The art of manufacturing : overcome control challenges for increasing efficiency in manufacturing using real-world examples / Ninad Deshpande and Sivaram Pothukuchi.

Cover
Title Page
Copyright
Foreword
Contributors
Table of Contents
Preface
Part 1: Introduction to the Manufacturing Landscape and Innovative Automation in Everyday Life
Chapter 1: Automation Is a Part of Our Daily Lives
Understanding our daily rituals and the products we use
Probing how consumer demands and needs are drivers
Analyzing the elements of a factory - production lines and machines
Continuous process versus discrete process
Mass/batch production versus customized production
Inside a factory
Analyzing the elements of automation - components and structures
Control, automation, and data technologies
Automation components
Summary
Chapter 2: The Art of Temperature Control
Highlighting the need for temperature control
The challenge and need for temperature control
The control challenge
An overview of an application (plastic)
Overview of another application (pharma)
Overcoming the control challenge
Summary
Chapter 3: Tension Control - Managing Material Tension
The need for tension control
Control challenge
An overview of an application
An overview of textile applications
An overview of newspaper printing
Overcoming the control challenge (tension control)
Ways to measure tension
Varying the tension
Summary
Chapter 4: Level Control - Controlling the Level of Liquid to Avoid Drying Up or Spilling Over
The need for level control
Challenge and the need for level control
Control challenge
Overview of applications
Overview of the automotive application
Overcoming the control challenge of level control
Overview of a boiler application
Summary
Chapter 5: Motion Control - Control, Synchronization, and Interpolation of Axes for Accuracy and Precision
The need for motion control.

Control challenges (motion control)
Overview of an application
Overcoming the control challenge (motion control)
Summary
Chapter 6: Material Dispensing Control
The need for quantity control
Control challenge (quantity control - weight or volume)
Overview of an application
Overcoming the control challenge (quantity control - weight or volume)
Summary
Part 2: Automation and Humans
Chapter 7: The Interplay of Humans-Machines-Automation
Humans and machines
The need for interaction with machines
Interaction while in operation
Interaction while the machine is constructed
Interaction at the design and testing stages
Interaction at the supply chain and procurement stages
Programming platforms and programming languages
IEC 61131-3 languages
Various formats of the application software
Data from the process - values, alarms, and events
Elementary operator interface - switches, dials, and meters
Supervisory control
Plantwide information
Digital dashboards
SCADA systems
DCSs
Advanced functions
Mobile first - control from anywhere
Summary
Chapter 8: Automation - Dramatically Helping Avoid Human Intervention
The need to reduce human intervention
The control challenge in designing machines without supervision
Application examples
Continuous processes
No-second-chance missions
A high cost of error
How the control challenge is solved
Stored program controllers
Maintenance techniques
Systems with redundancy
Fail-safe configurations
Graceful degradation
Lights-out factory
Almost-human machines
Summary
Chapter 9: Automation Can Build a Super-Organism with Awareness
A blueprint of automation with awareness
Automation as a super-organism
Automation and awareness
Technological advances to help realize the blueprint.

Controller chips are getting smaller and faster
Internet of things - controllers can talk to each other
Pervasive computing
Cloud and infinite processing power
Augmented reality
Data analytics
Pattern recognition
Classification
Machine learning
Robotics
Applications where such automation can be deployed
Quality control
Supply and logistics coordination
Safety
Smart factory
Autonomous vehicles
Challenges ahead
Summary
Chapter 10: What's Next?
The question
Need for the question
Can we simply extrapolate?
Is it too much of a good thing?
When do we call a stop to it?
What are the challenges?
Improving functional capability
Improving interaction
Which functionalities are to be avoided?
Improving security
How could automation address the challenges?
Quantum computing
Low power consumption
Context awareness
Unobtrusive functioning
More modes of command input: vocal, visual, mental
Updates on the fly
Security
Solving human problems
Summary
Index
About Packt
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