6 Benefits of Industrial Automation

There are inherent limits in manufacturing, limits that every manufacturing manager struggles against.

For example, there's always a price for raw materials that must be paid. Steel needs to be heated to a certain temperature over an exact amount of time to be processed. There are costs, time, and energy that must be paid and expended in manufacturing.

These base costs are why successful manufacturers are constantly seeking incremental improvements and process enhancements to improve revenue. Reducing the cycle time for a single step means you can send more products out the door while enjoying greater profitability. Lower scrap means raw material costs go down.

Small improvements can be the difference between profit and loss.

This is why there is so much opportunity to be found in industrial automation applications. However, many industries and manufacturers have been slow or reluctant to invest.

What Is Industrial Automation?

Industrial automation is the use of automated systems to monitor and control processes in industrial manufacturing. It’s a computerized or digital system that's connected to a machine, device, or process which then collects data or uses information to fulfill a task or function.

Typically, these systems operate automatically and independently to perform repetitive functions or tasks. When integrated, industrial automation can reduce the need for manual work while improving the operational efficiency of the business.

The Benefits of Industrial Automation

Most, if not all, manufacturers have implemented some industrial automation systems.

With new technologies, better sensors, more capable robots, analytic and control systems, machine learning, artificial intelligence, and the Internet of Things, modern industrial automation now provides more opportunity for manufacturers than ever before.

Even so, business leaders need to analyze and review the efficacy of investing in new industrial automation systems.

Is it too expensive? Are the benefits uncertain? Does it mean replacing employees, friends, and co-workers with a robot? What are the risks? Do they have the expertise and capability on staff to maintain and optimize the system? Before starting an industrial automation project, manufacturers need to analyze the expected benefits and compare it to the costs.

Let’s look at a few of the potential benefits of modern industrial automation, and the areas where manufacturers can expect to see a return.

Increased Productivity

The physical limit of an automation system is much higher than that of human workers. The system doesn’t need to take a break, eat lunch, or clock out after a shift. There is no burnout or bad days. With automation, some systems can run constantly, 24 hours a day.

Typically, this a significant improvement in overall productivity, especially when automation is used to support processes that slow production velocity. It also mitigates some of the pressure and challenges faced by manufacturers experiencing worker shortages and hiring gaps.

Increased Production Uptime

When automation systems include monitors and sensors that aid in the completion of a manufacturing process, the data they collect can often be used to improve production uptime. Automated data analysis can be used to track and monitor risk factors that can lead to machine failure. This gives maintenance and production leaders time to adjust work schedules in order to prevent downtime or service interruption. Data analysis can also increase output and maintain quality standards by optimizing maintenance schedules and identifying machines that aren’t working properly.

Lower Costs

While industrial automation requires a significant initial investment, manufacturers recover these costs over time due to long-term increases in productivity and reduction in manufacturing costs. Increased uptime, lower maintenance and repair costs for machines, and better analytics will all reduce expenses and lower the cost per unit.

Increased Quality and Conformity

With the automation system handling repetitive work, mistakes and errors that lead to quality gaps and nonconformance can be eliminated. Automation can precisely duplicate work each time, increasing reliability and delivering a uniform product. In addition, automation systems can also be used for quality reviews that automatically identify errors early on in the process, so they won’t impact work downstream.

Increased Manufacturing Flexibility

As automation takes over repetitive, but often time and labor-consuming tasks, it will free up workers for more complex work, like custom products or smaller product runs. With automation handling repetitive processes, your experienced and skilled team members can focus on this higher-priority work.

Improved Worker Safety and Satisfaction

With workers focused on higher-value, more exciting work, overall site morale will improve. Humans can work on more fulfilling projects, which increases satisfaction and prevents burnout. In addition, automation systems can be used in dangerous or uncomfortable tasks, which improves the overall safety of your operation. While it can be difficult to calculate the value of safety or satisfaction, both contribute to overall productivity.

Better Manufacturing with Industrial Automation

In the past, industrial automation was seen as a tool for enterprise manufacturers only. Sure, many manufacturers purchased a CNC machine, had an assembly line, or used robotics in finishing, but a full industrial automation strategy was simply out of reach.

Today, with better technology, lower equipment costs, and more opportunity for manufacturers, industrial automation is more promising than ever before. Take time to evaluate a potential industrial automation system. See where there is opportunity for improvement by identifying potential benefits and linking them to your current operations. This way, you can calculate the returns on industrial automation and build a case for the investment.

If you have questions or would like to talk to an automation expert about your needs, contact the team at OTC. Work with them to discuss your operations, potential budget, challenges, and requirements.