About JTS Automation Pvt. Ltd.
- Promoters of Jagruti Technical Services Pvt. Ltd. have 20+ year’s experience in various industries.
- We have enough backup of Knowledge & Experience in Design Engineering & Commissioning of Automation systems. We assure you our best services at any given point of time.
- Our strategy is to provide competitively priced equipment’s / system’s manufactured to the highest standards that meets our customer’s requirement’s, whether the requirement's are for small work or turnkey project
Why We Need Automation
- Optimization of manual errors to minimize production issues like as rework, rejection & un-standardization.
- Optimization of manpower to Gain SMART Process technology.
- Lower operating Costs will Increase profitability of organization.
- Upgradation to newer technologies further reducing the machine downtimes.
- Work in harsh environment or accidental areas to avoid Health issues.
Benefits Of Automation
- Improve worker safety to avoid Employee’s Safety issues.
- Reduce factory lead times to Full utilization of available time resources.
- Increase productivity To achieve production target before time.
- Machine efficiency To Reduce Breakdown and maintenance time.
- Improve Product Quality to maintained standardization.
- Ability to More Competitive.
- Orientation principle: study the system relationships thoroughly prior to preliminary planning in order to identify existing methods & problems, physical & economic constraints, & to establish future requirements & goals.
- Planning principle: establish a plan to include basic requirements, desirable options, and consideration of contingencies for all MH and storage activities.
- System principle: integrate the handling and storage activities that are economically viable into a coordinated system of operation including receiving, inspection, storage, production, assembly, packaging, warehousing, shipping, and transportation.
- Unit load principle: handle product in as large a unit load as practical.
- Space utilization principle
- Standardization principle
- Ergonomic principle: recognize human capabilities and limitations
- Energy principle
- Ecology principle: minimize adverse effects on the environment when selecting MH equipment ad procedures.
- Mechanization principle: mechanize the handling process where feasible to increase efficiency and economy in handling of materials.
- Flexibility principle: use methods and equipment that can perform a variety of tasks under a variety of operating conditions.
- Simplification principle: simplify handling by eliminating, reducing, or combining unnecessary movements and / or equipment. 13. Gravity principle
- Safety principle
- Computerization principle: improved material and information control.
- System flow principle: integrate data flow with the physical material flow in handling and storage.
- Layout principle
- Cost principle
- Maintenance principle
- Obsolescence principle
Robotics industrial automation is changing the face of production. Manufacturers around the globe are implementing some form of automation to become more efficient, safe and ultimately to increase revenues. While some advantages are obvious, there may be more than you think. Add them all together and you can see why so many industries are investing in industrial robots.
Advantages of Industrial Automation
- Quality Control - no one likes purchasing an item, only to be disappointed by the poor quality. Robots are a great solution for higher quality production. Quality builds trust from customers as well as pride knowing that you are contributing something of value.
- Repeatability - Being consistent and knowing that you will get the same quality end product is critical to efficiency. A robot is able to perform the exact same task, exactly the same way, over and over again. Less errors means less wasted time.
- Waste Reduction - Consistent repeatability allows manufacturers to reduce overall waste. Less errors not only saves time, but it also reduces the amount of material required to produce the product. A couple of examples: robots can use less wire for welding, less amount of paint, and cut closer to the edge.
- Faster Cycle Times - Unfortunately humans have their limitations. Robots have been known to greatly improve production cycle speeds. The more you can produce, the higher demand you can meet and ultimately bringing in more money.
- Improved Workplace Safety - There are so many dangerous work environments that can have horrible side effects on a human body. Separating workers from lifting too much weight, exposure to fumes and gases, close interaction with lasers or blades, can tremendously decrease the possibility of injury.
- Reduction of Labor Costs - Labor can be expensive, especially when you factor in medical benefits, paid time off, injury comp time, etc... Robots can replace certain jobs, but that doesn't mean they are going to take over the world. It just means we need to adjust our focus. Understanding that robots are there for our own safety and efficiency allows us to remove workers from tough tedious jobs, to more fulfilling roles.
- Reduced Floor Space - It's easy to start sprawling out across the shop floor with extra materials, tools, and machinery. Robots can help reduce the footprint of the required workspace by optimizing everything into a smaller, confined space.
- Integration with Business Systems - Now a days, communication between multiple data platforms is rapidly growing, improving efficiency. You can see when there's a bottleneck a lot quicker with proper technology installed. Robots and machinery are talking with one another to give business leaders a better view on the overall picture, helping them make smarter decisions on how to improve their process.
What is POKA YOKE ?
The term POKA YOKE comes from Japanese word POKA ( Mistake) and YOKE (Prevent). POKA – YOKE Refers to technique that make it impossible to make mistake . These technique can drive defect out of products and processes and substantially improve quality and reliability. POKA – YOKE ensures that proper conditions exist before actually executing process step, preventing defects from occurring in the first place.
- Omitted Processing.
- Processing Errors.
- Errors in setting up work Pieces.
- Missing Parts.
- Wrong Parts.
- Processing Wrong work Piece.
- Adjustment error.
- Wrong Operation.
- Equipment not set up properly.
- Tools and jigs improperly Prepared.
- Elimination of setup errors & improved Quality.
- Increased safety.
- Low Cost.
- Lower skill Requirement to understand work.
- Zero defects.
- Optimizing waste of Material.
- Electrical, Electronics & Instrumentation Mass Control Wiring of PLC, SCADA, HMI, ALARM System & any Other Electronic Peripheral.
- Installation & Wiring of Precision Instruments like Flow Meter, Pneumatics Valve, Level Sensor, Limit Switch, Pressure Transmitters, etc.
- Studying the Wiring Diagrams / Cable Schedules.
- Laying & Termination of Control / Signal Wires as per Diagrams.
- Instrumentation, Wiring & Terminations - Pre-checks & Commissioning Support.
JTS- Automation Systems, we understand that process automation streamlines your business, improves workflow, and increases efficiency. Our experience and knowledge in both mechanical design and controls / software engineering ensures that we deliver the right automation solutions when we work with you.
JTS-Automation has developed and implemented several solutions to assist customers in reducing manufacturing costs. Flexible automation solutions integrate multiple technologies into an entire processing line, resulting in improved efficiencies and increased throughput.
Factory owners want their equipment to deliver the highest output with as little production cost as possible. In many industries including oil, gas and petrochemicals, energy costs can represent 30 to 50 percent of the total production cost. In process automation, the computer program uses measurements to show not only how the plant is working but to simulate different operating modes and find the optimal strategy for the plant. A unique characteristic of this software is its ability to "learn" and predict trends, helping speed up the response time to changing conditions. The software and controls regulate equipment to run at the optimum speed that requires the least energy. They also ensure the consistency of quality, meaning less energy is wasted producing products that turn out to be defective, and they forecast when maintenance is needed so less time and energy is spent stopping and restarting equipment for routine inspections.
When it comes to the process automation and advanced system design, PLCs, SCADA, and HMIs play crucial roles. A PLC is a hardware-based device, SCADA is a system that works in conjunction with the PLC. But, an HMI is also a system that works in conjunction with a PLC. Since the SCADA system and an HMI can complete more or less the same functions, it’s crucial that you know the difference between these two. In this article, we’ll talk about each of them and explain their functions. Furthermore, we’ll discuss how they work together in a seamless system that controls different functions. We suggest that you grab a cup of coffee– it’s going to be a long read!
SCADA didn’t get its name by luck, it is actually an abbreviation that stands for Supervisory Control and Data Acquisition. As we said earlier, it’s a system that has both software and hardware elements and is usually used for a couple of things:
- Control of various processes from a remote location or locally
- Interaction with sensors, pumps, motors, and valves through an HMI (Human-Machine Interface) software
- Monitoring, acquiring, and processing real-time data
- Recording the events into a file.
In the modern time, there isn’t a serious organization that doesn’t take advantage of SCADA systems. These systems help save some time, they increase efficiency, they process data faster and with accuracy, and they allow for smooth communication between various parts of the system. As such, the SCADA architecture consists of two basic parts – an RTU (Remote Terminal Unit) and a PLC (Programmable Logic Controller). A PLC is essentially a microcomputer that directly communicates with a plethora of objects such as end devices, sensors, or numerous factory machines.
A PLC, however, is directly hooked to the factory machine, while the RTU is used remotely, as its name implies. The sheer power of SCADA software allows us to process, distribute, and display the required data, thus making it easier for employees to analyze it and come up with solutions if needed. It works exactly as it sounds. If there’s an error somewhere in the process, it notifies the operator who can then pause the production process and check the data from the SCADA system. This data can be checked via an HMI, which we’ll talk about later.
Where is SCADA Used?
As we mentioned earlier, SCADA systems are mostly used in factories and industrial organizations in both private and public sectors. The reason they’re being used is to maintain efficiency and accelerate the data distribution. This further leads to the faster decision-making process and smarter use of time. Thanks to the versatile capabilities of SCADA systems, they can be used in both simple and complex installations. SCADA systems are used in energy, manufacturing, power, recycling, transportation, oil, and gas, as well as many other industries. Not every SCADA system is greatly optimized. However, with the expertise of experienced engineers, SCADA systems can help save both money and time.
When it comes to the hardware-based part of the SCADA or HMI system, we can’t dismiss a PLC, as a crucial component in the system. PLC stands for Programmable Logic Controller and it is an industrial computer that is used for industrial automation. PLCs can differentiate in sizes and capabilities, depending on the company’s need. This powerful industrial computer works by continuously monitoring the state of input devices and makes decisions about controlling the state of output devices.
The great thing about PLCs is that they can control huge chunks of a production line, as well as the whole production line itself. Any kind of production line can be vigorously enhanced by using this technology, but the biggest advantage of PLCs lies in repetitiveness. This computer is able to replicate the operation or process over and over again, all while collecting vital information. Because of its minuscule size, PLCs are modular and highly portable. This means that the PLC can be brought to the production line, hooked up to a computer, programmed, and put into work the exact same moment.
How do PLCs Work?
So, how do they work? Well, it is actually a very simple matter. So simple that you’ll be surprised how it manages to keep everything under control. The first step in the process is called an Input Scan. As its name implies, the PLC detects the state of all input devices hooked up to the PLC. After that, the second step is the Program Scan, which scans the program that the user created and then executes it. The next step is the Output Scan. As its name implies, it scans the output devices connected to the PLC and either energize or de-energize them. Finally, the last step is Housekeeping. This step is more like a safety step in which the PLC communicates with internal diagnostics, programming terminals, etc. If the last step is done correctly and everything is under control, the PLC starts from the beginning until the loop is finished.
How are PLCs Programmed?
Even when they first came out, PLCs took advantage of Logic. Today, almost all PLC programming software offers an option to program in Ladder Logic. Ladder Logic is a traditional programming language that is used to mimic circuit diagrams that go from left to right. On the left side, the program consists of input contacts which can be closed or opened. An opened contact will conduct the current when pressed, while the closed one will stop the flow of the current when the signal initiates it.
On the right side, we have contacts of the output devices, which can be actuators, solenoids or valves. Usually, it’s a solenoid. When a signal reaches the input contact, it’s initiated and the condition (output) is fulfilled. The newest innovation is called “C” programming, but many programmers still use Ladder diagrams just because it’s easier to use and it’s been used for quite some time. Some manufacturers might also supply programming software; manufacturers like Mitsubishi and Omron do this.
The reason we left HMIs for the end is that they are used to communicate with Programmable Logic Controllers and as such, the whole system is completed. Whereas SCADA represents a remote system used to communicate and collect data, HMI is a local machine capable of doing the same thing. But, the only difference is, as we said, that HMIs are local machines. The Human-Machine Interface is the user interface that connects the operator to a system, device or machine.
An HMI isn’t a particular piece of hardware but rather a screen that allows a user to interact with a device. HMIs can also be called Operator Terminals, Local Operator Interface, Graphical User Interface, etc. If some of these names (OT, LOI, and GUI) sound familiar to you, it’s because you’ve already used some of them. Simply put, HMIs are used for visualization of particular data, for easier understanding and control. The prime modern example of an HMI is a tablet. A tablet is a GUI that allows you to control various processes. If you’re connected to your TV via Bluetooth, you can use your HMI (tablet or a smartphone) to control it. HMIs come in a variety of shapes and sizes – computer monitors and machines with built-in screens.
How Is It Different from SCADA?
As we mentioned earlier, SCADA and HMIs are almost the same, yet still different. Both SCADA and HMIs play a huge part in an industrial system that encapsulates them, alongside PLCs. However, they function in a different way. An HMI uses some amount of data and visually represent it, allowing for greater understanding and more efficient supervising process. On the other hand, SCADA systems are focused on control-system operations and they have a huge capacity for data collection. The main advantage of SCADA systems over HMI is that they collect and record information.