What is factory Automation?
Factory automation provides a compelling way to boost quality, efficiency, safety, sustainability, and security in a rapidly changing modern factory setting.
As competition grows and margins are squeezed, factory automation paves the way towards maximum profitability and better performance.
Factory automation is the implementation of technology and systems to automate a manufacturing process with the ultimate goal of increasing productivity and reducing costs.
The level of automation may be anything from single operation automations to end-to-end automation where there is no human involvement.
Factory automation can be implemented at any point in the manufacturing process from material quantity control, to production and assembly and finally to packaging and dispatch.
With the rise of modernization and technology, many industries have begun to adopt and embrace industrial automation systems to increase efficiency and productivity at the workplace.
The vast adoption of these systems has seen the industrial automation market growing globally, reaching $191 billion in 2021 and expected to grow to a staggering $395 billion by 2029, according to Fortune Business Insights.
While most industrial manufacturers already understand the growing global adoption of industrial automation systems, many don’t have a good grasp of the different types of automation systems and how each can benefit a company.
Whether it’s warehouse automation or automated conveyor systems, different types of automation can benefit different types of businesses.
Types of Factory Automation
As the statistics above show, there has been huge growth in the use of industrial automation systems. But how do you know what automation system is the right one for your business? The right automation system for you will be determined by:
- Labor conditions
- Competitive pressures
- Work requirements
- Manufacturing and assembly specifications
- Labor costs
There are four types of automation systems:
- Fixed Automation,
- Programmable Automation,
- Flexible Automation And
- Integrated Automation.
Let’s take a look at each type and their differences and advantages. Then you can try to determine which type of automation system is best for you.
#1. Fixed Automation.
Fixed automation systems, also known as hard automation, are designed to complete a single set of tasks repeatedly. Fixed automation systems typically are used for discrete mass production or continuous flow systems.
An example of a fixed automation system is an automated conveyor belt in the auto manufacturing industry that moves objects with minimal effort, increasing efficiency.
#2. Programmable Automation.
Programmable automation systems are controlled by commands delivered by a computer program. Because of this, the automated processes can vary based on the instructions sent to the computer by the designer’s code.
Programmable automation is commonly used in settings where similar items are produced using the same automated steps and tools. For example, paper and steel rolling mills use the same steps to create many different types of products.
#3. Flexible Automation.
Flexible automation, also known as soft automation, is typically used in batch processes with a variety of products.
Each piece of equipment is given instructions for a computer operated by a human, so changing code can be delivered to the computer, allowing for more flexible production.
The primary advantage of flexible automation is that the product changeovers occur quickly and automatically because they are conveyed by the control system, eliminating the extra time required to reconfigure the equipment in between batches.
Industries that use flexible automation include textile manufacturing, food processing or paint manufacturing.
#4. Integrated Automation.
Integrated automation systems involve totally automating manufacturing plants with minimal human involvement.
Computers can be used to design parts, test the completed designs and then fabricate the new parts. Integrated automation can be used with continuous process manufacturing and batch process manufacturing.
#5. Robotic Process Automation (RPA).
RPA in manufacturing is a type of automation that uses software robots to automate tasks that are typically performed by humans.
This can include things like data entry, customer service, financial transactions, and even more complex tasks such as quality control, inventory management, and assembly line processes.
RPA is a relatively new technology, but it is becoming increasingly popular as businesses look for ways to improve efficiency and reduce costs.
The type of manufacturing automation that is right for your company will depend on several factors, such as what type of products are being produced, The production volume and the budget.
However, all types of manufacturing automation can offer significant benefits, including increased efficiency, improved quality, and reduced costs, you just need to make sure that you are getting the perfect custom manufacturing software development of your business.
What is factory automation software?
Factory automation services rely on dedicated software. Manufacturing plants utilize digital tools to maximize efficiency, reduce costs, and increase output. Some examples of the most appreciated software gaining popularity in the industrial field are:
- Simulation software based on 3D models, mirroring the whole lifecycle of the manufacturing system. Used in concept design, virtual commissioning, and operations, the solution visualizes concepts, allows for eliminating potential risks, and shortens the overall time-to-market.
- Analytical tools enable managers of manufacturing plants to fully benefit from the potential of data acquired and generated in the process. Software aimed at production analytics, automated data collection, and monitoring of processes, enables companies to identify trends in occurring events, detect causes of losses, and conclude from reports.
- Inventory management solutions allow for building traceability and supervision of warehouses and logistics, without creating tons of paperwork. Staff armed with tablets have all they need within one digital tool to monitor stock levels, plan orders and deliveries, create documents and monitor overall warehousing operations.
- Training automation tools, like Nsflow, unburden trainers at manufacturing plants. Dedicated software is a way to exchange repetitive in-person training with a convenient digital approach, along with creating instructions, verifying progress through automated reports, and assigning a subsequent range of material for personnel.
- Process planning – automation in production allows for forecasting future needs and demands, scheduling processes, ordering the right amounts of raw materials in appropriate quantities, as well as scheduling available equipment and labour. Factory automation solutions ensure production operations are carried out as planned.
Benefits of Factory Automation
#1. Lowered operating costs
Robots can perform the work of three to five people, depending on the task. And bar feeders and APLs allow your machinists to attend to multiple machines at once.
In addition to savings on the cost of labor, energy savings can also be significant due to lower heating requirements in automated operations.
Automation integration streamlines processes and increases part accuracy, which means minimal material waste for your operation.
#2. Improved worker safety
Automated cells, bar feeders and APLs remove workers from dangerous tasks. Your employees will thank you for safeguarding them against the hazards of a factory environment.
#3. Reduced factory lead times
Automation can keep your process in-house, improve process control and significantly reduce lead times compared to outsourcing or going overseas.
#4. Faster ROI
Automation solutions are based on your unique needs and goals and pay for themselves quickly due to lower operating costs, reduced lead times, increased output and more.
#5. Ability to be more competitive.
Automated cells, bar feeders and APLs allow you to decrease cycle times and cost-per-piece while improving quality. This allows you to better compete on a global scale. Additionally, the flexibility of automation integration enables you to retool a cell to exceed the capabilities of your competition.
#6. Increased production output.
A robot has the ability to work at a constant speed, unattended, 24/7, as do bar feeders and APLs. Automation in manufacturing means you’ve got the potential to produce more.
New products can be quickly introduced into the production process and new product programming can be done offline with no disruption to existing processes.
#7. Consistent and improved part production and quality.
Automated cells, bar feeders and APLs typically perform the manufacturing process with better consistency than human machinists. This results in greater control and consistency of product quality.
#8. Smaller environmental footprint.
By streamlining equipment and processes, reducing scrap and using less space, automation uses less energy. A key benefit of automation is that it reduces your environmental footprint which can save you real money.
#9. Better planning.
Consistent production by automation integration allows a shop to reliably predict timing and costs. That predictability permits a tighter margin on almost any project.
#10. Reduced need for outsourcing.
Automated cells have large amounts of potential capacity concentrated in one compact system. This allows shops to produce parts in-house that have previously been outsourced.
#11. Optimal utilization of floor space.
Robots are designed on compact bases to fit in confined spaces. In addition to being mounted on the floor, robots can be mounted on walls, ceilings, rail tracks and shelves. They can perform tasks in confined spaces, saving you valuable floor space.
#12. Easy integration.
Productivity will work with you to provide a complete robotics solution system hardware, software and controls. Your cell will be proven out at Productivity and shipped out production-ready allowing you to start making parts as soon as it’s installed in your shop.
#13. Maximized labor.
Over the next three decades, statistics show that more than 76 million baby boomers will retire and only 46 million new workers will be available to replace them. During this time, your demand for labor will continue, making automation a real and viable solution.
#14. Increased productivity and efficiency.
- 24/7 production, JIT manufacturing-friendly
- More uptime with historic efficiency figures above 90 percent
- Secondary operations capability — gauging, washing, deburring, etc.
- Real-time factory communications with automated cells and machines
- Quick changeover for multiple parts, tooling and programs
- Flexible multi-operations capability — Op 10, Op 20, etc.
#15. Increased system versatility.
- System flexibility, easily retooled and repositioned for new production programs
- Robots, bar feeders and APLs are flexible and can easily be redeployed in new applications or parts
- Robots, bar feeders and APLs have the ability to easily switch between a wide range of products without having to completely rebuild production lines
- Quick changeover with auto grippers and vision allows for different part sizes and shapes to be part of the same run
- Mixed-flow production approach allows for flexibility in adjusting to demand fluctuations
- Robots are able to instantaneously “learn” new processes
- Reduced changeover time
Cost of Implementing Factory automation?
The initial outlay is usually high and the equipment used to automate a production line is very specialised and often needs to be designed and developed for a particular line.
The design may also be costly as it is important to develop a future-proof design that allows the throughput to increase as successes are realised.
Best practices exist, as do generic solutions. Employing an experienced automation engineer can help to design a system that uses existing technologies where possible to contain the costs.
There also will be the costs of upskilling operators to monitor the process or there will be the cost of sourcing and employing these people to supervise and monitor the production line.
How to approach factory automation in your business?
While the potential upside of factory automation is significant, the outlay required is also extensive, and it is important not to begin automating without developing a robust strategy that encompasses the following elements:
#1. Understand your goals.
The return on investment from an automation project will vary depending on how it is applied throughout the factory with automation of some systems generating a stronger, more immediate ROI than others.
Therefore, it’s vital to establish which processes on the factory floor should be automated first. When considering the spectrum of automation, understand which small steps, such as the introduction of single automated machines, will deliver the best ROI given your specific needs.
#2. Ensure all stakeholders are aligned.
Once an automation plan has been drafted, it’s important to achieve buy-in for the initiative from stakeholders throughout the organization.
The evidence in support of an automation strategy should be clear to all parties: a board of directors concerned about the capital cost of the project will be convinced if the downstream productivity improvements (and therefore profitability) are evident.
Similarly, the workforce may be concerned that automation will lead to job losses, while an effective strategy may actually result in enhanced health and safety outcomes and opportunities for staff to upskill from labor-intensive work to more fulfilling roles focused on oversight of the new automated processes.
#3. Evaluate tools and technology.
Take the time to fully evaluate the tools and technology available to achieve the required automation outcomes.
It’s easy for organizations to over-specify and over-complicate the journey towards what they are aiming to achieve and, in the process, spend much more than is necessary.
Getting the balance right requires starting with a solid understanding of existing manufacturing systems.
#4. Measure the impact on productivity.
To ensure automation initiatives deliver on their potential, invest in tools to measure the impact of the changes your organization is making.
To get a complete picture of the ROI from your digital transformation, it’s important to measure the increase in productivity over time.
Difference Between Factory Automation vs Process Automation
Factory automation, for instance, can be categorized further according to these automation types: fixed, programmable, and flexible automation.
Fixed automation is relatively fixed and inflexible in terms of the cells it can handle. It’s not possible to change a fixed cell line easily, without considerable cost and plant downtime.
Programmable automation allows for quick changes to product types, part numbers or production quantities within a single cell. The type of product or quantity to be produced is usually determined by the programming of computer systems that are directly linked to cell controls.
Flexible automation allows for quick changes to product types, part numbers or production quantities within a single cell with minimal cost and plant downtime.
The type of product or quantity produced can be changed using an ergonomically designed MMI (Man Machine Interface) that is also directly linked to the cell controllers.
At its core, factory automation is a holistic industrial process which, through automation, serves to reduce risk and harm to human works with increased automation in the tasks and production processes in a plant.
While process automation focuses on automating industrial control applications used in the operation of factories, plants, and other industrial facilities.