The manufacturing sector today is not as it was some two decades ago, as industrial automation has become the cornerstone of improving efficiencies and retaining staying power. Different categories of industrial automation systems are important for the businesses who want to heighten their business’s production. Various automation systems will be discussed in this article and will recommend the most appropriate system that suits you.
What is Industrial Automation and Why is it Important?
Industrial automation is operating industrial equipment in factories, boilers and heat treating ovens, switching on telephone networks, and aircraft with minimal or less human intervention. This type of automation is very advantageous to all industries since it leads to faster production rate, accuracy of products and reduction of repetitive work. With the aid of automation systems, tasks which may have previously needed considerable human effort can now be carried out under minimal control, enhancing overall production processes and efficiency and quality of the products.
It is true that industrialization has simplified factors in manufacturing, which have enhanced efficiency through the advantages of industrial automation. There is a decrease of mistakes and interventions from people when manufacturing processes are automated. Industry-wise, all automating solutions ensure that reliability and precision are not compromised as the operation is shifted from one process to another. Cost is also cut since there is no need for many human beings who will perform monotonous and time-wasting activities, allowing the company to concentrate more on innovating rather than on the drudgery of doing it the manual way.
To summarize, every expert knows that new advanced manufacturing systems and their associated automation help to accelerate the evolution of the specific sector of the economy while satisfying consumers’ desire to get high quality goods.
Overview of the Four Main Types of Industrial Automation Systems
As you embark on a journey through types of industrial automation, it would be helpful to note from the onset that there are four basic types of non-robotic industrial automation: these are, fixed automation, programmable automation, flexible automation and integrated automation. These systems are intended for different sectors in the industrial automation market tailored to the needs of complexity and volume of the entire production process.
- Fixed Automation: Behind this definition is a system known and which is appropriate for mass production because there is a duplication of the same production tasks. Fixed automation is typically used in continuous production and assembly systems which have low product changeover requirements. After it is installed, the system performs repeated functions in a highly efficient manner, increasing the level of production tremendously.
- Programmable Automation: In contrast to programmable automation, fixed automation does not offer any turndowns in the production operation. This particular kind of automation is useful in many situations where production processes are required to be more flexibleor when batch processes are expected. A manufacturer also can change the order of performance of the processes thanks to a computer or PLC program that is specialized for such tasks.
- Flexible Automation: Flexible automation systems offer even more flexibility in processes of reconfiguration. They are capable of handling a number of different products and performing a broadrange of specific operations without a need for a long reconfiguration such as change of any tools. This translates to satisfactory performance for production systems whose characteristics change rapidly with respect to both production rate and type of product.
- Integrated Automation: This form cuts out integration entirely as a full automation of the production process is exercised, starting from the gathering of information to the up till machine’s operation. Integrated automation systems contain the advantages of other models of automation systems where complete management and scope of work is provided for cases of large-scale expansion of production.
These four systems are different and cater for different needs, and the particular system selected depends on the peculiar characteristics of the manufacturing plant, production line and sorts of activities carried out.
Fixed Automation Systems: Benefits and Common Applications
Fixed automation systems, also known as hard automation systems, are permanent installation automation for work performed like drill press operations only a few times and typically complete a single set of tasks. Such systems are ubiquitous in production industries such as the automobile industry, as identical units of products require them to be manufactured by performing the same tasks over and over again thousands of times.
Benefits of Fixed Automation Systems
The biggest advantage of a fixed automation system is that it enables mass production of manufactured goods which is hardly feasible courtesy of other means. Because the system is designed to execute repetitive jobs, it is capable of running at very high speeds which is an added benefit in working on assembly lines. This also makes sure that high standards of product quality are maintained because there is little scope for human error. It also means that owing to the type of construction of fixed automation systems, they are task oriented and once that market stabilizes, such businesses will be less capital intensive.
Common Applications of Fixed Automation Systems
| Application Area | Specific Task |
| Automotive assembly lines | Repetitive tasks such as welding and assembly |
| Textile manufacturing | High-speed production of fabrics and garments using consistent processes |
| Food processing | Ensuring precise packaging and processing to meet strict quality standards |
Nevertheless, despite the positive aspects associated with the use of a fixed automation system, there are certain challenges which include the fact that there is loss of flexibility with this automation system. As the system is dedicated to one type of product or one type of task, a modification reaction in the production process is very expensive and it takes a lot of time. This type of system is perfectly designed for enterprises which engage in high volume production of the same product with no to few changes in nature.
Programmable Automation Systems: Flexibility in Manufacturing
When placed next to fixed automation, programmable automation systems demonstrate an even higher level of flexibility due to the sequence of operations involved. Such systems are intended for batch production and are useful to manufacturers who want to make different product types without changing the system entirely. These systems can be altered by changing a computer program or modifying a PLCso that they cater to different production needs.
This type of automation, including industrial robots, is useful to companies in which several lines of products are being produced. For example, as with the automotive industry, programmable automation systems are used in the design to manufacture different models of cars with no need to redesign the assembly line. In the food processing sector as well, programmable robots are commonly versatile automation used, for OEE centered switching the packaging of different products with minimal stoppage time.
The most functional benefits which a corporation obtains after applying programmable automation is its versatility. Unlike fixed automation systems which can be inflexible in most cases, programmable systems tend to change the order of events to satisfy the production demand. This leads to a more effective utilization of resources and time, especially in industries where multiple products are produced and changing from one to the other is inevitable. Further, it eliminates the manual operator intervention in the production processes hence increasing efficiency and decreasing mistakes.
However, while these systems are not as rigid as fixed automation, they are still relatively suited to businesses that manufacture in batches rather than cement industries. This type of changeover between product types requires some human element in reprogramming the system, which makes it less useful for mass production.
Exploring the Advantages of Flexible Automation Systems
Flexible automation systems represent a further evolution of the forms of industrial automation. Unlike both fixed and programmable automation systems, flexible automation applies minimal reconfiguration time to complete different tasks. This is why it is well suited for industries that typically have many product variants and frequent product changes. Production can be sustained even during such changes, which increase efficiency and lower non-productive time.
Advantages of Flexible Automation Systems
| Advantage | Description |
| Adaptability to Product Variations | Can handle multiple product variations with minimal reconfiguration time, making it ideal for industries with frequent product changeovers. |
| Increased Production Efficiency | Allows continuous operation by adapting on-the-fly without stopping production, reducing downtime and enhancing production efficiency. |
| Responsiveness to Market Demands | Enables manufacturers to quickly adjust production lines to meet changing customer demands, particularly in industries like automotive manufacturing. |
| Integration with Robotic Technology | Uses robotic systems to perform various tasks with little human intervention, resulting in higher production rates and reduced labor costs. |
| Capability for Task Variety | Handles multiple tasks such as packaging, assembly, or inspection for different products without requiring extensive downtime between tasks. |
| Seamless IoT Integration | Enables real-time data acquisition and predictive maintenance, optimizing production processes and reducing waste in the IoT-driven smart factory era. |
| Reduced Need for Retooling | Can switch between different product designs or materials without the need for extensive manual retooling, improving flexibility and saving time. |
The role of flexible automation is also useful in the IoT than the acquisition of the data and making preventive maintenance is easy for the manufacture. Many manufactures are optimizing their production processes by pulling information from machines in real time and using it in efforts to further increase efficiency, decrease waste and enhance product quality. The combination of these technologies with those of the IoT is revolutionizing the evolution of manufacturing business into smart factories that require very few, if any, operators.
Integrated Automation Systems: Full Control Over Production Processes
The most evolved type of automated system is the integrated one among the various kinds of automation systems. It brings together control capabilities of the entire cycle of production right from data gathering through operating machine tools and feedback loops which enable quality maintenance, leveraging artificial intelligence. Integrated systems are such that interconnect some or all aspects of the various automation technologies into a unitary type of operation. Often, such systems contain the robotics, PLCs, and computer software and achieve a fully automated factory.
Such systems have another important advantage in that they reduce the interaction of human beings and skilled human operators with the production. This promotes a smooth flow of activities without any break, and without the inclusion of a human being, the chances of mistakes are quite low. Integrated systems can perform material handling assembly lines and quality control activities, eliminating the human element from the process and increasing productivity greatly. It is also important in the sense that the system can take actions according to the feedback given, and there are no variations. These systems are particularly useful in a situation where there is a need for batch process manufacturing or very high levels of production volumes. In food processing, automotive and other manufacturing industries, integrated automation systems help to achieve the operation with minimal or no down time for maintenance and human intervention.
Integrated automation also improves the multifunctional character of the manufacturing plant itself. Even if it possesses some components of fixed, programmable, and flexible automation systems, it enables them to reconfigure the entire operation in accordance with the requirements of the production volume without the need for any manual interaction. This also makes it suitable for even those companies that wants to exercise end to end control over the production line since it integrates all the ability of different types of automation systems into one, which is powerful.
Choosing the Right Type of Industrial Automation for Your Factory
When thinking about the appropriate sort of industrial automation acquisition for the factory, some considerations must be made. The dimensions of the production plant, the assortment of goods produced, as well as changing production levels, will all be critical parameters in determining which configuration will best fit your requirements. Fixed automation systems, programmable automation systems, flexible automation systems, and integrated industrial automation systems are the four foremost types of industrial automation systems and they all have their respective benefits based on the manufacturing techniques.
- Should your business run activities that are predominantly repetitive in nature with very few possible tasks’ variations, then you run a risk of being a good candidate for fixed automation. This system is highly relevant in organizations where mass production is carried out with history and speed regardless of the direction of the company.
- With batch production premises and other scopes of production requiring regular changes of the product introduced to the market, programmable automation provides a better option. This system accommodates changes in the production because it consists of computers or programmable logic controllers to support the production process, thus it is very suitable for industries dealing with diverse product lines or undertaking varying tasks.
- In case your company works in a high market turbulence with many product variations and changes, the deployment of flexible automation, is what such companies usually go for. With this system, there are fewer productivity losses since the other task will be acquired and performed in a short time, which enables one to be in a position to meet customer needs.
- While specializing in broad operations that demand total supervision towards the production line, only elimination of production line’s peripherals structures Integrated Automation can offer. The integrated automation is a complex one that consists of many forms and utilizes the available technologies fully, that is automation systems, information collection and control feedback systems for effective and organized operation with little human intervention.
Finally, as stated in this summary, it is easy to pick the most efficient and effective system for your factory’s enhancement by knowing the definitions of industrial automation and also warehouse automation. It should be noted that every effort in implementing new technology would have drafted your decision as a commitment of improving your production assets and gaining relative advantage in the current business environment.
Omchele: Pioneering Automation Solutions Since 1986
At Omchele, since 1986, we have taken the first mover advantage in the industrial automation sector, where we have developed and provided products and services that suitably address the changing needs of the automation industry. We have nearly 37 years’ experience, during which we have been able to manufacture and offer approximately 3000 different products including proximity switches, photoelectric switches, cylinders, pneumatic valves. Permanent factory installations, Documentation of production processes, Quick response manufacturing – all these factors allow high performance levels in any industry. The HEBAI brand and other certified products from us are part of the reasons we are able to offer a reliable partner in the provision of automation solutions regardless of the world in question.
While in the modern era economics plat an important role in promotion of many businesses, all the automation offerings developed under the Omchele brand encourage ethical practices as well. From after-sales service and shipping from 6 warehouses nationwide to custom CNC machining services, we will make everything possible in order to ensure client’s comfort. With 72000 active clients and 86 branches, Omchele will offer you a journeyFrom OEM to migrations to Industry 4.0 , that’s how we appreciate as automation does make any product smarter.
