Optimized production schedules that yield better results
Manufacturing automation, in plain terms, denote the use of technology and modern tools to minimize human interference in manufacturing processes. It isn’t always about the involvement of robots & cobots. Automation in manufacturing could also mean the usage of AI tools, where production planning happens automatically based on demand prediction.
If-this-then-that automation may not be apt enough to meet changing demands
| Cluttered, manual processes, where everything is fixed and follows rules | A smart factory where everything is well-planned, automated, and improves on its own. |
|---|---|
❌ Follows fixed rules that has been set long back ago. | ✅ Learns from historical and real-time data; & changes without having to reprogram. |
❌ Load scheduled on time regardless of machine health. | ✅ Follows predictive maintenance, where failures & overloading are prevented. |
❌ Requires high monitoring. | ✅ Systems learn on their own & optimizes itself. Raises alerts when required. |
❌ Data serves only reporting purposes | ✅ Data becomes the heart of everything: facilitating continuous monitoring and improvement. |
❌ Scaling becomes difficult; requires more resources. | ✅ Can scale across the departments and plants with ease. |
Cluttered, manual processes, where everything is fixed and follows rules
❌ Follows fixed rules that has been set long back ago.
❌ Load scheduled on time regardless of machine health.
❌ Requires high monitoring.
❌ Data serves only reporting purposes
❌ Scaling becomes difficult; requires more resources.
A smart factory where everything is well-planned, automated, and improves on its own.
✅ Learns from historical and real-time data; & changes without having to reprogram.
✅ Follows predictive maintenance, where failures & overloading are prevented.
✅ Systems learn on their own & optimizes itself. Raises alerts when required.
✅ Data becomes the heart of everything: facilitating continuous monitoring and improvement.
✅ Can scale across the departments and plants with ease.
Benefits of automation in manufacturing
Reduction in cost
Less prone to error
More efficiency
Better quality
Better decision-making
Scale with better predictability
The most recent enhancements in manufacturing automation
Fixed automation: Fixed automation involves specific types of machines and equipment, hard programmed to do a specific task. Once set up, it can be hard to modify/reprogram, hence suitable for mass production of standardized goods, assembly lines, etc, with low variety ranges. Programmable automation: Programmable automation denotes flexible automation systems for manufacturing, which could be re-programmed for customization. This might be slower than fixed automation, but great for moderate to high product variations. Uses systems like CNC or PLCs, which can be updated by programming.
Flexible automation: Flexible automation uses computer-controlled machines, flexible like programmable, but reduces downtime between customizations. Hence, this is suitable for high variations, low volume production workflows. But this might be more complex than programmable and requires skilled personnel to handle them. IoT-driven automation: Internet of Things refers to sensors, alarms, and connected systems, which allows communication of data, makes real-time monitoring possible with fewer resources, aiming for autonomous control. Some IoT driven automation include predictive maintenance, smart quality control, energy optimization, & more.
How automation works in manufacturing industry?
Raw materials and planning
It starts with tracking inventory materials automatically, planning the needed quantities and goods for the current workload. Automation for planning requires connected systems including ERP to track stock levels, expiration dates, remaining stock, and safety stock levels after usage.
Machine programming
Machineries used, like CNCs, 3d printing machines, or robotic arms are programmed with process, raw materials handling, and instructions – cutting, welding, shredding, assembling operations, etc., also automating when to make, how much to make, based on the inventory & requirements.
Automated production
The second step is where automated production happens, with detailed processing instructions programmed to respective machinery. Many manufacturers use PLCs, SCADAs, and robotic arms for this process.
Smart monitoring
Use IoT devices and sensors to monitor stats like temperature, pressure, material flow, and other measurable metrics. This real-time data collection and processing enables remote monitoring, allowing personnels to interrupt when things go wrong.
Quality control
Once production cycle is over, AI-enabled cameras and scanners let products pass through them for automatic defect identification. It could be defects with measurements, surface flaws, packaging errors, or internal defects—anything could be identified.
Feedback and improvements
Collected data is also used to analyze anomalies and optimize performance whenever required. Based on observations, modifications or re-programming will be done to ensure continuous process improvement.
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Got questions? We got you covered.
What is automation in lean manufacturing?
How to automate a manufacturing process?
What is meant by smart manufacturing?
What is the difference between smart manufacturing and automation?
What are the industries that uses automation in manufacturing?
Food & beverages
FMCG and food manufacturers require consistency in taste, quality, size, and raw materials quantity. Industrial automation manufacturing can help maintain safety standards & consistency, while managing demand changes.
Automotive
Many automotive companies like Tesla have already introduced robotics and automation in assembly, testing, painting, etc. They employ this to reduce risk and hazards, while speeding up production & assembly.
Pharmaceuticals
Pharma industry must follow stringent compliance and acceptance standards. Manufacturing process automation can bring zero defect manufacturing that leads to high-quality, contamination-free products that pass every test.
Packaging
One of the perfect automation in manufacturing examples is packing, which has many repetitive tasks like sealing, labelling, wrapping, and more. With industrial automation manufacturing could optimize material usage, reduce packing & accelerate logistics.