Apply and Reflect – Introduction to Automation & Project Skills

Week 4 Lesson 8
Introduction to Automation and Project Skills

Section 1: Overview

In modern manufacturing, automation is the “digital brain” that increases efficiency, improves precision, and reduces human error. Programmable Logic Controllers (PLCs) are the specialized computers that automate these industrial processes, making them an essential skill for anyone entering advanced manufacturing, clean energy, or the skilled trades. This lesson introduces the basics of automation control systems, focusing on how Inputs and Outputs (I/O) are managed through Sequential and Conditional logic.

The goal of this lesson is to move beyond theory and understand how automation systems are managed as professional projects. You will learn how to define Project Scope to prevent “Scope Creep” and how to use the Plan-Do-Check-Act (PDCA) cycle to maintain quality and solve technical problems systematically. By completing this lesson, you will be equipped to design simple automated sequences and document them in a way that meets industrial compliance and professional standards.

Section 2: Apply – Skill Demonstration

Goal:

Students will demonstrate the ability to program a controller to manage an industrial safety sequence. You will then apply project management principles to document your process, troubleshoot errors, and track your technical competencies.

1. Identify core components of an industrial control system (Inputs, PLC, Outputs).
2. Differentiate between Sequential (step-by-step) and Conditional (If/Then) programming logic.
3. Apply the PDCA Cycle to troubleshoot a technical fault in a controlled environment.
4. Define Project Scope to manage a task without uncontrolled expansion (Scope Creep).

Assignment:

Part A – The Technical Build (Choose Your Pathway) Select one (or both) of the following methods to build a “Safety Interlocked Motor” sequence:

1. (Recommended) Hardware Pathway: Use an Arduino Super Starter Kit to wire two physical buttons (Inputs) and one LED (Output) to a breadboard.
2. Simulation Pathway: Use Wokwi (Online) to virtually wire and code the same components.

Logic Requirements:

• Safety Interlock: The “Motor” (LED) cannot turn on unless the “Safety Guard” (Button 1) is closed.
• Process: When the “Start Button” (Button 2) is pressed, the LED turns ON.
• Emergency Stop: If the Safety Guard is opened while the motor is running, the LED must shut off immediately.

* Remember that a key aspect of this course is your ability to be an independent learner. Follow instructions and use outside resources to complete requirements.

Tip: This assignment is rudimentary but sets in motion your capacity to understand logic ladders. Explore other patterns to deepen your understanding of PLCs (Programmable Logic Controllers)

Your Submission for this section:

• Logic Map: Capture a screenshot of your code and/or a photograph of your wiring setup (physical or digital).
• The PDCA Log: Write a brief log (3–5 sentences) describing one error you encountered during the build and how you used Plan-Do-Check-Act to fix it.

Section 3: Evaluation Rubric

Criterion	Exceeds (4)	Meets (3)	Approaches (2)	Needs Support (1)
Logic Implementation	Correctly executes both Sequential and Conditional logic with a working safety interlock.	Logic works, but interlock is bypassed or slightly inconsistent.	Logic is purely sequential; lacks conditional safety checks.	Code/Simulation does not function.
PDCA Troubleshooting	Provides a detailed log showing clear Plan, Do, Check, and Act phases for a specific error.	Outlines a basic troubleshooting step.	Mentions a problem but does not follow the PDCA format.	No evidence of troubleshooting documentation.
Technical Literacy	Correctly identifies and labels all Inputs and Outputs (I/O) in the project.	Generally identifies I/O correctly with minor errors.	Confuses inputs with outputs or lacks labels.	No technical documentation included.
Professional Presentation	Artifact is clear, formatted for a portfolio, and demonstrates “Craftsmanship”.	Generally clear and readable.	Lacks structure or clarity.	Incomplete or unprofessional presentation.

Section 4: Upload & Documentation Protocol

1. Combine all files (application evidence) into one PDF.
2. Name your file using this format:
   • Lastname_Week4.8.pdf
3. Upload to the assignment portal.
4. Keep a copy in your Career Portfolio Folder (Google Drive).

Mfg 4.8 - Apply Submission

Mfg 4.8 - Reflection