Curious about the different types of automation?
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You&#;re not alone. Many companies are excited by the prospect of increasing efficiency and productivity with some help from automated equipment.
But which technology type is right for your application?
Let&#;s take a deep dive and find out!
What Is Automation?
Automation is a term for technology and innovation applications where physical human input is minimized. This may include IT automation, business process automation (BPA), industrial robotics, and personal applications like home automation.
Automation includes using various equipment and control systems such as factory processes, machinery, boilers, heat-treating ovens, steering, etc. Examples of automation range from a household thermostat to a large industrial control system, self-driven vehicles, and warehousing robots.
When automation is used in industries or manufacturing, it is called industrial automation. The industrial automation market grew globally, reaching $191 billion in , and is expected to reach $395 billion by .
6 Types of AutomationAutomation has wide applications. There are many automated processes you probably already know.
But identifying instances of automation is more important than understanding the broad categories of automation.
So, the following are 6 types of automated manufacturing systems:
Fixed animation, or hard automation, is an automation type in which the configuration of the manufacturing process stays fixed. This type of automation is therefore best suited for completing a single set of tasks repeatedly. For instance, if the automation procedure repeats the same tasks with identical units, it is fixed automation.
In effect, fixed automation machines are controlled by programmed commands and computers that direct them on what to do, give notifications, and measure production metrics. Fixed automation is generally suitable for large-volume products. The operation in fixed automation&#;s sequence isn&#;t complex and involves fundamental functionalities like rotational or plain linear motion or both.
Fixed automation is best suited for:
An example of fixed automation in use is soft drink factories. They have fixed machines that enable their production of large quantities of soft same-unit drinks to meet high demands.
Programmable automation systems involve automated or robotic equipment controlled through programming for batch production. The automation is controlled through a program, which is coded in ways that allow it to change its sequence anytime there&#;s a need.
This industrial automation type allows easy product or process changes by modifying the control program. This also allows the implementation of new processes.
Programmable automation is most used in systems that produce similar items using the same automated steps and tools. It&#;s ideal for medium-to-high production volumes and suitable for batch production processes such as factories making food variants. If the product/production needs changing, the machine is reprogrammed.
In programmable automation, products are made in batch quantities at a time ranging from a few several dozen to several thousand units. And for each new product batch, the production equipment must be reprogrammed or changed over to accommodate the new or required product style.
Programmable automation is well suited for low/medium demand production and occasional changes in products:
In the last example, you only need to set a speed or temperature, and the machines consistently produce programmed outcomes.
In a numerical control machine tool, the program is coded in computer/program memory for each different product style, and a computer program controls the machine tool.
Flexible automation, also known as soft automation, is an extension of programmable automation with next-to-zero downtime and minimum manual changeover procedure. This means greater flexibility and results in a greater production rate.
Essentially, flexible automation allows the production of different product types without the need for complex reprogramming. This allows production to switch between tasks minimizing downtime.
Building upon programmable automation, flexible automation systems often involve precise electromechanical controls. Examples are industrial robots and multipurpose CNC machines.
Flexible automation is ideal for medium-demand and constant changes/large variety in products.
Industries that use flexible automation include food processing, textile manufacturing, and paint manufacturing.
Note: The chart below shows what options might be best when choosing an automation type, depending on the variety and product demand.
Process automation means using technology to automate manual processes through data and systems integration. It combines all other industrial automation types into one, connecting flexible and integrated automation systems.
Process automation is used more in businesses where software programs/apps execute a set of tasks within the modern, digital enterprise. It manages business processes for transparency and uniformity to increase a company&#;s workflow.
Using process automation can help increase productivity and efficiency in businesses. It can also provide new insights into business challenges and suggest solutions.
A process automation system typically has three functions:
The scope of process automation may be broad. Many businesses start by automating simple departmental processes or support, such as flow management in a warehouse, data capture, predictive maintenance, or expense approval.
Other businesses may automate more complex, advanced, or cross-functional activities using advanced technologies. For example, full warehouse automation to support event-driven, mission-critical system delivery.
An integrated automation system is a comprehensive automation framework that automates an entire manufacturing process through computer control.
Integrated automation aims to reduce the complexity of many independently automated work processes by streamlining communication between various automated processes.
For instance, rather than allowing three automated systems to function separately, integrated automation integrates them under one control system. So, data, independent machines, and processes will all work together under a single command system.
Overall, integrated automation is a holistic approach to industrial or manufacturing automation.
Robotic process automation (RPA) is a type of process automation where software technology makes it easy to create/build, deploy, and manage software robots that emulate and do human actions.
The robots are programmed with software technology to do rule-based tasks, such as extracting data from screens or insurance forms, arranging products on shelves, etc.
A business can use RPA tools to work and communicate with other digital systems, capture data, process transactions, and retrieve information.
But unlike human labor, robots do these tasks faster, more efficiently, and consistently.
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RPA is often quoted as a form of artificial Intelligence (AI), but it&#;s not. Unlike AI, RPA uses rule-based, structured inputs and logic to undertake tasks. The robots do what they&#;re told.
Financial firms were the first RAP adopters, but many companies in various industries now use it, including retail, healthcare, manufacturing, and warehousing.
Frequently Asked Automation Questions
Automation is the application of technology, programs, processes, programming, or robotics to achieve industrial or manufacturing outcomes with minimal human input.
Automation equipment includes machines, robots, and applications (like conveyors and special devices) used to automate production or warehouse activities with minimal human intervention.
There are different types of automated equipment for various industries, such as warehouse automation equipment, automotive, agricultural, food and beverage processing, etc.
Industrial automation is the application of automation equipment, control systems, robotics, machines, and computer software to perform tasks with limited human involvement.
Industrial automation can improve quality, productivity, and safety in warehouses, factories, industrial manufacturing, and other processes.
Industrial automation examples include:
Industrial automation involves using technology to manage repetitive tasks, including hazardous tasks that risk the safety of human laborers. Industrial automation increases the accuracy of production and improves factory/industry safety.
Common implementation examples of industrial automation systems include:
Computer automation refers to the use of computer software, electronics, computer-controlled devices, programming, and sometimes robots to control processes and replace manual work in warehouses, data centers, factories, cloud deployment, etc.
In , Oliver Evans developed an automatic flour mill, the first completely automated industrial process with continuous production without any human intervention. But the term &#;automation&#; was not used until .
The term automation is attributed to D.S. Harder, an engineer manager at Ford Motors Company, in . Harder coined automation in the automobile industry, describing it as the increased mechanization of production lines to control and improve production rates.
William Grey Walter developed the first autonomous robots in automation in .
In general, automation is technology machines that perform a process using computer-programmed commands with automatic feedback control to execute instructions.
This results in a system that can operate without human intervention to direct tasks, streamline processes, and improve production rates.
There are 4 different levels of automation in manufacturing. In order from most general to most specific, they are:
This is the top level of industrial automation. This level manages the whole industrial automation system, with tasks like production planning, orders, customer and market analysis, sales, etc. This level deals more with commercial activities of the company/warehouse and less with technical aspects.
At this level, monitoring systems and automatic devices facilitate the controlling and intervening functions in automatic systems, for instance, human-machine interface (HMI). It involves supervising various parameters and files, setting production targets, setting machine start and shutdown, historical archiving, etc.
This level involves more computer programming and human supervision. Supervisory Control and Data Acquisition (SCADA) or Distribution Control Systems (DCS) are popularly used at this level.
The automation control level has various automation devices, such as robots, CNC machines, PLCs, etc., which acquire the process parameters from sensors and other field-level devices. This level involves a small level of human interaction and supports automated systems&#; control function and strategy.
The lowest automation level is field automation, which includes the field devices like sensors, barcodes, valves, relays, actuators, etc. These automatic devices transfer data of processes and machines to a next higher level for monitoring, analysis, and control.
Some common types of automated material handling equipment include:
Automation is meant to streamline operations and improve a company&#;s workflow. Automaton reduces time, effort, cost, and manual errors while giving your business more production efficiency, rates, and outcomes.
Repetitive tasks can be completed faster to increase production rates and produce high-quality results without human error. Overall, the purposes of industrial automation are:
Automation is the creation and application of technology and systems to monitor and control the production, delivery, and service of products and services. Overall, automation is used to streamline production/manufacturing workflow, monitoring, and control to limit human involvement, reduce errors, improve accuracy, increase the production rate, and save costs.
Automation has many benefits for businesses and workers. Here are the core benefits:
Automation is present in factories, warehouses, modern businesses, schools, hospitals, and homes of all sizes, among other areas, to streamline operations and increase efficiency. Automation has different functions for different uses.
Automation has subtle features in common software apps, with obvious implementations like autonomous robots and self-driving vehicles.
Examples of automated systems include:
Examples of the latest automation technologies are:
Conclusion
That&#;s it: All 6 different types of automation.
Is automation &#;good&#; or &#;bad&#;? There are arguments on both sides of this issue. On one hand the cost of production on a per item basis is generally lower, on the other hand it is often said that automation takes jobs from people. The following is from the first chapter of my book:
Human beings have been making things for many thousands of years. Originally most products were made on an individual as-needed basis; if a tool was required it was fashioned by hand and in turn used to make more tools. As time passed, more complex techniques were developed to help people accomplish fabrication and production tasks. Metalworking technology, weaving looms, water-driven grinding mills and the development of steam and gasoline engines all contributed to a greater ability to make various products, but things were still generally made one at a time by craftspeople skilled in various techniques. It was only after the industrial revolution and common use of electrical energy and mechanisms that manufacturing of products on a large scale became commonplace.
Some disadvantages of automation are:
&#; Technology limits. Current technology is unable to automate all desired tasks. Some tasks cannot be easily automated, such as the production or assembly of products with inconsistent component sizes or in tasks where manual dexterity is required. There are some things that are best left to human assembly and manipulation.
&#; Economic limits. Certain tasks would cost more to automate than to perform manually. Automation is typically best suited to processes that are repeatable, consistent and high volume.
&#; Unpredictable development costs. The research and development cost of automating a process is difficult to predict accurately beforehand. Since this cost can have a large impact on profitability, it is possible to finish automating a process only to discover that there is no economic advantage in doing so. With the advent and continued growth of different types of production lines, however, more accurate estimates based on previous projects can be made.
&#; Initial costs are relatively high. The automation of a new product or the construction of a new plant requires a huge initial investment compared to the unit cost of the product. Even machinery for which the development cost has already been recovered is expensive in terms of hardware and labor. The cost can be prohibitive for custom production lines where product handling and tooling must be developed.
&#; A skilled maintenance department is often required to service and maintain the automation system in proper working order. Failure to maintain the automation system will ultimately result in lost production and/or bad parts being produced.
A few advantages of automation are:
&#; Replacing human operators in tasks that involve hard physical or monotonous work.
&#; Replacing humans in tasks performed in dangerous environments such as those with temperature extremes or radioactive and toxic atmospheres.
&#; Making tasks that are beyond human capabilities easier. Handling heavy or large loads, manipulating tiny objects or the requirement to make products very quickly or slowly are examples of this.
&#; Production is often faster and labor costs less on a per product basis than the equivalent manual operations.
&#; Automation systems can easily incorporate quality checks and verifications to reduce the number of out-of-tolerance parts being produced while allowing for statistical process control that will allow for a more consistent and uniform product.
&#; Economic improvement. Automation can serve as the catalyst for improvement in the economies of enterprises or society. For example, the gross national income and standard of living in Germany and Japan improved drastically in the 20th century, due in large part to embracing automation for the production of weapons, automobiles, textiles and other goods for export.
&#; Automation systems don&#;t call in sick!
Overall, the advantages would seem to outweigh the disadvantages. It can be safely said that countries that have embraced automation enjoy a higher standard of living than those that have not. At the same time, a concern is often aired that automating tasks takes jobs from people that used to build things by hand. Regardless of the social implications, there is no doubt that productivity increases with the proper application of automation techniques.
What do you think? Is automation &#;good&#; or &#;bad&#;?
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