The Art of Manufacturing

The Art of Manufacturing

by Ninad Deshpande, Sivaram Pothukuchi
Released February 2023
Publisher(s): Packt Publishing
ISBN: 9781804619452

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Book description

Demystify automation and solve control-related problems with the help of real-world products and case studies put together by two industrial automation experts

Key Features

  • Real life applications and case studies of automation curated from authors rich experience
  • Overcome tricky automation and control issues in the manufacturing process
  • Implement automation in manufacturing for higher efficiency and productivity in the industry

Book Description

Engineering disciplines focus mainly on programming control systems, while the challenges they overcome or their industry applications largely go uncovered, leaving a huge gap between the theory and industry practices. This leads to engineers learning about subjects without actually understanding their purpose and entering the industry needing months of training.

The Art of Manufacturing cuts across pedantic theory and reaches practical applications. You'll begin your learning journey by starting from the product and moving backward to the manufacturing landscape, factories, machines, and finally to the automation and control challenges faced in manufacturing. The book builds on the authors' valuable on-field experience, providing a detailed view of the manufacturing of real-world products, while simultaneously providing various analogies and references to daily tasks. As you advance through the chapters, you'll work on interesting control problems and find out how to overcome them in applications. The concluding chapters offer you a sneak peek into the future of automation and factories.

By the end of this book, you'll be able to relate a real-world product with an associated control challenge and discover ways to overcome these challenges.

What you will learn

  • Understand the role of machines, factories, and plants in manufacturing a product
  • Explore the manufacturing landscape and its continuous evolution
  • Use practical applications to mitigate control challenges in manufacturing
  • Resolve implementation challenges of various applications in a machine
  • Discover how humans and automation work together in factories
  • Find out how to solve the same control challenge in different ways
  • Discover links between Industry 3.0, Industry 4.0, digitalization, and lean manufacturing

Who this book is for

The book will interest an inquisitive student of engineering (electrical, electronics, mechatronics, E&TC) who wishes to explore beyond the classroom textbook content. It will also serve as a teacher's handbook helping the lecturer bring the flair of industry into the classroom. Moreover, it will be useful for a practicing engineer, with cross-disciplinary knowledge that is needed to manufacture any real product. You must have basic knowledge of electronics, electrical, and mechatronics (engineering).

Table of contents

  1. The Art of Manufacturing
  2. Foreword
  3. Contributors
  4. About the authors
  5. About the reviewer
  6. Preface
    1. Who this book is for
    2. What this book covers
    3. To get the most out of this book
    4. Download the color images
    5. Conventions used
    6. Get in touch
    7. Share your thoughts
    8. Download a free PDF copy of this book
  7. Part 1: Introduction to the Manufacturing Landscape and Innovative Automation in Everyday Life
  8. Chapter 1: Automation Is a Part of Our Daily Lives
    1. Understanding our daily rituals and the products we use
    2. Probing how consumer demands and needs are drivers
    3. Analyzing the elements of a factory – production lines and machines
      1. Continuous process versus discrete process
      2. Mass/batch production versus customized production
      3. Inside a factory
    4. Analyzing the elements of automation – components and structures
      1. Control, automation, and data technologies
      2. Automation components
    5. Summary
  9. Chapter 2: The Art of Temperature Control
    1. Highlighting the need for temperature control
      1. The challenge and need for temperature control
    2. The control challenge
    3. An overview of an application (plastic)
    4. Overview of another application (pharma)
    5. Overcoming the control challenge
    6. Summary
  10. Chapter 3: Tension Control – Managing Material Tension
    1. The need for tension control
    2. Control challenge
    3. An overview of an application
      1. An overview of textile applications
      2. An overview of newspaper printing
    4. Overcoming the control challenge (tension control)
      1. Ways to measure tension
      2. Varying the tension
    5. Summary
  11. Chapter 4: Level Control – Controlling the Level of Liquid to Avoid Drying Up or Spilling Over
    1. The need for level control
      1. Challenge and the need for level control
    2. Control challenge
    3. Overview of applications
      1. Overview of the automotive application
    4. Overcoming the control challenge of level control
      1. Overview of a boiler application
    5. Summary
  12. Chapter 5: Motion Control – Control, Synchronization, and Interpolation of Axes for Accuracy and Precision
    1. The need for motion control
    2. Control challenges (motion control)
    3. Overview of an application
    4. Overcoming the control challenge (motion control)
    5. Summary
  13. Chapter 6: Material Dispensing Control
    1. The need for quantity control
    2. Control challenge (quantity control – weight or volume)
    3. Overview of an application
    4. Overcoming the control challenge (quantity control – weight or volume)
    5. Summary
  14. Part 2: Automation and Humans
  15. Chapter 7: The Interplay of Humans-Machines-Automation
    1. Humans and machines
    2. The need for interaction with machines
      1. Interaction while in operation
      2. Interaction while the machine is constructed
      3. Interaction at the design and testing stages
      4. Interaction at the supply chain and procurement stages
    3. Programming platforms and programming languages
      1. IEC 61131-3 languages
      2. Various formats of the application software
    4. Data from the process – values, alarms, and events
      1. Elementary operator interface – switches, dials, and meters
    5. Supervisory control
      1. Plantwide information
      2. Digital dashboards
      3. SCADA systems
      4. DCSs
      5. Advanced functions
    6. Mobile first – control from anywhere
    7. Summary
  16. Chapter 8: Automation – Dramatically Helping Avoid Human Intervention
    1. The need to reduce human intervention
    2. The control challenge in designing machines without supervision
    3. Application examples
      1. Continuous processes
      2. No-second-chance missions
      3. A high cost of error
    4. How the control challenge is solved
      1. Stored program controllers
      2. Maintenance techniques
      3. Systems with redundancy
      4. Fail-safe configurations
      5. Graceful degradation
      6. Lights-out factory
      7. Almost-human machines
    5. Summary
  17. Chapter 9: Automation Can Build a Super-Organism with Awareness
    1. A blueprint of automation with awareness
      1. Automation as a super-organism
      2. Automation and awareness
    2. Technological advances to help realize the blueprint
      1. Controller chips are getting smaller and faster
      2. Internet of things – controllers can talk to each other
      3. Pervasive computing
      4. Cloud and infinite processing power
      5. Augmented reality
      6. Data analytics
      7. Pattern recognition
      8. Classification
      9. Machine learning
      10. Robotics
    3. Applications where such automation can be deployed
      1. Quality control
      2. Supply and logistics coordination
      3. Safety
      4. Smart factory
      5. Autonomous vehicles
      6. Challenges ahead
    4. Summary
  18. Chapter 10: What’s Next?
    1. The question
    2. Need for the question
      1. Can we simply extrapolate?
      2. Is it too much of a good thing?
      3. When do we call a stop to it?
    3. What are the challenges?
      1. Improving functional capability
      2. Improving interaction
      3. Which functionalities are to be avoided?
      4. Improving security
    4. How could automation address the challenges?
      1. Quantum computing
      2. Low power consumption
      3. Context awareness
      4. Unobtrusive functioning
      5. More modes of command input: vocal, visual, mental
      6. Updates on the fly
      7. Security
    5. Solving human problems
    6. Summary
  19. Index
    1. Why subscribe?
  20. Other Books You May Enjoy
    1. Packt is searching for authors like you
    2. Share your thoughts
    3. Download a free PDF copy of this book

Product information

  • Title: The Art of Manufacturing
  • Author(s): Ninad Deshpande, Sivaram Pothukuchi
  • Release date: February 2023
  • Publisher(s): Packt Publishing
  • ISBN: 9781804619452