Role of Automation in Manufacturing for Competitive Advantage, With Special Reference to Automotive Industry

Abstract

The present study attempts to analyze the response of manufacturers in designing production processes to handle customer demand for product variety, or models, especially in the automotive sector. In this context, the role of technology, especially the information technology (IT) and application of automation in manufacturing process controls with the integration of industrial software has been analyzed for bringing about improvements in energy efficiency, productivity, product quality, reduction in costs and wastage, reduction in human error, and boosting other performance indicators like faster response in processing of customer orders for delivery. The process control automation helps in analyzing and controlling the production operations to see whether the plant is operating as per set objectives. The human machine interface (HMI) embedded in the software helps in remote operation of equipment and thus is important for maintaining productivity and equipment uptime. Further, it helps in removal of bottlenecks in the system, automates batch- oriented manufacturing, and works on optimizing production and implementing quality assurance practices. Automation in process control helps in reduction of maintenance costs, improves equipment performance and reduces downtime. Since Robots have an important role in repetitive tasks where precision and timing are important for jobs execution, applications in automotive manufacturing like robotic vision, spot and arc welding, assembly line operations, painting and coating, machine tending and parts transfer, use of cobots, and material removals, cutting and trimming jobs have been highlighted and discussed. Also included is a case study on Hyundai Motor Corporation, where Hyundai’s production model is discussed. Under this system, production relies less on factory workers (human labour), and instead relies more on automation in manufacturing, besides making use of procured modular assemblies/subassemblies/components as contracted and received from its suppliers. Apart from mass production of certain models like SUVs, the company is planning to switch-over to multiple batch production system in a single production line. Further, Hyundai is implementing “Smart factory” concept by making use of digital data and ICT (information and communication technology) platform. Technologies for production processes include Smart tag system, and Automated Inspection protocol for advanced driver assistance systems (ADAS) besides implementing Virtual reality (VR) assisted design evaluation platform to review and to make changes to car design and structure before it enters production. With the help of automation software, automotive manufacturers are also implementing the concept of Just-in-sequence (JIS) production, which is different from Just-in-time (JIT) philosophy. Under this system, various parts needed for car assembly are delivered at the scheduled time and in the exact order that are required for assembly. The main advantage of JIS system is that it facilitates to carry out mixed-models manufacturing. A single assembly line can produce multiple product models