Low Cost Automation

Ubiquity of Industrial Engineering Principle of  Industrial Engineering

Industrial Engineering is applicable to all branches of engineering.

Illustration: Google's  Engineering Productivity Department - Evolution of the Department through Automation of Testing. Emergence of Software Engineering Productivity Engineer & Specialist. 

Mechanization refers to the replacement of human power with mechanical power of some form. 

Automation and mechanization are often confused with each other; Mechanization saves the use of human muscles whereas automation saves the use of human judgement.

Atomation can be defined as the technology by which a process or procedure is performed without human assistance. Automation is done by using mechanical, hydraulic, pneumatic, electrical or electronic devices and computers. The obvious advantage of  automation is requirement of human effort, hence high man's productivity. Automation also provides  improvement in material handling, improvement in quality , accuracy and precision. 

Low cost automation is a technology that automates some activities of  the existing equipments, tools, 

methods and people, using mostly standard automation components available in the market.

Automation for Productivity and Cost Reduction  - Productivity Automation Engineering. - Lesson 112 of  Industrial Engineering ONLINE Course

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.

https://nraoiekc.blogspot.com/2021/04/jidoka-automation-and-mechanization.html

2002

Low-cost automation (LCA) involves the introduction of standard equipment, mechanisms, and devices to convert manual operations to automatic ones. Investment cost is low, as the term itself implies, and the ROI in terms of improved productivity and better work efficiency is high. In the workshop, participants see LCA as automation that assures quality, provides flexibility, increases productivity, and reduces cost. At the same time, it is easy to implement and affordable for small and medium enterprises (SMEs), the main users of LCA. Common areas in the manufacturing process for LCA application are machining, cold extrusion, grinding, material handling, quality inspection, dimensional accuracy, surface finishing, and assembly and packaging.

A workshop topics: 

The different means of automation; 

The concept and practice of LCA; 

Problems relating to introducing LCA; 

Planning and designing for LCA; Cost-benefit analysis of LCA: and 

Process for implementing LCA.

The benefits of using LCA:

It contributes to process improvement, cutting machine downtime, cost reduction, better product quality, more precision manufacturing, on-time delivery, greater job safety, reduction in manpower requirements and human error, and environmental protection. 

The key success factors for the implementation of LCA are:  trained and skilled manpower, appropriate product types, availability of the requisite hardware and software, 

Low Cost Automation, APO news item

https://www.apo-tokyo.org/wp-content/uploads/sites/5/2002_Jun_p5a.pdf

CII National Competition on Low Cost Automation (LCA)

CII Institute of Quality, in 2018 eastablished National Competition on Low Cost Automation (LCA) to support the "Make-in-India" campaign by enhancing the competitiveness of Indian Industry in the global market. This competition catalyzes the wide spread adoption of LCA practices across Indian Industry through sharing best case studies. This competition focuses on core techninial concepts / inovative ideas resulted in improvement in PQCDSM (Productivity, Quality, Cost, Delivery, Safety & Morale). LCA Awards will be presented in six categories (Productivity Improvement, Karakuri Kaizen, Quality Improvement, Pokayoke, Set-up Change (SMED) and Safety & Energy).

My personal enquiry got the answer that for LCA, the ROI (payback period) has to be less than two years.

https://www.cii.in/AwardsDetail.aspx?enc=pbnMjbR4QGbdNAmJaE2LJiqKO8WX9O/AdNTOCBg6qIY=

There is a very good site offering tutorials on low cost automation
331 tutorials are there starting from 001 given below.

http://www.misumi-techcentral.com/tt/en/lca/



001. Tutorial 1. Principal Components for Low Cost Automation
https://www.misumi-techcentral.com/tt/en/lca/2009/07/0001-pictorial-and-explanations-on-lca-standard-components---1-how-to-select-standard-components.html

The LCA is comprised of the following configuration, and this establishes the reference for the components' functionality.

LCA = Mechanism + Actuator + Controller

Some important topics - First tutorial starting numbers

002 - Precision shafts.

008 - Hollow shafts

009 - Linear guide mechanisms

011 - Bearing mounting

015 - Hinge pins

017 - Sensor mounting

021 - Motion mechanism design

022- Principles of positioning

023 - Locating pins

026 - Mechanical LCA

029 - LCA Construction Elements

031 - Ball screw

036 - Timing belt

037 - Sensor usage 

041 - System configuration

Fundamental technologies required for automating screw fastening process

173 Production Technology Level-up Course for Machine Designers - 9: Automating Screw Fastening - 1
http://www.misumi-techcentral.com/tt/en/lca/2013/12/173-production-technology-level-up-course-for-machine-designers---9-automating-screw-fastening---1.html
174 Production Technology Level-up Course for Machine Designers -10: Automating Screw Fastening - 2
http://www.misumi-techcentral.com/tt/en/lca/2014/01/vol-174-production-technology-level-up-course-for-machine-designers--10-automating-screw-fastening--.html

175 Production Technology Level-up Course for Machine Designers - 11: Automating Screw Fastening - 3
http://www.misumi-techcentral.com/tt/en/lca/2014/02/175-production-technology-level-up-course-for-machine-designers---38-automating-screw-fastening---3.html


Related articles

Automation - Current Status and Issues
https://nraoiekc.blogspot.com/2014/11/automation-current-status-and-issues.html

Productivity Automation Engineering
https://nraoiekc.blogspot.com/2017/09/productivity-automation-engineering.html

Bibliography: Low Cost Automation

Slideshare Presentations

Low cost automation - SlideShare

https://www.slideshare.net/ishwarbhoge/low-cost-automation

Jan 31, 2015 

Automation slides,plc,scada,HMI

BOSCH

https://www.slideshare.net/vcbxvdf/pathania-plc

https://www.slideshare.net/saianjaneya/industrial-automation-history

https://www.slideshare.net/indira_kundu/basics-of-automation-plc-and-scada

Google: "low cost automation" examples

A study of automation of business operations in large scale manufacturing industries with reference to production lines in maharashtra state

Researcher: Yambal,Sucheta S.

Guide(s): Bajpai,S.A.

University: Dr. Babasaheb Ambedkar Marathwada University

Completed Date: 3/12/2016

https://shodhganga.inflibnet.ac.in/handle/10603/140378

LOW COST INTELLIGENT AUTOMATION IN MANUFACTURING

Heinz-H. Erbe

Published 2002, IFAC Proceedings Volumes

https://www.semanticscholar.org/paper/LOW-COST-INTELLIGENT-AUTOMATION-IN-MANUFACTURING-Erbe/019212ca050dcb21ccf4ac259413eb2298cdc124

Videos

1:14

Low Cost Automation - Institute for Manufacturing (IfM), University of Cambridge

Jun 25, 2018

https://www.youtube.com/watch?v=AZh-AdZAXZg

10:34

Low Cost Automation ~ In Hindi ~ with examples - Learn Mech Tech

Dec 16, 2018

https://www.youtube.com/watch?v=HpJKAL-o3Bc

Automatic Needle Filling Machine

Padmatech Industries Pvt Ltd formally my known as Padmatech Engineering system provide Low cost industrial Automation, Since last decade. in process industry. PIPL optimize processes of client and results of this clients reduces there manufacturer cost, safety operation, less risk in operation, less manpower dependency.   Padmatech Industries Pvt Ltd achieve pay back period from 28 days to 1 year/18 months depends upon automation cost and volume of work.

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https://www.youtube.com/watch?v=66QDOmzyRts

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2:14

Low Cost Intelligent Automation - increase productivity and flexibility and achieve Zero Defects -· AviasLCIA

Aug 27, 2010

https://www.youtube.com/watch?v=7uROwd6S2R0

Low Cost Automation — A case study - INDUSTR.com

Toyota Kirloskar Auto Parts Pvt. Ltd.BENGALURU, INDIA 

https://www.industr.com/en/low-cost-automation-a-case-study-2289389

May 23, 2017

Adopting conventional automation is still impractical in terms of return on investment (ROI usually requires 10 ~ 15 years).  An automation, which consumes zero or very little power (eco-friendly), with zero or minimum actuators (safety), highly flexible & reliable in nature, which occupies less space (lean concept), that needs zero or minimum maintenance (high efficiency), with minimum investment and running cost, is termed as LCA.

Karakuri Automation

‘Karakuri’ is  a Japanese word, which means achieving motion with no power or low power. It’s an ancient Japanese technique to move dolls without actuators or power. In Karakuri technique,  different mechanisms like rope & pulley mechanism, counter weight mechanisms, cam & follower mechanisms, etc, are used to achieve unique motion or to convert one form of motion into another like vertical to horizontal and linear to rotary. Combining these motions together to form an automation solution requires an engineering approach. 

Unlike conventional automation, Karakuri LCA provides safer, cost-effective, lean & maintenance-free flexible solutions with a target ROI of less than 2 years.

Video: “Jishuken” & “Low Cost Automation(Karakuri)” – Toyota Kirloskar Auto Parts

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https://www.youtube.com/watch?v=jK1bobq6K3s

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Low Cost Automation Tutorial | Technical Tutorial - MISUMI

www.misumi-techcentral.com › lca

#230 Safety Design - 2: Case Examples of Intrinsic Safety ... #140 Low Cost Automation and Quality - 3: Automating Molded Platic Product Extraction and Quality ...

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PDF Low Cost Automation(LCA): A Case Study - ResearchGate

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Abstract: - Low Cost Automation (popularly known as LCA) is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing ...

Development of a Pneumatically Driven Cell for Low Cost ...

www.hindawi.com › journals › jie

by AC Valdiero · Cited by 1 — ... a pneumatically driven manufacturing cell for low cost automation applications. ... such as pneumatic servo position applications [1–5]; for example, Festo has ...

Pneumatic cylinder A: O1

Pneumatic cylinder C: O3

Pneumatic cylinder B: O2

Manual actuation button: I1

A review on low cost automation using pneumatic system

data.conferenceworld.in › BVCOE18

PDF

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Low Cost Automation & Robotics - Igus

https://www.igus.com/info/low-cost-automation

drylin® delta robots and robolink® DP robotic arms offer the same technical advantages as our gantries. Delta is available in two sizes and starts as low as $6,200. Countless component combinations are available for robolink® so you can design an individual solution that meets the needs of your business.

low cost automation using electro pneumatic system - IAARC

www.iaarc.org › fulltext › isarc2007-5.2_5_028.pdf

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robolink® Low Cost Automation - Igus

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https://open.unido.org/api/documents/4689973/download/LOW-COST%20AUTOMATION%20FOR%20THE%20FURNITURE%20AND%20JOINERY%20INDUSTRY%20(06948_1977.en)

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The tetrahedron is the Best Simple & Low-Cost Automation Industry. It provides a solution for small & medium level companies. Automation in an assembly line.

Missing: examples ‎| Must include: examples

Low Cost Automation - SAE International

https://www.sae.org/publications/technical-papers/content/982080/ (More papers from SAE)

Aug 11, 1998 —  Tilt tables, turn tables, and lift tables are all examples of simple LCA.

Karakuri - Home

karakuri.item24.de › ...

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Low cost automation | INCIBE-CERT

www.incibe-cert.es › blog › low-cost-automation

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o-Controller Based Low Cost Automation - Industrial Research ...

www.ircc.iitb.ac.in › archives › sept_2002 › focus-sharm

Low Cost Automation ... For example, if the system indicates "fault in pneumatic system", or "defect in clamping system", the maintenance people will find it much ...

Kitchen Jidoka: Low Cost Automation Example - An interestng example of cover of dust bin getting open when the door of the sink is opened. Good explanation of "nagara" also.

May 24, 2017 — This photo from the kitchen of an apartment-hotel is an example of the first type of jidoka – low cost automation eliminating a step of human work. 

https://blog.gembaacademy.com/2011/11/19/kitchen_jidoka_low_cost_automation_example/

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www.ijltemas.in › DigitalLibrary

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Low cost automation is a technology that creates some ... In low cost automation using Robotic arm is generally ... Some examples of techniques for such.

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www.rejinpaul.commsajce-edu.in › images › Mech › Mech-Open-elective

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Karakuri - Low-Cost Automaiton | Haberkorn

www.haberkorn.cz › karakuri-low-cost-automaiton

... parts and components on the one hand and the creativity of the on-site workforce on the other (low-cost automation). ... Field-proven application examples.

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Low-cost automation 'on a shoestring' demos in action. Leave a Comment / News / By admin. The Digital Manufacturing on a Shoestring project continued to ...

Cutting Costs with Pneumatics: Low-cost Automation from the ...

books.google.com › books › about › Cutting_Costs_with...

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Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...

Karakuri | FlowStore Systems | Lean Manufacturing principles

www.flowstore.co.uk › karakuri

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low cost automation ppt

eventiinlive.it › Crusher

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Low Cost Automation | Pneumatics | Automation - Scribd

www.scribd.com › document › Low-Cost-Automation

Jan 29, 2014 — Low Cost Automation - Free download as Word Doc (.doc), PDF File (.pdf), Text File (.txt) or read online for free. capstan.

Introduction of Industrial Automation - bbsbec

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Low Cost Automation ESP32 and 16 Relays : 25 Steps ...

www.instructables.com › Circuits › Microcontrollers

25 steps

1.

ESP32 Pinout

2.

In this image you can notice that I only used two pins to connect 16 relays, which is made possible by MCP23017. You can see about this in the video, “IO ...

3.

In the image, you see our assembly and a cell phone connected to our local IP-based application, with relay and ESP32 boards being powered by USB.Through ...

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lean automation - DiVA

www.diva-portal.org › diva2:588910 › FULLTEXT01

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by A Delkhosh · 2012 · Cited by 8 — At last some industrial and educational examples are reviewed to check the circumstances of ... Toyota have developed so-called low-cost automation. Lean.

Karakuri Kaizen: Automation with smarts | item America ...

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Global study and implementation of Karakuri

odr.chalmers.se › bitstream

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by P Bellur Shashi Kumar · 2018 — studies, examples of low cost automation that can be used in further studies. The studies will also help understand the differences in continuous improvement ...

Laboratory automation - Wikipedia

en.wikipedia.org › wiki › Laboratory_automation

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May 9, 2020 — Justify with proper description why low cost automation is required to improve productivity in small scale industries. List out some examples. 1.

1 answer

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PLC Controlled Low Cost Automatic Packing Machinewww.ripublication.com › ijame-spl

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Low Cost Automation (popularly known as LCA), is the introduction of simple pneumatic, hydraulic, mechanical and electrical devices into the existing production ...

Low cost plc with hmi

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Low Cost Automated Systems 

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Get familiar with low cost automation techniques like efficient material handling and inventory management. ... Analysis, Design Methods and. Worked Examples.

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Low-cost automation (LCA) relieves strain on workers and boosts productivity without requiring complex control systems or drives. For example, by connecting ...

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by S Seifermann · 2014 · Cited by 44 — Keywords: Low Cost Automation; Cellular Manufacturing; Work Measurement; Lean Machining. 1. ... MTM-1 for example shows a system-immanent deviation of.

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by E Hendrickson · 2001 · Cited by 4 — result, I have examples of good test automation stories. A tool that took a ... Further, otherwise low cost automation can become high cost as maintenance costs.

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Video for "low cost automation" examples

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Jun 25, 2018 · Uploaded by Institute for Manufacturing (IfM), University of Cambridge

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Koichi Shimokawa, ‎Ulrich Jürgens, ‎Takahiro Fujimoto · 2012 · ‎Technology & Engineering

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Allan R. Coletta · 2017 · ‎Business & Economics

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Marek Zaremba, ‎Jerzy Z Sasiadek, ‎H H Erbe · 2005 · ‎Business & Economics

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Process Automation Handbook: A Guide to Theory and Practice

Jonathan Love

Springer Science & Business Media, 22-Dec-2007 - Technology & Engineering - 1093 pages

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Tire manufacturing industry, analysing the cost and margin

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https://www.televisory.com/blogs/-/blogs/tire-manufacturing-industry-analysing-the-cost-and-margin-trends

Updated on 31.5.2021,  28.11.2020, 24 June 2019, 22 February 2014