Short Answer:

Levels of automation describe how much human involvement is required in a system or process. It refers to the degree to which machines, computers, or robots perform tasks instead of humans. The higher the level, the less human control is needed, and the more the system operates automatically.

Automation levels are divided into several stages — from manual operation, where humans control everything, to full automation, where machines make all decisions and perform all actions. Each level represents a balance between human effort and machine capability, depending on the process and production needs.

Detailed Explanation:

Levels of Automation

The levels of automation refer to the extent to which different functions in a manufacturing or industrial process are performed automatically, without human intervention. It shows how control and decision-making are shared between humans and machines. Automation does not always mean full independence of machines — instead, it may range from completely manual work to systems that are fully controlled by computers and artificial intelligence.

The goal of defining automation levels is to understand how technology can best support humans in manufacturing, improve productivity, and reduce human error while maintaining control and flexibility in the process.

1. Manual Level (No Automation)

At the manual level, all tasks are performed entirely by human workers. Machines and tools may be used, but they are fully controlled and guided by the operator. The human decides, operates, and monitors every action in the process.

Example: Operating a manual lathe, where the worker adjusts the cutting tool and controls the feed manually.

Characteristics:

• Full human involvement in control and decision-making.
• Low investment in machines.
• Suitable for small-scale or customized production.
• Requires skilled labor and constant attention.

Advantages:

• High flexibility for changes.
• Simple setup and maintenance.

Disadvantages:

• Slower production rate.
• Higher labor cost and human fatigue.

2. Mechanized Level

At this level, machines assist workers by performing some physical work, but humans still make decisions and control operations. Mechanization reduces manual effort and increases efficiency but does not include independent control systems.

Example: Using power presses, mechanical drills, or conveyor belts operated by humans.

Characteristics:

• Machines perform mechanical tasks, humans control the process.
• Reduces physical strain on workers.
• Improves speed and consistency compared to manual work.

Advantages:

• Higher production than manual systems.
• Better quality and reduced fatigue.

Disadvantages:

• Still requires human monitoring and control.
• Limited automation in decision-making.

3. Semi-Automatic Level

In this level, machines perform operations automatically after setup, but humans still handle tasks such as loading, unloading, and supervision. The operator may also start or stop the process as needed.

Example: A CNC machine where the operator inputs data, but the machine executes operations automatically.

Characteristics:

• Shared control between human and machine.
• Machines follow programmed instructions.
• Increases accuracy and reduces human error.

Advantages:

• High precision and consistency.
• Reduced need for manual operation.

Disadvantages:

• Requires skilled operators for programming and setup.
• Human involvement still needed for monitoring.

4. Automatic Level (Full Automation)

At this stage, machines perform all production operations automatically without continuous human control. The system can start, run, and stop based on pre-set instructions. Sensors and control devices help maintain accuracy and safety.

Example: Automated assembly lines in the automobile industry or robotic welding systems.

Characteristics:

• Machines perform all tasks autonomously.
• Human role limited to supervision or maintenance.
• High production rate and consistent quality.

Advantages:

• Fast production speed.
• High reliability and uniformity.
• Reduces human errors and labor cost.

Disadvantages:

• High initial investment.
• Less flexibility for design changes.

5. Intelligent or Computer-Integrated Level

This is the most advanced level of automation, where systems use artificial intelligence, sensors, and feedback controls to make decisions and adapt to changes. Machines can analyze data, correct errors, and optimize performance automatically.

Example: Computer Integrated Manufacturing (CIM), smart factories, and robotic systems with machine learning.

Characteristics:

• Systems make independent decisions using AI and data.
• Integrates manufacturing, quality control, and management.
• High coordination between machines, sensors, and control software.

Advantages:

• Very high efficiency and adaptability.
• Real-time monitoring and automatic error correction.
• Minimum human involvement.

Disadvantages:

• Extremely high cost and technical complexity.
• Needs skilled engineers for design and maintenance.

Summary of Levels of Automation:

1. Manual Level: All tasks by human.
2. Mechanized Level: Machines assist humans.
3. Semi-Automatic Level: Machines perform with some human control.
4. Automatic Level: Machines operate independently.
5. Intelligent Level: Machines think, decide, and self-correct.

Each level represents a step forward in technology and productivity. The choice of automation level depends on product type, production volume, cost, and required accuracy.

Conclusion:

Levels of automation show the gradual shift from human-controlled processes to fully automated and intelligent systems. Starting from manual work to computer-integrated automation, each level increases efficiency, precision, and speed while reducing human effort. In modern manufacturing, industries aim for higher automation levels to meet demands for large-scale production, high quality, and low cost. Thus, understanding automation levels is essential for designing efficient and modern production systems.