What is factory Automation?
In the context of an evolving modern factory, automating the factory floors is a plausible method to enhance quality, efficiency, safety, sustainability, and security.
With intensifying competition and squeezed profit margins, automation is the route to improved performance and maximum profitability.
Factory automation refers to the integration of technology and machinery to a manufacturing process with the intent of maximizing productivity and minimizing operational costs.
Automation can be defined by its scope, ranging from simple procedure automations to full automation where no human operators are present for the entire process.
Any factory can utilize automation technology at any stage of the production process from monitoring material quantities, production and assembly, and packaging and shipping.
Most industries have started adopting industrial automation systems due to the prevalence of modern technology in the workplace in an effort to boost their efficiency and productivity.
As per Fortune Business Insights, the widespread adoption of such systems is what has caused the expansion of the global industrial automation market, which reached $191 billion in 2021 and is expected to exceed $395 billion by 2029.
Many industrial manufacturers comprehend the incrementing adoption of industrial automation systems, yet the complexity of the automation system’s functions is baffling to most of them. However, it remains a mystery how these functions can benefit to company.
Different types of businesses may benefit from different types of automation, such as an automated conveyor system or warehouse automation.
Types of Factory Automation
As indicated in the aforementioned statistics, we have seen rapid development in the application of industrial automation systems. But how do you know what automation system is the right one for your business? To figure out the answer consider the following:
- 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
- Integrated Automation
Let’s analyze all types of systems and try to understand their innovations and differences. This may help you choose the most suitable automation system.
#1. Fixed Automation.
Fixed Automation systems, also referred to as Hard automation, are set to perform a specified range of tasks on repeat. Forsuch systems, Fixed automation is most typically of Application in Case of discrete mass production systems or Continuous flow systems.
A fixed automation system example is an automated conveyor belt in the auto manufacturing industry, where objects are moved with little effort resulting in maximum efficiency.
#2. Programmable Automation.
The automation systems are executed by commands provided through a computer program. In this case, the automated processes can be different because of the instructions sent to the computer by the designer’s code.
Programmable automation is frequently implemented in processes where many similar products are produced by the same automated steps and tools. Take the case of paper and steel rolling mills – the basic steps remain the same for many products.
#3. Flexible Automation.
Flexible automation, or soft automation, is more common in batch processes with multiple products. Each piece of equipment is assigned a set of instructions from a human operated computer, so more flexible production is possible because the code can be modified.
Flexible automation’s main advantage is the rapid and automatic changes between product types due to control system communication, which removes the need to reconfigure the equipment between batches. Industries that use flexible automation include manufacturing of textiles, foodstuff or paint.
#4. Integrated Automation.
Automated Integrated Systems are defined as the complete automation of a manufacturing plant with little to no human intervention.
These processes can be designed on computers that can draft the parts needed, test the design, and build them. Integrated automation can be applied in both continuous process production and batch process production.
#5. Robotic Process Automation (RPA).
RPA in manufacturing refers to the use of software based robots with the capabilities of performing human-like tasks on their own.
This can include data entry, providing customer support, performing financial services, and more detailed procedures such as managing quality, controlling inventory, and operating production lines.
Although not so old, RPA is an advancing technology, with more and more companies adopting it to increase efficiency and cut expenses.
The specific company strategy defines what type of mechanization or automation will suite each particular business best and it will depend on several consideration like what products are being manufactured, The scale of production and financial allocations.
Al the different types of automation offered, though, have one thing in common: they can all improve the effectiveness and productivity while reducing the value of the operation alongside the quality of goods and services offered.
What is factory automation software?
Automation services require particular software to work efficiently. Digital applications exist for the aid of manufacturing plants to improve efficiency, cut expenses, and boost their output. Here are some emerging software solutions that are getting attention in the industrial sector:
- 3D model based simulation software that is able to replicate the complete “life cycle” of a manufacturing system. It is used in concept design, virtual commissioning, and operations. This solution helps visualize a concept, removes risks, and shortens the time it takes to bring it into the market.
- Analytical tools designed for managers in manufacturing plants to help them fully utilize the available and generated data. Production analytics, automated data collection, and process supervision software help businesses spot patterns in what is happening, figure out the reasons for losses, and produce useful reports.
- Tools designed to aid in inventory management help establish control and traceability to warehouses and logistics without having to deal with massive amounts of paperwork. Employees equipped with tablets can monitor stock levels, plan orders and their deliveries, produce necessary documents, and in general supervise all warehousing activities.
- Tools such as Nsflow make the lives of trainers in manufacturing plants much easier. This application enables users to trade time-consuming, hands-on training sessions for more flexible and efficient digital formats. It can also be used to create instructions, validate progress with automated report checks, and set up task ranges for employees to complete.
- Procurement became easier with the automation of process planning. One can only forecast the future demand for a product, schedule processes, order raw materials in optimal volumes, and arrange the use of equipment and human resources well in advance. Positive outcomes are guaranteed when factories are automated and equipped with modern industrial computer systems.
Benefits of Factory Automation
#1. Lowered operating costs.
Robots can accomplish the work of three to five employees, depending on the operation. Furthermore, your machinists can monitor multiple machines simultaneously thanks to bar feeders and APLs.
Apart from the savings arising from the use of labor, there can be significant savings on the use of energy due to the lower heating needs for automated processes. Materiel conservation is better for the environment due to streamlined processes and greater precision integration.
#2. Improved worker safety.
Automated cells with safety features such as bar feeders and APLs enable employees to avoid dangerous processes. Employees will appreciate you for protecting them from being exposed to risks related to the factory environment.
#3. Reduced factory lead times.
Automation enhances process control and helps keep your labor in-house, which saves time compared to outsourcing or offshoring.
#4. Faster ROI.
Automation solutions and services are paid back quickly due to lower operating costs, reduced lead times, increased output, and many other factors.
#5. Ability to be more competitive.
Automated cells, bar feeders, and APLs increase production speed and quality while decreasing per-piece cost and cycle time. This allows for better competition in the world market. Flexibility in the integration of automation also means that the cell can be retooled to outperform rival cells.
#6. Increased production output.
Automation means more potential output from manufacturing. Bar feeders, APLs, and robots can all function unattended at a constant speed, 24/7, so the production output can rise.
The brewing and offline programming of new products can be done without any disruption to the processes that are currently running.
#7. Consistent and improved part production and quality.
Bar feeders, APLs, and automated cells operate the manufacturing process with greater consistency than human machinists, which translates into better control and consistency of product quality.
#8. Smaller environmental footprint.
The automation of equipment, processes, and the reduction of energy waste translates into lower power consumption. Another important advantage of automation is the reduction of the environmental footprint which is beneficial in not only helping the environment but making you money.
#9. Better planning.
The seamless implementation of automation also enables consistent production which allows for accurate prediction of expenses and time. The company easily saves costs with almost every project due to greater predictability.
#10. Reduced need for outsourcing.
Automated cells have large amounts of potential capacity concentrated in one compact system, which allows shops to internally produce components that were previously sourced out.
#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 the walls, ceilings, rails, and shelves. They can work in tight spaces and therefore save you valuable floor space.
#12. Easy integration.
Productivity will work with you to provide a complete robotics integration system containing needed hardware and software. The cell will be proven out at Productivity and shipped out production-ready to help you make parts immediately after installation in your shop.
#13. Maximized labor.
Over the next 30 years, data projects that more than 76 million baby boomers will retire while only 46 million new workers will be available to take their places. Moreover, during this period there will still be a greater need for labor on your end which makes automation a viable option.
#14. Increased productivity and efficiency.
- Supports Continuous production and friendly JIT manufacturing.
- Better worked off-time with historic efficiency over 90%.
- Ability to perform secondary operations- gauging, washing, deburring, etc.
- Automated cell/ machine real time communications for factory and machine.
- Fast changeover for mix of parts, tools, and programs.
- Capable of flexible multi-operations such as Operation 10, Operation 20, etc.
#15. Increased system versatility.
- Adaptable system that can be easily reconfigured for differing production objectives.
- Robots, bar feeders and APLs can be easily used in new applications or parts.
- Robots, bar feeders and APLs can change their activity for a number of different products without deconstructing and reconstructing the production line.
- Different sizes and shapes of parts can be machined in one cycle is made possible by the use of auto grippers and vision for quick changeover.
- A mixed-flow production system enables rapid adaptation to changes in order volume or size.
- New processes can be “taught” to robots in real-time.
- Time to switch between tasks is lowered.
Cost of Implementing Factory automation?
The costs involved are usually relatively high as the equipment used to automate a production line is very specialised and often needs to be designed and developed for a specific line.
The initial design can be expensive as there are additional restraints of making sure the design is fail-safe meaning the throughput will increase over time as more successes are achieved.
There are universally accepted standards, as well as solutions that can solve any problem. Hiring an automation engineer is the best way to create a system where costs are minimized by implementing already developed technologies.
Equally, consideration will have to be given to the costs related to upskilling existing employees to be able to meet the new requirements or alternatively, hiring new operators to fill these positions will incur further costs.
How to approach factory automation in your business?
Even though automated factories have their advantages, the initial investment needed is considerable. Hence, undertaking automation needs careful strategic planning in which amound expenditures, targets, and other factors are considered:
#1. Understand your goals.
When we consider ROI for automation, some investments will have greater payback in certain areas compared to others. The ROI is often strongest when multiple subsystems are automated as opposed to only a singular controllable unit.
Identifying which parts of the factory should both be and can be automated is critical. Investing in the automation spectrum, however, means it is equally crucial to consider what increments such as introducing individual automated machines will cater for the best return based on the needs.
#2. Ensure all stakeholders are aligned.
Once a comprehensive automation proposal has been developed, getting agreement to pursue it from every level within your company is vital.
All parties should have rationale towards the evidence supporting an automation strategy. A board of directors that is nervous about capital cost of the project will be sold if productivity improvements (and thus, profitability) are clear downstream.
In the same manner, the workforce may fear that automation will eliminate jobs, while an effective strategy may actually improve health and safety outcomes and enable staff to upskill from physically demanding positions to more rewarding positions that involve overseeing automated systems.
#3. Evaluate tools and technology.
Make the necessary efforts to evaluate the technologies and tools needed to provide the required automation goals.
Organizations tend to get stuck in elaborate level of details, making it easy for them to overspend on achieving their desired goals.
Striking this balance is challenging, but it is imperative to begin with an adequate appreciation of current manufacturing systems.
#4. Measure the impact on productivity.
In order to ensure that automation initiatives achieve their promise, pre-emptively invest in measures that track the value of changes your organization undertakes.
It is important to make sure that all aspects of ROI associated with digital transformation are captured, and the most important aspect is the measurement of productivity over time.
Difference Between Factory Automation vs Process Automation
Particularly, factory automation can be subdivided into these specific types of automation: Fixed automation, programmable automation, and flexible automation.
Fixed automation systems tend to be rigid and inflexible with regard to the specific cells that it can accommodate. A fixed cell line is not easy to modify without significant expense and production facility downtime.
“Programmable” denotes automation that provides for change over in relatively short time as far as product variety, pieces, or production volume controlled within a cell is concerned. The control system for a cell typically is computer controlled where the governing program determines what product, and in what quantity, is to be produced.
Flexible Automation provides for change over in relatively short time as far as product variety, pieces, or production volume controlled within a cell is concerned, but at a minimum expense and production facility downtime.
An ergonomically designed monitor-man machine interface (MMI) which can be programmed to change the product or amount to be outputted is directly connected with the cell controllers.
Broadly, factory automation is an integrated industrial sequence within which, by means of automation, attempts to mitigate and minimize damage to human workers with enhanced mechanization to the efforts and processes involving production in a workshop.
While process automation targets on automating a factory or plant’s industrial control applications, it also extends to other industrial units.