Why consider an automated production line?
A series of workstations connected by a conveyor system and an electrical control system is called an automated production line. Each of these workstations performs a specific task or operation, and products are processed at each workstation, performing different steps as the products move along the line in a set order.
Following programmed commands, an automated production line is a process where raw materials enter and finished products leave with little human intervention. Accurate, fast and consistent production processes increase production time and reduce the cost of manufacturing products, while reducing the room for human error and providing consistent output.
Performing heavy repetitive tasks can be dangerous and mind numbing, by introducing automation employees can improve their skills and avoid risks such as RSI and staff shortages, robots can also perform tasks deemed too dangerous for humans, being able to lift large amounts of weight and size with increased speed and endurance. Allow employees to become programmers and supervise the machines, providing input only when necessary.
There are three types of automation systems in production; hard automation (also known as "fixed automation"), programmable automation and soft automation (also known as "flexible automation"). The type of automation to be used depends on the product and volume.
These different types of automation have both advantages and disadvantages.
Hard Automation
Advantages
- Automated material handling
- Low unit cost
- High productivity
Disadvantages
- High initial investment
- Relatively inflexible in adapting to product changes
Programmable automation
Advantages
- Flexible to design changes
- Suitable for mass production
Disadvantages
- High investment in general purpose equipment
- Lower productivity than hard automation
Soft automation
Advantages
- Continuous production of variable mixtures to products
- Flexibility to respond to changes in product design
Disadvantages
- Medium production rates
- High investment
- High unit costs compared to hard automation
Automation or not?
A well-planned investment in automation can also have significant financial benefits. The ROI on the investment can be recouped within a year or two through reduced labor costs and increased output. Quick to embrace automation, many companies are now experimenting and reaping the rewards.