Curious about the different types of automation?
Contact us to discuss your requirements of high speed integrated production line. Our experienced sales team can help you identify the options that best suit your needs.
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 2021, and is expected to reach $395 billion by 2029.
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.
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
Are you interested in learning more about High Productivity 2 Sides 1 Coating Line? Contact us today to secure an expert consultation!
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 1785, 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 1946.
The term automation is attributed to D.S. Harder, an engineer manager at Ford Motors Company, in 1946. 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 1948.
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.
Productivity knows that when it comes to manufacturing, change can seem overwhelming, time-consuming and scary — to say the least. While not all change is created equal, many shops resist changing to automation for a number of reasons. The good news is that it doesn’t have to be that way, and automation integration shouldn’t keep you up at night nor should workers fear being replaced. In fact, you’ll be surprised by the number of productive hours you’ll gain and new projects and business you’ll be able to take on with automation. The best place to start is with Productivity’s applications and automation experts who are committed to helping companies implement innovative automation solutions that meet manufacturing challenges. They’ll guide you through the process of your robotics integration projects from start to finish. Whether you’re adding one or many robots, automating your turning production processes with bar feeders, automatic pallet loaders (APLs), or using vending systems to automate control of tooling and accessories, this guide will demonstrate the multitude of benefits of automation and help you make the best decision for your manufacturing facility.
With the push for Just-In-Time (JIT) manufacturing and the importance of reaching higher productivity and efficiency levels, automation in manufacturing is paramount. Over the decades, automation has become a standardized production tool empowering manufacturers to gain better control of their operations and production processes. With automation’s ability to streamline repetitive, hazardous, and tedious tasks, an automated system can perform load/unload tasks, processing, inspection, assembling or handling of parts unattended or lights out, allowing one employee to work on several machines or other jobs at the same time.
Automation in manufacturing can help lower costs, improve worker safety, reduce factory lead times, provide faster ROI, allow your operation to become more competitive, increase production output, and so much more!
Explore the benefits of automation in detail with this guide. You can also check out Productivity’s Robotics & Automation Services.
Robots can perform the work of three to five people, depending on the task. And bar feeders and APLs allow your machinists to attend to multiple machines at once. In addition to savings on the cost of labor, energy savings can also be significant due to lower heating requirements in automated operations. Automation integration streamlines processes and increases part accuracy, which means minimal material waste for your operation.
Automated cells, bar feeders and APLs remove workers from dangerous tasks. Your employees will thank you for safeguarding them against the hazards of a factory environment.
Automation can keep your process in-house, improve process control and significantly reduce lead times compared to outsourcing or going overseas.
Automation solutions are based on your unique needs and goals and pay for themselves quickly due to lower operating costs, reduced lead times, increased output and more.
Automated cells, bar feeders and APLs allow you to decrease cycle times and cost-per-piece while improving quality. This allows you to better compete on a global scale. Additionally, the flexibility of automation integration enables you to retool a cell to exceed the capabilities of your competition.
A robot has the ability to work at a constant speed, unattended, 24/7, as do bar feeders and APLs. Automation in manufacturing means you’ve got the potential to produce more. New products can be quickly introduced into the production process and new product programming can be done offline with no disruption to existing processes.
Automated cells, bar feeders and APLs typically perform the manufacturing process with better consistency than human machinists. This results in greater control and consistency of product quality.
By streamlining equipment and processes, reducing scrap and using less space, automation uses less energy. A key benefit of automation is that it reduces your environmental footprint which can save you real money.
Consistent production by automation integration allows a shop to reliably predict timing and costs. That predictability permits a tighter margin on almost any project.
Automated cells have large amounts of potential capacity concentrated in one compact system. This allows shops to produce parts in-house that have previously been outsourced.
Robots are designed on compact bases to fit in confined spaces. In addition to being mounted on the floor, robots can be mounted on walls, ceilings, rail tracks and shelves. They can perform tasks in confined spaces, saving you valuable floor space.
Productivity will work with you to provide a complete robotics solution system — hardware, software and controls. Your cell will be proven out at Productivity and shipped out production-ready — allowing you to start making parts as soon as it’s installed in your shop.
Over the next three decades, statistics show that more than 76 million baby boomers will retire and only 46 million new workers will be available to replace them. During this time, your demand for labor will continue, making automation a real and viable solution.
Download our new Benefits of Automation PDF.
The company is the world’s best coil coating machinery supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.