Low cost automation (LCA) is a technology that creates some degree of automation around the existing equipment, tools, methods, people, etc. by using standard components available in the market with low investment, so that the payback period is short.
The benefits of low cost automation are numerous. It not only simplifies the process, but also reduces the manual content without changing the basic set up. Major advantages of low cost automation are low investment, increased labor productivity, smaller batch size, better utilization of the material, and process consistency leading to less rejections.
A wide range of activities such as loading, feeding, clamping, machining, welding, forming, gauging, assembly, and packing can be subjected to low cost automation systems adoption. Besides, low cost automation can be very useful for process industries manufacturing chemicals, oils, or pharmaceuticals. Many operations in food processing industries, which need to be carried out under totally hygienic conditions, can also be rendered easy through low cost automation systems.
A wide variety of systems (mechanical, hydraulic, pneumatic, electrical, and electronics) are available for deployment in LCA systems. However, each has its own advantages as well as limitations. For uncomplicated situations, one can build a simple LCA device using any of the above systems, through a rapid techno-economic evaluation. However, in most of the practical applications, hybrid systems are used because that can allow use of the advantages of different devices, while simultaneously minimizing individual disadvantages.
Issues in Low Cost Automation
1. Assessment of the Current Productivity Level: There are some simple procedures for this. Work sampling (activity sampling) is one of them. It needs no equipment and little time to collect the data. If the data is processed, considerable information will come out about the current productivity level.
2. PMTS: Predetermined Motion and Time Studies is a very useful tool to check whether an existing manual operation is correctly pasted. If the time taken is more than desirable, PMTS will help in identifying it and improving it.
3. Design for Automation and Assembly: When components are made and assembled manually one may not have thought about the complexity of automation. For example, putting together half a dozen nuts and bolts is very easy in a manual assembly but very complex for an automatic system.