existing complexes to new principles without serious costs.

Creation and structure

Depending on the level of production development, the flexibility of automation is achieved through a coordinated and integrated interaction of all elements of the system: manipulators, microprocessors, robots, etc. transport, warehouse and other units of the company are involved in these processes.

The principle of completion

An ideal automated production system should be a complete cyclical process without intermediate transfer of products to other units. The quality of this principle is ensured by:

The versatility of the equipment, allowing for one unit of time to process several types of raw materials at once;

The technology of the manufactured goods by reducing the required resources;

Unification of production methods;

minimum additional installation work after the equipment is put into operation.

The principle of integrated integration

The degree of automation depends on the interaction of production processes with each other and with the outside world, as well as on the speed at which a single technology is integrated into a common organizational environment.

The principle of independent execution

Modern automated systems operate on the principle: “Don’t let the machine work.” In fact, all processes during the production cycle must be carried out without human participation, only minimal control on his part is allowed.

Objects

Production can be automated in any field of activity, but computerization works most effectively with complex monotonous processes. Such operations occur in:

Light and heavy industry;

Fuel and energy complex;

Agriculture;

Trade

medicine, etc.

Machineization assists in technical diagnostics, scientific and research activities within a separate enterprise.

Goal

The introduction of automated tools in the production, which are able to improve the processes, is a key key to progressive and effective work. Key goals of automation of production processes include:

Staff reductions;

Increase productivity with maximum automation

Expanding the product line

Increased production

Improving the quality of goods

Reducing the consumable component

Creating clean production by reducing harmful emissions to the atmosphere;

The introduction of high technology into a normal production cycle with minimal cost;

improving the security of technological processes.

In achieving these goals, the company benefits from the introduction of mechanized systems and recoups the cost of automation (provided stable demand for products).

The quality of the tasks of mechanization is determined by the introduction of:

Modern automated tools

individually developed methods of computerization.

The degree of automation depends on integrating innovative equipment into the existing technology chain. The level of implementation is assessed individually depending on the specifics of the production.

Components

As part of a single automated production environment, the company considers the following elements:

Design systems used to develop new products and technical documentation

Microprocessor-based software machines

industrial robotic complexes and technological robots;

A computerized quality control system in the enterprise;

Technological warehouses with special lifting and transport equipment;

General Automated Production Management System (ASUP).

Strategy

Compliance with the automation strategy helps to improve the entire range of necessary processes and get the ultimate benefits from the introduction of computer systems in the enterprise. Only those processes that are fully studied and analyzed can be automated, because the program developed for the system should have different variations of the same action depending on the factors of the external environment, the number of resources and the quality of performance of all stages of production.

After defining the concept, studying and analyzing the technological processes comes the turn of optimization. It is necessary to simplify the structure qualitatively by removing from the system processes that do not bring any value. If possible, you should reduce the number of activities you’re doing by combining some operations into one. The simpler the structural order, the easier it is to computerize. Once the systems are simplified, you can start automating production processes.

Design

Design is a key stage in the automation of production processes, without which integrated mechanization and computerization cannot be implemented at work. It creates a special diagram that displays the structure, parameters and key characteristics of the devices used. The scheme is standard:

Scale of automation (described separately for the entire enterprise and for individual production units);

Identify the control parameters of devices that will later act as verification markers;

Description of control systems

Configuration of the location of automated tools

information about equipment lockdown (when it is applicable, how and by whom it will be launched in case of an emergency).

Classification

There are several classifications of enterprise computerization processes, but it is most effective to separate these systems depending on their degree of integration into the overall production cycle. On this basis, automation happens:

Partial;

Comprehensive;

Full.

These varieties are just levels of production automation that depend on the size of the enterprise and the amount of technological work.

Partial automation is a set of operations to improve production, within which one action is machine charged. It does not require the formation of a complex management complex and the full integration of related systems. At this level of computerization, human participation is allowed (not always to a limited extent).

Comprehensive automation allows to optimize the work of a large production unit in a single complex mode. Its use is justified only in a large innovation enterprise, where the most reliable equipment is used, because the breakdown of even one machine risks stopping the entire work line.

Full automation is a set of processes that ensure the independent operation of the entire system, which includes production management. Its implementation is the most expensive, so this system is used in large enterprises in conditions of profitable and stable production. At this stage, human participation is kept to a minimum. Most often, it is about controlling the system (e.g. checking sensor readings, fixing minor problems, etc.).

Advantages

Automated processes increase the speed of cyclical operations, ensure their accuracy and safety of health, regardless of the factors of the external environment. By eliminating the human factor, the number of possible errors is reduced and the quality of work is improved. In the case of typical situations, the program memorizes the algorithm of actions and applies it with maximum speed.

Automation allows you to increase the accuracy of business process management in production by covering a large amount of information, which is simply not possible in the absence of mechanization. Computerized equipment can perform multiple technological operations at once without compromising the quality of the process and the accuracy of the calculations.

The notion of process automation is inextricably linked to the global process. Without the introduction of computerization systems, it is impossible to develop the current development of individual departments and the enterprise as a whole. Machine manufacturing allows you to improve the quality of finished products as efficiently as possible, expand the range of products on offer and increase output.

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