Automation and Mechanization:

Mechanization refers to the use of machinery rather than manual labor to perform tasks. It is a significant trend in manufacturing aimed at reducing human effort by adopting mechanical and electrical methods to automate various processes. This may involve automating material handling, component loading and unloading, job operations, or transportation. However, mechanization typically lacks feedback from the process or machinery.

Automation extends mechanization by introducing closed-loop systems where feedback from sensors controls operations automatically. It can be applied to some or all operations of a machine or group of machines, resulting in semi-automatic or fully automatic systems. The concept of automation emerged after World War II, particularly in industries like the Ford Motor Company, to describe the automatic handling of materials and parts between process operations.

Automation is the process of executing predetermined operations with minimal human intervention, using specialized equipment and devices to control the manufacturing process. While automatic machines existed before the term "automation" was coined, not all of them qualify as automation. It involves applying mechanical, electronic, and computer-based systems to operate and control production processes.

Every machine should incorporate some degree of automation, determined primarily by economic factors. Automation involves a system where many or all processes in production, movement, and inspection of parts are controlled by self-operating devices called controllers. Fundamental elements of automation include mechanization, sensing, feedback, and control devices.

The reasons why one should go for automation are:

1. Increased productivity.
2. Reduced cost of labor and dependence on labor shortages.
3. Improved quality.
4. Reduced in-process inventory.
5. Reduced manufacturing time.
6. Reduced dependence on operator skills.
7. Increased safety or reduced risk of humans.

Automation can be classified into three categories, viz.

1. Fixed automation.
2. Programmable automation.
3. Flexible automation.

1.Fixed Automation:

Also referred to as Hard Automation, fixed automation is employed to manufacture a standardized product such as gears, nuts, and bolts, among others. While the operating conditions may be adaptable, fixed automation is suited for large-scale production of one or a few slightly different components. Specialized tools, devices, equipment, and dedicated machine tools are utilized to efficiently produce a product or component at high production rates, aiming for minimal unit costs compared to other manufacturing methods.

2.Programmable Automation:

In programmable automation, one can change the design of the product or even change the product by changing the program. Such technique is highly useful for the low quantity production of large number of different components. The equipments used for the manufacturing are designed to be flexible or programmable. The production normally carried out in batches.

3.Flexible Automation:

A third category between fixed automation and programmable automation is termed as adaptable automation, utilizing Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) techniques. This approach is also known as a versatile manufacturing system (VMS), allowing for the production of diverse products on the same equipment in any sequence or combination. An important example of programmable automation in discrete manufacturing is computer numerical control (CNC). Robots are another instance of programmable automation. As an integral component of VMS and Computer-Integrated Manufacturing (CIM) systems, robots can perform numerous manufacturing tasks, replacing human labor.

In today's globalized manufacturing landscape, the integration of hardware and software concepts utilizing mechatronics for rapid mechanization and automation of manufacturing processes have  become essential to be incorporated in the manufacturing areas.

Computer Aided Manufacturing (CAM):

Computer aided manufacturing involves manufacturing processes that are assisted or controlled by computers. In a broader sense, it encompasses all activities within the manufacturing environment, such as the use of computers in inventory management, project planning, material requirements planning, data collection, testing, and quality assurance. The adoption of CAM leads to enhanced reliability due to improved manufacturing methods and controls during the production stage, resulting in highly reliable products and manufacturing systems. With integrated diagnostics and monitoring facilities in most CAM systems, maintenance requirements are reduced compared to traditional manufacturing methods. The utilization of Computer Numerical Control (CNC) machines and part programs generated from design stage geometries minimizes scrap levels and virtually eliminates the need for rework. With computer-based information and control functions, CAM enables better management control over manufacturing activities. These advantages translate into lower total costs and higher overall profitability. Hence, any manufacturing operation, whether in job shop production or mass production, can benefit from Computer Aided Manufacturing. However, optimal results are achieved when design and manufacturing activities are closely integrated. Additionally, CAM is well-suited for managing changes or adjustments in production programs, particularly in cases of product variety or minor modifications.

Following are the main advantages of using CAM.
1. Greater design freedom:
Any changes that are required in design can be incorporated at any design stage without worrying about any delays, since there would hardly be any in an integrated CAM environment.
2. Increased productivity:
In view of the fact that the total manufacturing activity is completely organized through the computer, it would be possible to increase the productivity of the plant.
3. Greater operating flexibility:
CAM enhances the flexibility in manufacturing methods and changing of product lines.
4. Shorter lead time:
Lead times in manufacturing would be greatly reduced.

The integration of CAD and CAM systems is called Computer Integrated Manufacturing (CIM) system. The role of computer in manufacturing may be in two major groups namely computer monitoring and control of the manufacturing process and manufacturing support applications, which deal essentially with the preparations for act of manufacturing and post manufacture operations. Computers are used in controlling machine tools and other material handling equipments.