In the fast-changing modern factory environment, factory automation offers a compelling way to improve quality, efficiency, safety, sustainability and security. As competition increases and margins are squeezed, factory automation paves the way for maximum profitability and better performance.
Defining Factory Automation
Factory automation is the combination of automation of end-to-end manufacturing processes. In a manufacturing environment, automation typically utilizes technologies such as pneumatic systems, hydraulics, and robotic arms to create more complex systems. In today's competitive environment, automation can help increase output and efficiency while reducing costs. It is also designed to significantly reduce the risks that operators may face when handling hazardous equipment.
Types of Breakdowns
Digitization and the Industrial Internet of Things (IIoT) underpin all types of factory automation, but that doesn't mean that all factories implement industrial automation in the same way. Here are some possible approaches.
Partially manual processes
This combines automation with human expertise and supervision, such as in partially automated manual workstations. Simple tasks are automated, but trained professionals make the final decisions. Partially manual processes are common in quality assurance and complaint management, for example, where companies believe that human judgment should still have the final say.
Automated stand-alone machine
Also known as automated assembly machines or specialized machines, these machines are set up to handle a specific repetitive action. This could mean feeding and handling parts or other robotic systems, visual inspection, packaging, welding, cutting, rotating indexing tables or many other single actions.
Automated Production Lines
They combine a series of workstations, each responsible for a specific operation. These workstations are connected by a conveyor system and an electrical control system, which means that the products are passed from one machine to another in a defined sequence and are handled in a different way by each of them on the way to completion. If the production line is fully automated, then you don't need anyone involved in the process at all. This means that the role reserved for people tends to focus on aspects such as system design, monitoring and supervision, and making enhancement adjustments, rather than the actual operation of the equipment.
End-to-end automated factories
The next step from here is end-to-end factory automation. These facilities are often referred to as "lights out" or "dark" manufacturing environments, simply because there are no people in the factory and you don't even need to turn on the lights. These plants can operate 24 hours a day, 365 days a year and are not limited by human capacity. In fact, most factories don't need anyone at all to supervise and adjust their processes or to check the quality of their products.