OTC's Guide to Manufacturing Automation Solutions
Manufacturers are looking for every edge in the competitive marketplace.
Shave a few seconds off a production run to bring in additional revenue. Cut waste by a few cents per order to boost profit. Increase efficiency incrementally to see compounding returns every month.
While the goals are simple, the path and successful strategy can be perplexing. To reach their goals, more manufacturers are turning to manufacturing automation.
What Is Manufacturing Automation?
Automation is the use of technology, software, and tools to automate processes.
In manufacturing, this focuses on production processes, but it can also incorporate front office processes and tasks, engineering approvals, and shipping needs.
While many hear the term “manufacturing automation” and immediately imagine robots replacing humans on the shop floor, this is rarely the focus or goal of automation. More often, it is utilizing technology to manage simple and repetitive tasks so the more valuable human skilled labor resources can focus on higher-priority work. There are tasks that are better suited for automation. In other areas, there is work that can only be completed by a human.
Striking this balance is the key to successfully utilizing manufacturing automation.
Download Our Guide to Manufacturing Automation
Types of Manufacturing Automation
As you consider how to leverage automation technology for your manufacturing processes, it helps to know the types of automation currently available.
- Fixed automation uses machines dedicated to a specific task. There is little to no operator involvement, and it works best in manufacturing where large volumes of identical or similar products are produced. Tasks like machining, welding, and assembly can be handled by fixed automation.
- Programmable automation uses machines that can be programmed to perform different tasks. While operators are required to program and set up tasks, programmable automation offers more flexibility and greater efficiency than fixed automation.
- Flexible automation offers even more options than programmable automation, utilizing machines that can be reconfigured and programmed to perform additional tasks. Changes can be made even on the production line without having to stop and switch tools and machines. This is an excellent option for discrete manufacturers.
- Integrated automation uses multiple machines that are linked, or integrated, into one system. The machines communicate and share data, enabling automation across machines. This further increases efficiency, saves time, and reduces waste.
While this provides a brief overview of the types of automation, there are vast capabilities possible even within a single automation type. In many cases, it is better to consider your manufacturing goals and find the automation system that meets those goals, rather than picking an automation type and finding a place to use it.
There have never been more options, or more affordable options, for manufacturers ready to implement an automation strategy.
Getting Started with Manufacturing Automation
While the opportunities available for manufacturing automation have increased as the technology has become widely available and costs have gotten lower, many companies are still struggling to implement it.
The exact reasons for this struggle are varied, but it often comes down to the mistaken perception that manufacturing automation is expensive, difficult, complex, or risky. Many companies don’t see how it will work for them and their production processes. Perhaps they see it as a betrayal of their workers.
No matter the misconception or reason, with the right team and process in place, manufacturers can successfully leverage automation in production. Here are a few steps we’ve collected for manufacturers ready to get started with an automation project.
- You need to set manufacturing goals. By looking at smaller, achievable goals with an expected ROI, you can realize quick, easy wins that will provide motivation for future, more ambitious goals. In addition, you’ll identify key best practices as you go.
- Every company needs an automation team. By gathering key stakeholders on a team, you can align company efforts on the automation project. You’ll have key insight from different areas of the business, and champions spearheading the project with other employees.
- Start with a small trial to test the technology. Rather than shutting down production, set up a smaller, closed trial. Use automation at a single workstation or production line. Record key learnings from the trial to use in the wider implementation.
- Build a schedule and timeline for the implementation. By putting dates and a timeline on the project, you help communicate how the project will work and set accountability. This will help build support and excitement, and should reduce the worry and confusion many feel about automation.
- Set and communicate expectations. With automation, there can be a lot of misconceptions and assumptions about the capabilities of the system and what this can mean for everyone. Get ahead of the false assumptions by setting up training and answering questions. Quickly address any problems and welcome the feedback.
Just like every business is different, every manufacturing automation project will be different. Using the above steps and tips will provide you and your business with a road map for the project.
Working with the Experts on Manufacturing Automation
Manufacturing automation is the future of production. It’s letting machine technology manage tasks where it makes sense so your most valuable resource, your people, can handle higher-priority work. It’s not taking work away from people, it’s helping them do more.
The companies you work with during your manufacturing automation implementation project can have an impact on its success. Where some companies focus only on selling you the tools and technologies, others can provide the expertise, support, and experience that can give you an edge.
OTC Industrial Technologies and our companies have been leaders in manufacturing automation, providing the services and expertise manufacturers need. As an end-to-end solution provider of automation services, providing not only the latest equipment and sensors, OTC also offers fabrication services, engineering, repair, and service. In addition to the latest technology, OTC can provide the critical support you need to optimize and enhance your project. Contact OTC today to learn more.
Check out the latest trends impacting manufacturing and industrial automation.
What can automation do to improve your finishing operations? Find out here.
See how automation can help mitigate the labor crisis in manufacturing.
See how automation is increasing efficiency for the food and beverage industry.