Over recent years, the manufacturing sector has encountered significant disruptions, causing considerable alterations and adaptations on the factory floor. It’s hardly surprising that industry leaders are now, more than ever, searching for methods to enhance their operations to achieve higher output and reduce expenses.
The continual quest for cost reduction and enhanced efficiency is ideal for manufacturers eager to embrace more automation technologies within the scope of Industry 4.0 to secure successful results. This article delves into the ascent of automation in manufacturing and its role in aiding companies to attain crucial production monitoring KPIs. We will also discuss the effective integration of various automation forms into your business processes.
Defining Industrial Automation
In the manufacturing context, automation typically refers to the utilization of machinery to automate systems or production workflows to boost efficiency and minimize manual intervention. Automation aids in accelerating production and significantly lowering costs as it reduces the manual labor requirement, allowing employees to concentrate on strategic management of their respective roles.
Industrial automation entails employing machinery to execute tasks traditionally done by humans. It’s synonymous with electromechanical systems programmed to execute various tasks and processes. While industrial automation may not suit every manufacturer, many can benefit from the diverse automation types discussed in further detail below.
Industrial automation systems come in three types:
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Fixed Automation
Known as ‘hard automation,’ this type refers to systems designed for specific tasks and not readily adaptable to different product styles. Characterized by high production speeds and substantial initial investment, the programming in fixed automation is embedded within the machine using gears, cams, wiring, and other components. Fixed automation is ideal for high-volume product manufacturing, exemplified by machining transfer lines in the auto industry, automatic assembly machines, and certain chemical processes. Although changeovers are possible, they necessitate production halts and manual tooling adjustments by technicians.
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Programmable Automation
Programmable automation involves the use of programmable mechanisms that enable the production of different product batches, varying from a small number to thousands. Each transition to a new product necessitates reprogramming and altering the production machinery, which leads to downtime. While programmable automation offers lower production speeds compared to fixed automation, it’s designed to streamline the transition between product types.
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Flexible Automation
The primary challenge with programmable automation is the downtime incurred during equipment modification for new product production. Flexible automation addresses this issue by automating these changeovers, although this may restrict the machinery to components that use similar tools or necessitate extra apparatus for changeovers. Consequently, flexible automation typically supports a narrower range of products to ensure swift automatic transitions. Given the need for program alterations, flexible automation systems are frequently networked, enabling remote production control. This approach allows for the simultaneous production of various products, moving beyond the batch production model inherent in programmable automation.
Automation Examples in Manufacturing
This segment examines various automated production workflows, assisting businesses in determining the most suitable automation type for their manufacturing needs. Manufacturers use industrial robots for:
- Automated assembly machines
- Chemical manufacturing processes
- Material handling conveyor systems
- Machining transfer lines
- Paint & coating automation processes
- Web Handling and converting systems
Examples of Programmable Automation
Programmable automation is best for manufacturers making batches of different products. Examples include:
- Numerically controlled (NC) machine tools
- Programmable logic controllers (PLCs)
- Industrial robots
- Production of frozen foods
Examples of Flexible Automation
Flexible automation is best for producing a variety of similar products quickly and performing changeovers automatically. The best example of flexible automation is a robot arm that can be programmed to perform different tasks such as insert screws, drill holes, sand, weld, insert rivets and spray paint. Manufacturers use industrial robots for:
- Arc Welding
- Spot Welding
- Materials Handling
- Machine Tending
- Painting
- Assembly
- Mechanical Cutting, Grinding, Deburring and Polishing
Gluing, Adhesive Sealing and Spraying Materials
