Name:Zuhaib Ahmad Mir

Rollno: 53

Assignment: Integration of automated processes with production processes.

Date:2 October 2020

Sub: production and operation management

 Integrated automation systems incorporate the total manufacturing system

into a computer-controlled, digitally processed and coordinated system.

 Integrated automation systems work through a common manufacturing

system database. This central automation control point makes it possible to
integrate industrial and non-industrial processes and robot integration through
automated production technologies. Integrated automation systems are used
in computer integrated manufacturing and several types of advanced process
automation systems.

 A well-designed integrated automation system opens the door to

implementing advanced technologies that could greatly increase efficiency
and productivity across the entire manufacturing facility, including bringing
together:

 Computer-Aided Process Planning (CAPP)

 Computer-controlled scheduling and production line control processes
 Manufacturing Execution System (MES) / Manufacturing IT integration
 Programmable Logic Controller (PLC) and Distributed Control System
programming
 Coordinated Drive systems and advanced Motion Control
 Production Process Test Systems and Process Monitoring Sensors
 Part validation and Vision Inspection Systems
 Industrial Energy Management systems
 Automated material handling systems
 Automated retrieval and storage systems
 RFID and Bar Code part tracking systems
 INTEGRATED AUTOMATION Is the latest among the types of automation.
These involve all the latest technologies in Automation. This is not just about
AI (artificial intelligence)or RPA( Robotic process automation) and Analytics. It is
the combination of RPA, AI and Analytics.  We do not solve the system or
business problems using a standalone technology. We use a combination of
technologies to get it sorted out. This is where Integrated Automation comes
into play. Some of the places where it plays a huge role are in improving the
overall capability of the business and enabling cognitive vision and mission.
With this automation process, you can increase your business credibility to
the next level.

 The mortgage industry could be the best point to focus on our integrated
automation platform. After a decade passed after the global financial crisis,
the US mortgage industry is getting more regulated soon to protect its
customers. The complexity of the process and the associated costs have
become more. Considering the number of documentation and data validation
we require to process from origination to services, automation would seem
like an obvious opportunity. When you have unstructured and inconsistent
data in your mortgages, it would get harder to use different tools like RPA.

 With the dawn of digitalization, businesses are looking for better opportunities
in all aspects. There is also the new concept called digital twin. The digital
twin involving production activities are becoming more popular nowadays.
This would help businesses of any sizes to flourish.

 This Integrated Automation Software holds an appealing and attractive user

interface. This has been in demand in the market for a few days.

 Some of the examples of Integrated Automation Software include:

 PLC/HMI application development and integration
 VB related projects
 Integrate and program for Servo, VFD’s using control system
 Recommendation and integration of technology
 The interface of different control devices

 A process in the development of mechanized production in which the control

and monitoring functions previously performed by humans are transferred to
instruments and automatic devices. Automation of production is the basis of
the development of modern industry and a general trend in technical
progress. Its goal is to improve the efficiency of labour and the quality of
manufactured products and to create conditions for the optimum utilization of
all production resources. Partial, integrated, and total automation of
production are distinguished.
 Partial automation of production is defined more precisely as automation of
specific production operations and is achieved in those cases where process
control is practically inaccessible to human effort because of the complexity or
rapidity of the process and where simple automatic devices can effectively
replace human labour. As a rule, working production equipment is partially
automated. As automation equipment is perfected and its range of application
is expanded, partial automation is found to be most effective where the
manufacturing equipment is designed to be automated from the outset. Partial
automation includes automation of control operations.
 In integrated automation of production, the production section, the production
shop, the plant, or the electric power station functions as a unified interrelated
automated complex. Integrated automation of production encompasses all of
the basic functions of the enterprise, farm, or service. It is feasible only in the
case of highly developed production based on modern technology and
sophisticated methods of control using highly reliable production equipment
acting according to a prespecified or self-adaptive program. The human
function is limited to overall monitoring and control of the entire complex.

 While driving your business, you may confine with so many challenges and
the prime one is to gain more out of the very limited resources whether it is
financial or human resources. The challenges become worse with the rapidly
changing responsibilities and technology. However, system integration is one
of the best solutions that can deal with the emerging challenges.
 Businesses that have multinational operations or joint ventures can obtain a
number of conveniences as well as facilities. For example, they can manage
supply chain and organization and bring out advanced convenience to the end
users. Information technology can help in extraction of maximum profit and
information through the minimum possible way after software integration.
 System integration is an engineering or IT process that accumulates various
components or subsystems to create a fully customized system. System
integration helps you to connect different platforms together. The process
 consists of combining multiple computer systems and software applications
physically or functionally. The end target of integration IT systems is to have
everything act as a single system.
 IT system integration can be done through various techniques. Some of these
techniques include computer networking, managing business processes,
integrating enterprise applications and manual programming.


 The art of combining all sub-systems using technology so that the effective
efficiency is higher than a single system and is more result oriented is known
as system integration. Almost all big companies today are coming up with
joint-ventures and having branch offices in different countries, in such a
situation system integration becomes most important part for any
organization. System Integration saves time and improves efficiency.
 As the complexity of products and manufacturing processes increases, so
does the opportunity for human error in material processing and data
collection. Integration and automation of the equipment used in the execution
of manufacturing processes offers a solution to prevent those errors from
occurring. Equipment integration and automation provides a means of
accurate and timely data collection, process controls, and optimization efforts.

 Equipment integration and automation benefits equipment operators,

production managers, production engineers, and the overall enterprise. Some
areas where benefits can be seen:

 Accurate and timely data collection for data-driven decision making



 Enhanced quantity of collected data and events provide a solid foundation

for sophisticated analytics to inform process optimizations

 Reduction of scrap and increase in yield by automatically controlling and

adjusting the process at the equipment

 Improved equipment utilization by removing delays caused by unavailable

operators

 Visibility into the state of production, enabling staff to understand quickly

where and why the production landscape is experiencing issues

 Concepts
 Manufacturers leverage a wide range of process automation capabilities and
commonly have at least some level of automation along with other manual
efforts. The level of manufacturing process automation can range from basic
to high automation. Achieving higher levels manufacturing automation
capabilities depends largely on:
 current communication capabilities of the existing components
 effort required to develop the capabilities that don’t currently exist
 budget for such initiatives
 Considerations
 Before approaching equipment integration and automation initiatives, it’s
important to clearly identify the following:
 the main goal of the initiative, for example error prevention over throughput
optimization
 existing processes that have to be automated or changed
 standardization of processes
 the availability of different stakeholders, especially production, industrial
engineering, equipment engineering, etc. to participate in and help guide the
solution
 budget available for automation initiatives
 Designed the right way, equipment integration and automation can be an
iterative process beginning with the most important things first while
simultaneously laying the foundation for more advanced functions to be
implemented in later phases.
 Goals of Equipment Integration & Automation
 Integrating manufacturing equipment with other IT systems and enabling
those systems to control manufacturing equipment accomplishes the
following:
 prevents errors and misprocessing
 enables accurate and timely data collection
 improves product quality
 In addition, automation provides a standardized workflow for all material
processed in a factory that can be customized for specific equipment, material
and processing scenarios.

 Automation
 Equipment integration and automation involves the connection of various
manufacturing systems for the purpose of orchestrating and automating
process scenarios.
 Connection of Systems
 One major benefit of automation is realized by its ability to connect
manufacturing equipment to other manufacturing IT systems within the
manufacturing environment. Automation then serves as a layer of abstraction
between the particular equipment interface and the rest of the factory data
systems. The result is a tremendously simplified interaction for the end-user in
that they no longer have to interact directly with each system individually.
They simply interact with the automation interface, which then handles the
interactions with all underlying systems.

 Manufacturing equipment types vary greatly in the ways in which they present
connection interfaces to automation, ranging from industry standard formats
to no interface at all. Regardless of the type of connection interface offered by
the manufacturing equipment, automation can act as a bridge between the
equipment and other manufacturing IT systems. The types of interfaces
offered by manufacturing are numerous and can include:
 SECS-GEM
 OPC UA
 MQTT
 Modbus
 MT Connect
 web services
 file systems
 proprietary protocols
 IIoT gateways
 and others
 Orchestration of Scenarios
 As material moves through a manufacturing line, there are usually some
common activities that take place, regardless of the material’s particular
product or processing step. These activities are required by the business rules
of the organization, and serve purposes like consistent tracking, validation of
material ID, confirmation of equipment readiness, and so on. These activities
can be organized into common “scenarios” which can be handled by
automation software at each processing step. By identifying and standardizing
common scenarios, the automation can present a common and familiar
processing sequence to a manufacturing operator at each step in the material
flow and that processing sequence can then be applied to provide automation
for many different process scenarios. A simplified standard scenario might
look like this:
 Fetch material to be processed
 Identify the material at the equipment
 Verify material is at the appropriate manufacturing step and equipment
 Verify the equipment is ready to process the material
 Select/download recipe for material
 Track in the material (in MES)
 Process the material
 Collect data for use by MES and other systems
 Track out the material (in MES) and move it to the next step
 If a particular process step or product requires additional or exceptional
activities, the standard automation scenario can easily be modified or
extended to accommodate them. The advantages of using automation to
orchestrate common processing scenarios includes:
 Equipment operators can be more easily trained on the common scenario and
can easily learn a few exceptions, rather than having to learn different
scenarios for each and every product and process.
 Consistent application of business rules ensures proper product tracking and
verification, and validation of equipment readiness, thereby reducing the
chance of untraceable or incorrectly processed material.