A PROJECT ON IMPLEMENTING ADVANCED

AUTOMATION IN SMART MANUFACTURING SYSTEM

By

SWARUP MONDAL (10300721177)

SARNAKAMAL MONDAL (10300721161)
BIBHIDIPAN RAKSHIT (10300721138)
DEBKUMAR HALDER (10300721142)
UNDER THE SUPERVISION OF

Prof. (Dr.) TARUN KANTI JANA

(PROFESSOR & DEAN)

DEPARTMENT OF MECHANICAL ENGINEERING

Interim Report submitted in Compliance with Course: PW-ME-891

Course Name: Project – IV

HALDIA INSTITUTE OF TECHNOLOGY

Autonomous institution under MAULANA ABUL KALAM AZAD UNIVERSITY

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 HALDIA INSTITUTE OF TECHNOLOGY

Affiliated to
MAULANA ABUL KALAM AZAD UNIVERSITY OF TECHNOLOGY
FORWARDING CERTIFICATE
Dated: 30/04/2024
any Degree/Diploma or any other academic award anywhere before. This is to
certify that the Project Interim Report entitled “ADVANCED AUTOMATION IN
SMART MANUFACTURING SYSTEM” submitted by Bibhidipan Rakshit,
Sarnakamal Mondal, Swarup Mondal, Debkumar Haldar and Sudipta Ghorai
is absolutely based upon their own work under the supervision of Prof. (Dr.)
Tarun Kanti Jana, Professor & Dean that neither their project interim report nor
any part of the same has been submitted for

…………………………… …………………………….
Dr. Goutam Kumar Bose Dr. Tarun Kanti Jana
(Head of The Department (Professor & Dean Department Of

of Mechanical Mechanical Engineering)

Engineering)

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ACKNOWLEDGEMENTS

The final year report opportunity we have got here in my college is a

great chance for learning and professional development. Therefore, we
consider our self as a very lucky individual as we provided with an
opportunity to be a part of it. We would like to express my hurtful gratitude
to our department Prof. (Dr.) Goutam Bose sir and Prof. (Dr.) Tarun Kanti
Jana sir departmental professor of Mechanical Engineering, Haldia
institute of technology who made this project possible.

We perceive as this opportunity as a big milestone in our career

development. We will strive to use grant skills and improvement, in the
best possible way, and we will continue to work on their improvement, in
order to attain desire career objectives. Hope to continue corporation
with all you in future, sincerely.

Signature of Students
…………………………….
……………………………
………………………………
……………………………..

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HALDIA INSTITUTE OF TECHNOLOGY
Affiliated by
Maulana Abul Kalam Azad University of Technology

The foregoing project is hereby approved as a creditable study of an engineering

subject carried out and presented in a manner satisfactory to warrant its
acceptance as a prerequisite to the degree for which it has been submitted. It is
understood that by this approval, the undersigned do not necessarily endorse or
approve any statement made, opinion expressed or conclusion drawn therein but
approve the thesis only for the purpose for which it is submitted.

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ABSTRACT

The project on Advanced Automation delves into the rapidly evolving landscape
of automation technologies, aiming to provide a comprehensive overview of
innovations, challenges, and implications for various industries and society as
a whole. project report on advanced automation, which aims to provide a
comprehensive understanding of the various types of automation technologies,
their benefits and challenges, and their implications for industries and society.
The project explores cutting-edge advancements in automation, including
robotics, artificial intelligence, machine learning, and the integration of these
technologies into existing systems. The study also addresses the potential
benefits and risks associated with advanced automation, while considering the
ethical, social, and economic ramifications.

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 INDEX

CHAPTER-1
1.1 INTRODUCTION

CHAPTER-2
2.1 HISTORY OF AUTOMATION

CHAPTER-3
3.1 CONCEPT OF ADVANCED AUTOMATION IN SMART MANUFACTURING
3.2 SMART MANUFACTURING
3.2.1 CPPS
3.2.2 SMART FACTORY
3.2.3 DIGITAL TWIN
3.2.4 IOT
3.2.5 KEY CONCEPT OF SMART MANUFACTURING
3.2.6 SMART MANUFACTURING TECHNOLOGIES

CHAPTER-4
4.1 ADVANCED AUTOMATION IN MATERIAL REMOVAL PROCESS

CHAPTER-5
5.1 APPLICATION OF ADVANCED AUTOMATION IN VARIOUS ORGANIZATION
5.2 BENEFITS OF ADVANCED AUTOMATION
5.3 CHALLENGES AND CONSIDERATIONS

CHAPTER-6
6.1 CONCLUSION

CHAPTER-7
7.1 REFERENCES

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LIST OF FIGURES

FIG. 3.2-1 Key concept of smart manufacturing

FIG. 3.2.2-1 Smart Factory
FIG. 3.2.3-1 Various Application of Digital Twin
FIG.3.2.4-1 Practical application of IIoT in industrial Automation
FIG. 3.2.1- 1 5C Architecture of CPPS

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 OBJECTIVES OF PROJECT

The project aims to seamlessly integrate CPPS technologies into existing

manufacturing processes. By doing so, manufacturers can achieve greater
efficiency, reduce manual labour, and enhance overall productivity. Smart
manufacturing involves optimizing various processes, from production lines to
supply chain management. The project aims to identify bottlenecks, streamline
workflows, and minimize waste through automation and data-driven decision-
making. Real-time monitoring and feedback loops help maintain quality
standards. Implementing automation can reduce operational costs. Predictive
maintenance prevents costly breakdowns, and efficient resource allocation
minimizes waste. The project aims to achieve cost savings while maintaining
or improving production output. Smart manufacturing relies on data collection
and analysis. The project aims to leverage data from sensors, machines, and
production lines. Insights gained from data help optimize processes, predict
maintenance needs, and make informed decisions. The project aims to create
a flexible system that adapts to changing demands. Scalability ensures that
automation can grow alongside business requirements.

In summary, to enhance manufacturing processes by integrating CPPS

technologies, improving efficiency, reducing costs, and ensuring high-quality
production.

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 CHAPTER -1

1.1 INTRODUCTION
Advanced automation has made considerable progress from basic transport
lines. Realizing which sort of automation and how it will help the organization
will assist you with remaining on the main edge of the contest. As additional
information is available the better managers will actually want to see where the
best advantages are and what Industry 4.0 innovations will enhance the
creation, quality, income streams, and laborers.

Advanced automation is revolutionizing manufacturing by transforming

traditional production lines into intelligent ecosystems. This integration of
cutting-edge technologies like industrial robotics, machine learning, and big
data analytics empowers manufacturers to achieve unprecedented levels of
efficiency, quality, and productivity. Here's a glimpse into how advanced
automation is shaping smart manufacturing:
Intelligent Machines, Industrial robots equipped with advanced sensors and
machine learning can perform complex tasks with exceptional precision and
adaptability, consistently exceeding human capabilities in speed and accuracy.
Real-time Optimization, Machine learning algorithms analyze real-time data
from sensors embedded in machines and throughout the production process.
This enables them to identify inefficiencies, predict equipment failures, and
optimize production parameters for peak performance.
Autonomous Decision-Making, Advanced automation empowers machines to
make autonomous decisions within predefined parameters. This can involve
self-correcting for minor errors or adjusting production lines based on real-time
data insights.

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Predictive Maintenance, By analyzing sensor data, advanced automation can
predict equipment failures before they occur. This enables proactive
maintenance, preventing costly downtime and ensuring smooth operation.
Enhanced Quality Control, Machine vision systems powered by AI can perform
high-speed, non-destructive quality inspections, ensuring consistent product
quality throughout the manufacturing process.

Industry 4.0’s provenance lies in the powerhouse of German manufacturing.

However, the conceptual idea has since been widely adopted by other
industrial nations within the European Union, and further afield in China, India,
and other Asian countries. The name Industry 4.0 refers to the forth industrial
revolution, with the first three coming about through mechanization, electricity,
and IT. The fourth industrial revolution, and hence the 4.0, will come about via
the Internet of Things and the Internet of services becoming integrated with the
manufacturing environment. The vision of Industry 4.0 is that in the future,
industrial businesses will build global networks to connect their machinery,
factories, and warehousing facilities as cyber-physical systems, which will
connect and control each other intelligently by sharing information that triggers
actions. These cyber-physical systems will take the shape of smart factories,
smart machines, smart storage facilities, and smart supply chains. This will
bring about improvements in the industrial processes within manufacturing as
a whole, through engineering, material usage, supply chains, and product
lifecycle management. At the center of this vision will be the smart factory,
which will alter the way production is performed, based on smart machines but
also on smart products. It will not be just cyber-physical systems such as smart
machinery that will be intelligent; the products being assembled will also have
embedded intelligence so that they can be identified and located at all times
throughout the manufacturing process. The miniaturization of RFID tags

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enables products to be intelligent and to know what they are, when they were
manufactured, and crucially, what their current state is and the steps required
to reach their desired state. This requires that smart products know their own
history and the future processes required to transform them into the complete
product. This knowledge of the industrial manufacturing process is embedded
within products and this will allow them to provide alternative routing in the
production process. Another key element in the industry 4.0 is vision, and that
is the integration of the vertical manufacturing processes in the value chain.
The vision held is that the embedded horizontal systems are integrated with
the vertical business processes, (sales, logistics, and finance, among others)
and associated IT systems.
They will enable smart factories to control the end-to-end management of the
entire manufacturing process from supply chain through to services and
lifecycle management. Smart factories do not relate just too huge companies,
indeed they are ideal for small- and medium-sized enterprises because of the
flexibility that they provide. For example, control over the horizontal
manufacturing process and smart products enables better decision-making
and dynamic process control, as in the capability and flexibility to cater to last-
minute design changes or to alter production to address a customer’s
preference in the products design. Furthermore, this dynamic process control
enables small lot sizes, which are still profitable and accommodate individual
custom orders. These dynamic business and engineering processes enable
new ways of creating value and innovative business models.

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 CHAPTER -2

2.1 HISTORY OF AUTOMATION

Automation has been a consistent objective of industrial revolution from as early
as the 18th Century. Starting from the onset of the Industrial Revolution, there have
been deliberate efforts to enhance the ease and efficiency of doing work through
automation of complex processes requiring heavy workforce involvement Janssen
(2019). According to Janssen et al., industrial revolution has been driven mostly
by need and the needs keep evolving over time. The continuous evolution has led
to the most recent outcomes in terms of AI and Internet of Things, among others,
which are characterized as serious in-roads into automation.

The world has experienced four phases of the industrial revolution with the first
having occurred in the late 18th and early nineteenth centuries. The process of
manufacturing in this period changed to an optimized form of labour using steam,
steam-enabled engines, and various machine tools traditionally used by individuals
from the manual labor0 system (Marengo 2019).

In the early twentieth century, the second phase of the industrial revolution ensued
with steel and electrical factories being introduced. The introduction of steel and
electricity boosted the efficiency and mobility of factory machines for the
manufacturers, thus improving productivity through novel concepts, such as
assembly lines (Kumar et al. 2005).

An important milestone for business process automation was 1913, when Henry
Ford conceived of the moving assembly line, an invention that enhanced the
production of Model T cars in mass (Kotorov 2003).

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The late 1950s witnessed the emergence of the third phase—computer technology
integrated with electronics in factories—and digital technology and automation
started gaining traction as compared to analogue and mechanical technology
(Hitomi 1994).

Over the years, automation has made significant advancements with the aid of new
technologies, including artificial intelligence (Makarius et al. 2020).

Although mechanization and industrial robots have been commonly used in

manufacturing industries for several decades, the emergence of AI has opened up
new possibilities for automation (Davenport et al. 2020).

Particularly in non-manufacturing industries like healthcare, finance, and retail.

With the help of machine learning and natural language processing, AI-powered
automation is now capable of automating complex tasks such as data analysis,
decision-making, and customer service that were once deemed too challenging
(Frey and Osborne 2017).

Automation has increased the efficiency of work and enhanced the quality of
outcomes. With the emergence of Industry 4.0, automation has become an even
more important concept. Industry 4.0 technologies, such as the Internet of Things,
big data analytics, and artificial intelligence, have enabled manufacturers to create
highly flexible and adaptive production systems that can respond quickly to
changes in the market (Ding et al. 2021). This level of automation has transformed
the manufacturing landscape, enabling manufacturers to achieve unprecedented
levels of efficiency, productivity, and profitability.

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Businesses could now even employ automation to their marketing, operations,
analytics, sales, customer relationships, and planning. Business process
automation lets businesses or managers execute strategies and employ tools
automatically after commanding and organizing them (Herm et al. 2022).

AI-powered automation is among the trends widely researched under Industry

4.0. It has infiltrated all dimensions of business activity, including manufacturing,
marketing, customer resource management, enterprise resource management,
warehousing operations, and human resource management (Altaf 2022).

In marketing, for instance, machine learning algorithms have been used to predict
consumer behaviour and to develop marketing messages and strategies aligned
with the consumer behaviour (Altaf 2022).

Similarly, in sectors such as healthcare, AI automation has resulted in greater

efficiency in service delivery due to the use of interactive technologies to foster an
understanding of patient needs (West and Allen 2018; Benner 2017).

Remarkably, AI-powered automation has been recognized as a massive

transformational force in the world. There is increasing interest in research on AI
automation due to the observed transformational effect of the technology and the
expected changes in the business environment (West and Allen 2018).

A lot of the completed studies on AI-powered automation focus on the relevance of

it on different domains of corporate performance and the expected impacts of AI
on the future of business in various sectors (Chao et al. 2018).

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 CHAPTER -3

3.1 CONCEPT OF ADVANCED AUTOMATION IN SMART MANUFACTURING:

Advanced automation refers to the integration and utilization of cutting-edge
technologies, including robotics, artificial intelligence (AI), machine learning (ML),
internet of things (IoT), and data analytics, to create intelligent, self-adapting
systems that can perform complex tasks with minimal human intervention. Unlike
traditional automation, which primarily involves rule-based and repetitive
processes, advanced automation incorporates cognitive capabilities, learning
from data and adapting to dynamic environments.

Types of Advanced Automation

• Robotic Process Automation (RPA)

• Cognitive Automation

• Industrial Automation

• Autonomous Vehicles

• Smart Manufacturing

• Healthcare Automation

We are doing this Advance Automation in which we will discuss Manufacturing:

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3.2 SMART MANUFACTURING:
Smart Manufacturing, often referred to as the Fourth Industrial Revolution or
Industry 4.0, represents the convergence of digital technologies, data analytics,
and automation to transform traditional manufacturing processes into agile,
efficient, and intelligent systems. Smart Manufacturing extends beyond individual
components or processes; it involves the holistic integration of data, technologies,
and people to create interconnected, data-driven production environments. Smart
manufacturing is a combination of various technologies and solutions, including
artificial intelligence (AI), robotics, cybersecurity, Industrial Internet of Things (IIoT),
and blockchain that are implemented into a manufacturing ecosystem to optimize
manufacturing processes by generating and/or accepting data.

Figure 3.2-1: Key Concept of Smart Manufacturing

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3.2.1 CPPS

Cyber-Physical Production Systems are systems of systems of autonomous and

cooperative elements connecting with each other in situation dependent ways, on
and across all levels of production, from processes through machines up to
production and logistics networks, enhancing decision-making processes in real-
time, response to unforeseen conditions and evolution along time. Cyber-Physical
System (CPS) is a new kind of digital technology that increases its attention across
academia, government, and industry sectors and covers a wide range of
applications like agriculture, energy, medical, transportation, etc. The traditional
power systems with physical equipment as a core element are more integrated with
information and communication technology, which evolves into the Cyber-Physical
Power System (CPPS). The CPPS consists of a physical system tightly integrated
with cyber systems (control, computing, and communication functions) and allows
the two-way flows of electricity and information for enabling smart grid
technologies. Even though the digital technologies monitoring and controlling the
electric power grid more efficiently and reliably, the

power grid is vulnerable to cybersecurity risk and involves the complex

interdependency between cyber and physical systems. Analyzing and resolving the

problems in CPPS needs the modelling methods and systematic investigation of a

18
Figure3.2.1- 1: 5C Architecture of CPPS

complex interaction between cyber and physical systems. The conventional way of
modelling, simulation, and analysis involves the separation of physical domain and
cyber domain, which is not suitable for the modern CPPS. Therefore, an integrated
framework needed to analyze the practical scenario of the unification of physical
and cyber systems. A comprehensive review of different modelling, simulation, and
analysis methods and different types of cyber-attacks, cybersecurity measures for
modern CPPS is explored in this paper. A review of different types of cyber-attack
detection and mitigation control schemes for the practical power system is
presented in this paper. The status of the research in CPPS around the world and
a new path for recommendations and research directions for the researchers
working in the CPPS are finally presented.

Cyber-Physical Production Systems (CPPS) are industrial automation systems that

combine physical components, such as machines, robots, and sensors with digital
components, such as software, networks, and databases. CPPS enable the
integration of physical and digital processes, allowing for the automation of
production processes and the optimization of maintenance operations. CPPS are
used in a variety of industries, including manufacturing, automotive, aerospace,
and energy. CPPS can be used to monitor and control production processes,
detect and diagnose faults, and optimize maintenance operations. CPPS can also
be used to improve safety, reduce costs, and increase efficiency. Cyber-Physical
Production Systems (CPPS) consist of autonomous and cooperative elements and
subsystems that are connected based on the context within and across all levels
of production, from processes through machines up to production and logistics
networks (Monostori et al., 2016), with three main characteristics that describe
them:

19
3.2.1 CPPS

Cyber-Physical Production Systems are systems of systems of autonomous and

cooperative elements connecting with each other in situation dependent ways, on
and across all levels of production, from processes through machines up to
production and logistics networks, enhancing decision-making processes in real-
time, response to unforeseen conditions and evolution along time. Cyber-Physical
System (CPS) is a new kind of digital technology that increases its attention across
academia, government, and industry sectors and covers a wide range of
applications like agriculture, energy, medical, transportation, etc. The traditional
power systems with physical equipment as a core element are more integrated with
information and communication technology, which evolves into the Cyber-Physical
Power System (CPPS). The CPPS consists of a physical system tightly integrated
with cyber systems (control, computing, and communication functions) and allows
the two-way flows of electricity and information for enabling smart grid
technologies. Even though the digital technologies monitoring and controlling the
electric power grid more efficiently and reliably, the

power grid is vulnerable to cybersecurity risk and involves the complex

interdependency between cyber and physical systems. Analyzing and resolving the
problems in CPPS needs the modelling methods and systematic investigation of
acomplex interaction between cyber and physical systems. The conventional way
of a modelling, simulation, and analysis involves the separation of physical domain
and cyber domain, which is not suitable for the modern CPPS. Therefore, an
integrated framework needed to analyze the practical scenario of the unification of
physical and cyber systems. A comprehensive review of different modelling,
simulation, and analysis methods and different types of cyber-attacks,
cybersecurity measures for modern CPPS is explored in this paper. A review of
different types of cyber-attack detection and mitigation control schemes for the

20
practical power system is presented in this paper. The status of the research in
CPPS around the world and a new path for recommendations and research

directions for the researchers working in the CPPS are finally presented.

Figure3.2.1- 1: 5C Architecture of CPPS

Cyber-Physical Production Systems (CPPS) are industrial automation systems that

combine physical components, such as machines, robots, and sensors with digital
components, such as software, networks, and databases. CPPS enable the
integration of physical and digital processes, allowing for the automation of
production processes and the optimization of maintenance operations. CPPS are
used in a variety of industries, including manufacturing, automotive, aerospace,
and energy. CPPS can be used to monitor and control production processes,
detect and diagnose faults, and optimize maintenance operations. CPPS can also
be used to improve safety, reduce costs, and increase efficiency. Cyber-Physical
Production Systems (CPPS) consist of autonomous and cooperative elements and
subsystems that are connected based on the context within and across all levels
of production, from processes through machines up to production and logistics
networks (Monostori et al., 2016), with three main characteristics that describe
them:

Intelligence (smartness), i.e. the element is able to acquire information from their
surroundings and act autonomously and in a goal-directed manner

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• Connectedness, i.e. the ability to set up and use connections to the other
elements of the system including human beings – for cooperation and
collaboration, and to the knowledge and services available on the Internet
• Responsiveness towards internal and external changes.

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23
3.2.2 SMART FACTORY

The heart of Industry 4.0 in conceptual terms is the Smart Factory (Figure 3.1.2-
1) and everything revolves around this central entity that makes up the business
model. Similarly, all the external interfaces from supply chain partners, smart
grids, and even social media conceptually have the smart factory at the hub—it
is the sun around which other processes orbit.

Figure 3.2.2-1: Smart Factory

A Smart Factory hosts smart manufacturing processes. A Smart Factory is

futuristic in that it can produce and deliver productivity well beyond our
expectations. Smart Factories are a bringing together of technologies that
provide the optimum methods and techniques in manufacturing.
This is one of the basis of Smart Manufacturing, because we can reduce waste
and inefficiency by identifying products on the production line and determining
their status and what is more their history and what specific stage of production
they must next pass through.
Using RFID tags that are so miniaturized that now they can be embedded
into a label or use NFC (near frequency contact) such as in card payment

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systems. NFC is a bit fragile it requires close proximity to the reader,
whereas RFID is astonishingly capable. Take for instance a racing car
embedded with an RFID tag and during each lap, an RFID reader counts
the number of laps. Incredibly, an RFID reader can count reliably every lap
a racing car performs even at speeds of 200 mph and more. Therefore,
RFID tags are perfect for Smart Factory applications where the speed of the
production process must not be compromised.
As the name implies, a smart factory is… smart. An interconnected network
of machines, Communication mechanisms, and computing power, the
smart factory is a cyber-physical system that uses advanced technologies
such as artificial intelligence (AI) and machine learning to analyze data,
drive automated processes, and learn as it goes. Smart factories and smart
manufacturing are part of the technological transformation known as
Industry 4.0 or the Fourth Industrial Revolution. Each of the first three
industrial revolutions was born out of innovative new technology that
completely changed the way we worked and manufactured goods: namely,
the steam engine, the assembly line, and the power of the computer. Today,
the fourth revolution is driven by digital transformation and intelligent
automation.

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3.2.3 DIGITAL TWIN

A digital twin is a virtual representation of a physical object, system, or process

that is used to simulate, analyze, and optimize performance in real-time. It
integrates data from various sources, including sensors and IoT devices, to
mirror the physical counterpart's characteristics, behaviors, and conditions.
Digital twins are transforming industries by providing a powerful tool for improving
efficiency, reducing costs, and enhancing innovation through better-informed
decision-making. In the context of smart manufacturing, a digital twin can be used
to simulate and optimize the production process, predict and prevent equipment
failures, and improve efficiency and quality of part production. The digital twin
can provide a detailed, accurate representation of the physical object or system,
including its behavior, performance, and interactions with the environment.
Digital twins use machine learning, data analytics, and multi-physics simulation
in order simulate and analyze different working conditions and other factors affect
a system. The creation of the digital twin is a critical component of future
technology that will have an impact on several global sectors. By analyzing data
from the physical object, the Digital Twin can provide real-time feedback, monitor
its performance, and identify potential issues before they occur. A digital twin can
be used in order to optimize the operation of a physical system, by simulating its
behavior and identifying areas where improvements can be made. Furthermore,
companies can utilize digital twins to model, anticipate, and improve products
and manufacturing processes in different industries, including automotive, green
energy, and aviation before organizations invest in actual prototypes and assets.
As a result, digital twins can help businesses and manufacturing process in order

26
to make better decisions, reduce costs, and improve performance across a range
of industries and applications.

Figure 3.2.3-1: Various Applications of Digital Twin

Here are key aspects of digital twins:

Data Integration: Digital twins rely on continuous data streams from sensors
and IoT devices embedded in the physical counterpart. This data is used to
update the digital model in real time.

Simulation and Modeling: They use advanced simulations, machine learning,

and analytics to replicate the physical object's performance, allowing for virtual
testing and experimentation.

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Predictive Maintenance: By analyzing data trends and patterns, digital twins
can predict potential failures or maintenance needs, helping to prevent downtime
and extend the lifespan of the physical asset.

Optimization: They enable real-time monitoring and control, optimizing

performance, energy use, and other parameters by providing insights into how
changes in one part of the system affect the whole.

Application Areas:
• Manufacturing: To optimize production processes and improve
product design.
• Healthcare: To create personalized treatment plans based on the
digital twin of a patient.
• Smart Cities: To manage infrastructure, utilities, and services
efficiently.
• Automotive: For vehicle design, testing, and real-time monitoring of
performance.
• Aerospace: For maintenance and performance optimization of aircraft
and space systems.

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3.2.4 IOT

Internet of Things (IOT) plays a crucial role in advancing automation within the
manufacturing industry.

• Advanced Automation:

• Robotics: IoT enables industrial robots to operate autonomously

using sensors, cameras, wireless devices, and edge computing.
These robots perform tasks such as assembly, defect detection,
sorting, stacking, and routing.
• Autonomous Machine Operation: By integrating IoT sensors and
data analytics, machines can optimize their own operation, leading
to improved efficiency and productivity.

• Safety and Efficiency:

• Real-time monitoring through IoT helps prevent accidents and

ensures worker safety.
• Predictive maintenance based on machine data minimizes downtime
and reduces maintenance costs.

• Visibility and Insights:

• IoT provides visibility into manufacturing operations, allowing

businesses to make informed decisions.
• Data collected from IoT devices can be analysed to optimize
processes and enhance overall efficiency.

IoT in manufacturing creates advanced automation, enhances safety, and

improves productivity, making it a key driver in the industry 4.0 revolution. The
Internet of Things (IoT) is a system of computing devices, machines, and objects

29
or people that are interconnected. Data can automatically be transferred over a
network. Some examples of IoT in action include wearable smart devices,
connected cars, smart cities (i.e., pollution or traffic being monitored with smart
technology), smart homes, and smart appliances. Through IoT technology, we
are more responsive and more efficient with our resources, and identifying
areas for improvement. In manufacturing, the IoT is used to create smart
factories that are more efficient and productive with sensors and devices to
gather data, optimize processes, and identify and offset potential problems.
In terms of energy consumption, IoT can be used to create smart grids that help
us reduce and improve our energy usage. Beyond manufacturing, IoT has the
potential to revolutionize other industries (i.e. distribution, retail, healthcare) and
it will continue to become better at understanding our needs and being more
adaptive to them.

Figure 3.2.4-1: Practical Application of IIoT in Industrial Automation

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3.2.5 KEY CONCEPTS OF SMART MANUFACTURING:

Smart manufacturing (SM) is a technology-driven approach that utilizes Internet-

connected machinery to monitor the production process. The goal of SM is to
identify opportunities for automating operations and use data analytics to improve
manufacturing performance.
SM is a specific application of the Industrial Internet of Things (IIoT). Deployments
involve embedding sensors in manufacturing machines to collect data on their
operational status and performance. In the past, that information typically was kept
in local databases on individual devices and used only to assess the cause of
equipment failures after they occurred. Now, by analyzing the data streaming off
an entire factory's worth of machines, or even across multiple facilities,
manufacturing engineers and data analysts can look for signs that particular parts
may fail, enabling preventive maintenance to avoid unplanned downtime on
devices.

Manufacturers can also analyze trends in the data to try to spot steps in their
processes where production slows down or is inefficient in their use of materials.
In addition, data scientists and other analysts can use the data to run simulations
of different processes in an effort to identify the most efficient ways of doing things.
As smart manufacturing becomes more common and more machines become
networked through the Internet of Things, they will be better able to communicate
with each other, potentially supporting greater levels of automation.

For example, SM systems might be able to automatically order more raw materials
as the supplies, allocate other equipment to production jobs as needed to
complete orders and prepare distribution networks once orders are completed.

31
A lack of standards and interoperability are the biggest challenges holding back
greater adoption of smart manufacturing. Technical standards for sensor data
have yet to be broadly adopted, which inhibits different kinds of machines from
sharing data and communicating with each other effectively.

In the United States, the National Institute of Standards and Technology (NIST) is
investigating opportunities to develop and promote standards with various industry
stakeholders, including technology companies and manufacturers. The process is
ongoing. Other challenges include the cost of implementing sensors broadly and
the complexity of developing predictive models.

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3.2.6 SMART MANUFACTURING TECHNOLOGIES:

Critical considerations such as cybersecurity and strategic business integration are

all part of the digital transformation landscape. But below, we will just look at the

most foundational technologies that underpin smart manufacturing practices.

IoT/IIoT: When devices and machines are equipped to send and receive digital

data, they comprise an IoT network. Data sent from the device reports on its status

and activity, and data sent to the device controls and automates its actions and

workflows. An Industrial IoT (IIoT) network is at the core of smart manufacturing as

it not only comprises the connected assets, but the smart systems and automated

processes with which they are integrated.

AI/Machine Learning: The most comprehensive data in the world is meaningless

until you can leverage it and use it to tell a story. AI brings manufacturing data to

life with advanced analytics and the inherent ability to manage and amalgamate

broad and disparate data sets. Manufacturers armed with all that data can then use

machine learning algorithms to get their systems to tell them what they need to

know – about what’s going on right now, and what is predicted to happen in the

future.

Big Data: If AI and machine learning put the “smart” in smart manufacturing, then

Big Data is the fuel. Big Data is not so-called simply because it’s voluminous. It’s

defined by its variety and complexity. By feeding an AI system with enormous sets

of complex and disparate manufacturing data, you give it the scope it needs to draw

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increasingly accurate conclusions and learn more quickly over time.

Autonomous robots: As already discussed, robotics is nothing new in

manufacturing. It is not the ability to externally automate assets that is the game-

changer – it’s the ability for those cloud-connected assets to use smart

technologies to automate themselves. Smart factories depend upon autonomous

automation for the agility and speed that they need.

Additive manufacturing/hybrid manufacturing: Better known as 3D printing,

additive manufacturing boosts resilience and agility. For example, a Boeing 747 jet

is made up of over six million parts – all which require replacement on different

schedules. Instead of trying to warehouse all those parts, smart metal or plastic 3D

printers can access the maintenance logs and produce the parts as needed,

allowing the company to hold a “virtual inventory”.

Cloud computing: Cloud connectivity and computing give manufacturers on-

demand availability of system resources such as IIoT data, analytics, and process

automations, all across wireless channels like Wi-Fi or 5G. Large clouds may be

centrally managed yet distributed over regional or global locations.

5G connectivity: With 5G, businesses take the advantages and benefits of

internet cloud connectivity and ramp them up with less latency, much faster speeds,

and almost limitless capacity to scale.

Edge computing: Today’s smart factories are all about pivoting fast and

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responding quickly in real time. It takes time to send data gathered in one place, to

systems housed in another physical location – and for smart factories, that

downtime represents loss. Edge computing helps to bring the brains (AI and data

analytics) to the shop floor and eliminate lags in the IoT network.

Simulation/digital twin: A digital twin or simulation is created to be an identical

virtual copy of a machine or process that exists in the real world. It allows

manufacturing teams to test new ways of doing things, and to push virtual

prototypes to their absolute limits, without the cost and risk of damaging anything

in real life.

Design for manufacturing: This is not so much a technology itself as it is a cross-

functional practice that exists because of technology. Design for manufacturing

principles allow R&D professionals to learn from data – from across the factory floor

and customer base. These insights then help them design win/win products that

meet customer demands for quality and personalization, and create designs are

also easier, leaner, and faster to manufacture and customize.

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 CHAPTER -4

4.1 ADVANCED AUTOMATION IN MATERIAL REMOVAL PROCESSES

Advanced automation in material removal processes, such as machining, grinding,

and additive manufacturing, involves using sophisticated technologies to optimize
the material removal rate (MRR). Here are some key aspects and technologies
related to this:

CNC Machining and Automation

• Computer Numerical Control (CNC): Modern CNC machines are
equipped with advanced software that allows for precise control of cutting
tools and machining parameters, optimizing MRR while maintaining quality.

• Adaptive Control Systems: These systems adjust machining parameters

in real-time based on sensor feedback to optimize MRR and tool life.

• Robotic Integration: Robots can automate the loading and unloading of

workpieces, tool changes, and even some aspects of the machining process
itself.

Additive Manufacturing
• Selective Laser Sintering (SLS) and Direct Metal Laser Sintering
(DMLS): These additive processes can be optimized for efficient material
usage and high build rates through advanced software algorithms.

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 • Automated Post-Processing: Includes automated support removal and
surface finishing to streamline the entire manufacturing process.

Advanced Sensors and IoT Integration

• Force and Vibration Sensors: Monitor the cutting process in real-time to
detect issues such as tool wear or excessive force, enabling adjustments to
maintain optimal MRR.

• Internet of Things (IoT): Connects machinery to a network, allowing for

remote monitoring and optimization of machining processes.

Artificial Intelligence and Machine Learning

• Predictive Maintenance: Uses AI to predict when tools need to be
replaced, preventing downtime and maintaining consistent MRR.

• Process Optimization: Machine learning algorithms analyze historical data

to find optimal machining parameters for different materials and cutting
conditions.

Advanced Tooling

• High-Speed Machining (HSM): Utilizes tools and machines capable of

very high spindle speeds, reducing cutting time and increasing MRR.

• Cryogenic Machining: Uses super-cooled cutting environments to

increase tool life and cutting speeds.

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Automated Quality Control

• In-line Inspection: Automated measurement systems, such as coordinate

measuring machines (CMMs), integrated into production lines for real-time

quality control.

• Non-Destructive Testing (NDT): Automated systems for real-time defect

detection without damaging the workpiece.

Digital Twins and Simulation

• Digital Twins: Virtual replicas of the physical machining process that can

be used to simulate and optimize the process before actual production,

ensuring optimal MRR.

• Finite Element Analysis (FEA): Simulation tools used to predict the

effects of machining parameters on material removal and part quality.

Automation in Grinding and Finishing

• Automated Grinding Machines: Equipped with sensors and controls to

optimize the grinding process for higher MRR while ensuring surface

quality.

• Robotic Finishing Systems: Robots equipped with abrasive tools for

consistent and high-quality finishing operations.

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 CHAPTER -5

5.1 APPLICATION OF ADVANCE AUTOMATION IN VARIOUS ORGANIZATION

The application of automation across various industries. The rapid adoption of

automation, with a growth rate of 15% in the last two years, reflects how technology

is transforming businesses and unlocking new possibilities. As automation

becomes increasingly pervasive, it is reshaping the very fabric of India’s economy,

driving innovation, and redefining the roles of human workers and machines.

I. Automation in the Hospitality Industry: The hospitality industry has

enthusiastically embraced automation to create unparalleled guest

experiences while optimizing operational efficiency. With the goal of

enhancing customer satisfaction and personalization, automation has found

its way into various aspects of the hospitality sector:

II. Online Reservations and Check-ins: Automation has revolutionized the

reservation process, providing customers with the convenience of booking

hotel rooms, flights, and other services online. Additionally, automated

check-in kiosks at hotels have expedited the check-in process, eliminated

long queues and streamlined the arrival experience for guests. The

seamless integration of technology into these processes leaves guests with

39
 a positive first impression, setting the tone for an enjoyable stay.

III. Personalized Guest Experiences: Automation’s data analysis capabilities

have ushered in a new era of personalized services in the hospitality

industry. By analyzing guest preferences and behaviors, hotels can offer

tailored recommendations and experiences, making guests feel valued and

understood. This personalization fosters a sense of loyalty among guests,

leading to repeat visits and positive word-of-mouth marketing.

IV. Room Service Robots: The advent of room service robots in select hotels

has not only captured the imagination of guests but also optimized service

efficiency. These automated assistants navigate hotel corridors and deliver

orders to guest rooms promptly, minimizing wait times and allowing human

staff to focus on other essential tasks. The novelty and practicality of room

service robots enhance the overall guest experience, distinguishing hotels

as pioneers in hospitality automation.

V. Inventory Management: Effective inventory management is crucial in the

hospitality industry to ensure that hotels maintain adequate supplies of

essentials while minimizing wastage and controlling costs. Automation

streamlines inventory management processes, enabling real-time tracking

of stocks and automatic reordering when necessary. This not only reduces

the risk of stockouts but also promotes sustainable practices by minimizing

unnecessary waste.

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 VI. Automation and the Manufacturing Sector: The manufacturing sector

has been at the forefront of automation adoption, and its transformative

effects are evident in the concept of “smart factories.” The integration of

automation into manufacturing processes has revolutionized production and

supply chain management.

VII. Robotic Assembly Lines: The introduction of automated assembly lines,

equipped with robotic arms, has ushered in a new era of efficiency and

precision in manufacturing. These robotic systems can handle complex

tasks that were once challenging or time-consuming for human workers,

significantly increasing production speed and output. By automating

assembly processes, manufacturers can maintain consistent quality

standards and meet the growing demands of consumers.

VIII. Quality Control: Automation has emerged as a game-changer in quality

control for manufacturers. Equipped with cameras and sensors, automated

systems inspect products for defects, ensuring that only flawless items

reach consumers. This enhanced quality control not only reduces customer

complaints and product recalls but also instils trust and confidence in the

brand.

IX. Supply Chain Management: Automation has transformed supply chain

management, optimizing logistics and reducing lead times. Real-time

tracking of materials and products enables manufacturers to identify

potential bottlenecks and make informed decisions for timely delivery. The

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 efficiency gained from streamlined supply chain processes enhances the

overall productivity of manufacturing operations.

X. Predictive Maintenance: One of the most significant advantages of

automation in manufacturing is predictive maintenance. Utilizing sensors

and data analytics, machines can predict when maintenance is needed,

enabling proactive measures to prevent breakdowns and costly reactive

repairs. Predictive maintenance minimizes downtime and extends the

lifespan of machinery, resulting in significant cost savings for

manufacturers.

XI. Electronic Health Records: The automation-enabled digitization of patient

records has transformed the way healthcare providers access and manage

information. Electronic health records (EHRs) have replaced traditional

paper-based systems, making patient data easily accessible, secure, and

shareable among authorized medical professionals. This seamless flow of

information streamlines diagnosis and treatment, ultimately benefiting

patient outcomes.

XII. Robotic Surgery: Automation has ushered in a new era of precision and

safety in surgical procedures through robotic assistance. Robotic surgical

systems allow for minimally invasive surgeries, enabling more precise

incisions and reducing recovery times for patients. Surgeons can

manipulate robotic arms with greater dexterity and accuracy, leading to

improved surgical outcomes and patient satisfaction.

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43
A hole with 40mm diameter and 50mm depth is to be drilled in mild steel
component. The cutting speed can be taken as 65m/min and the feed rate as
0.25 mm/rev. Calculate the machining time and material removal rate.
Assume a=59°
Given data:
d = 40 mm; L = 50 mm; v = 65 m/min; f= 0.25 mm/rev
𝜋.𝑑.𝑁 𝑣.103
𝑣= 𝑁= = 517.25 rev/min
103 𝜋.𝑑

Assume a= 3 a,b are approach and over travel distances

b= a
𝑑
c= = 12.02 mm c= distance travelled by the lip
2 𝐭𝐚𝐧 𝛼

𝐿+𝑎+𝑏+𝑐
T= =0.53 minutes
𝑓.𝑁
𝝅
MRR= . 𝑑 2 . 𝑓. 𝑁 = 162500 𝑚𝑚3 /𝑚𝑖𝑛
𝟒

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5.2 BENEFITS OF ADVANCED AUTOMATION:

Lowered operating costs: Robots can perform the work of three to five people,
depending on the task. And bar feeders and APLs allow your machinists to attend
to multiple machines at once. In addition to savings on the cost of labor, energy
savings can also be significant due to lower heating requirements in automated
operations. Automation integration streamlines processes and increases part
accuracy, which means minimal material waste for your operation

Improved worker safety: Automated cells, bar feeders and APLs remove workers
from dangerous tasks. Your employees will thank you for safeguarding them
against the hazards of a factory environment.

Consistent and improved part production and quality: Automated cells, bar
feeders and APLs typically perform the manufacturing process with better
consistency than human machinists. This results in greater control and consistency
of product quality.

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5.3 CHALLENGES AND CONSIDERATIONS:

Job displacement and unemployment: Implementing automation to perform

tasks and processes results in the potential loss of jobs for human beings. When
industries and offices start using machines and robots to enhance their
productivity, the unemployment rate will increase, particularly for low-skilled or
repetitive roles. This can lead to economic and social challenges, including
income inequality and unemployment rates.

Initial implementation costs: While automation can lead to long-term cost

savings, the initial investment required to implement automated systems can be
significant. It involves expenses such as purchasing equipment, software,
training employees, and restructuring processes. Due to these upfront costs,
small businesses or industries with limited resources may find it challenging to
adopt automation.

Technical challenges and limitations: Automation relies heavily on technology

and complex systems. Technical issues such as software glitches, hardware
failures, or cybersecurity vulnerabilities can disrupt operations and cause
downtime. Moreover, certain tasks may be challenging to automate due to their
complexity or the need for human judgment and creativity.

Reduced human interaction and customer experience: Automation can result

in reduced human interaction, which may negatively impact customer experience
in certain industries. Customers may prefer personalized services or assistance
from human representatives, and automated systems may not always be able to
provide the same level of empathy, intuition, and problem-solving abilities.

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 CHAPTER -6

6.1 CONCLUSION:

The project aims to foster a nuanced understanding of advanced automation and

its potential impact on society. It will equip readers with the knowledge to make
informed decisions about adopting and regulating automation technologies, while
considering their broader implications. By showcasing real-world case studies
and discussing both positive and negative aspects, the project contributes to the
ongoing discourse surrounding the responsible integration of advanced
automation into our lives. the era of advanced automation represents a paradigm
shift, where the fusion of human ingenuity and technological prowess creates a
synergy that propels us into a future marked by efficiency, sustainability, and
innovation. As we continue to explore and refine these technologies, the horizons
of what is achievable in automation expand, opening doors to possibilities limited
only by our imagination. The journey of advanced automation is not just a
technological evolution; it is a testament to our ability to shape a smarter, more
connected world. Through the integration of cutting-edge technologies such as
artificial intelligence, IoT, and machine learning, advanced automation systems
have transcended the limitations of conventional automation. These systems are
not mere tools; they are the architects of a new industrial revolution, where tasks
are executed with unparalleled precision, adaptability, and intelligence. In the
ever-evolving landscape of technology, advanced automation systems stand as
the epitome of innovation, transforming traditional industries and redefining the
way we perceive efficiency, precision, and interconnectivity. The journey through
the realm of advanced automation has unveiled a myriad of possibilities and
advancements that hold the promise of shaping a smarter, more efficient future.

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 CHAPTER -7

7.1 REFERENCES:
❖ “Industry 4.0: The Industrial Internet of Things” by Alasdair Gilchrist.

❖ "Automation, Production Systems and Computer Integrated Manufacturing” by

Mikell P Groover.

❖ "Automation Encyclopedia: A to Z in Advanced Manufacturing" by G Graham.

❖ Application of automation www.qodenext.com

❖ Benefits of Advanced Automation www.productivity.com

❖ Figure 3.1.2-1, Smart Factory Industry 4.0: The Industrial Internet of Things

Alasdair Gilchrist.

❖ Figure3.1.1- 1, 5C Architecture of CPPS

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