Automation Services
Industrial automation is the use of control systems, such as computers or robots, and information technologies for handling different processes and machineries in an industry to replace a human being.
There are many benefits to industrial automation such as:
Improved quality: automated work cells are typically less variable and less prone to error when compared to human operators. The precision provided by industrial automation results in higher consistency and reproducibility along the manufacturing process – ultimately providing higher quality products.
Higher efficiency and throughput: robots can operate 24 hours a day and 7 days a week – and simply work faster than human operators. This additional work time elevates efficiency and results in higher throughput from the work cell. Additionally, industrial automation provides flexibility to adjust the work cell. For example, if the work cell needs to be optimized or modifications made for a new product, the automated system can be reprogrammed offline, oftentimes with little to no downtime, and minimal to no operator training required.
Lower costs: utilizing robots is simply less expensive than human operators. Once the initial cost of a robot is paid, the only costs are maintenance and the energy required during operation. Over time, the cost savings is significant when compared to operator salaries and benefits. Additionally, robots optimize the process and improve quality, resulting in less waste – providing even further cost savings.
Improved Speed to Market: industrial automation provides a more efficient production line that reduces product lead times and, in some cases, makes a strong case for keeping production in-house instead of outsourcing.
Better Safety: improved operator safety is one of the biggest advantages of industrial automation as operators no longer need to perform hazardous tasks such as working with dangerous chemicals, picking up heavy objects, working in poor conditions such as elevated temperatures, and performing tasks with repetitive motion. Operators are safer when these types of tasks are performed by robots and other automation solutions.
Types of Industrial Automation
Industrial automation is currently employed across a myriad of industries with automated systems doing everything from performing manufacturing tasks to operating an ATM. The level of complexity and human interaction with an automated system varies by application. While there are countless applications of industrial automation solutions, nearly all fall into 1 of 3 automation categories: fixed, programmable, and flexible. Below is a little more about each of these types of industrial automation.
Fixed: this type of automation is also referred to as rigid or hard automation. As the names imply, this form of industrial automation is the least flexible and is often used to execute repetitive tasks with dedicated equipment in order to improve production efficiency and through-put rates. Once a fixed automation solution is setup, it is challenging to modify the process or reconfigure the equipment. Fixed automation solutions are good options for production that is consistent and stable over time and has high volume through-puts. Examples of fixed automation are assembly lines in the automotive industry.
Programmable: this type of automation is best for batches of products where the instructions for the automated system change over time depending on which product is being manufactured. The control program can be reprogrammed for each batch with the given specifications and the necessary processing tasks and sequencing. This changeover process takes time as in most cases the equipment must also be reconfigured from batch to batch. Programmable automation is often used for medium volumes but can also be used for low or high volumes when economics are justified. Industrial robots are an example of programmable automation.
Flexible: this system is often referred to as soft automation. It is similar to programmable automation in that it provides flexibility for product changeovers. The big advantage of flexible automation is that the product changeovers are conveyed via the control system and occur quickly and automatically – eliminating the time required to reconfigure the equipment in between batches. CNC machines are an example of flexible automation.
