The main goal of automated systems is to reduce human intervention. Human operators are prone to errors and fatigue, which can lead to a variety of problems. Adapting an automated system will yield substantial benefits in terms of profit, productivity, safety and quality. Listed below are the advantages and disadvantages of using automated systems.
Advantage:
More consistent production: when properly designed, robotic systems can reduce the amount of production time required by efficiently performing complex movements. Higher productivity means greater output and better profits. To achieve faster movements, the driver must provide sufficient force and the flow of movement of the linkages and joints must be smooth without any unwanted transitions. In addition, computers can process faster and more efficiently than humans. It is true that humans can process more complex information than computers, but when human error, breaks and sick days are taken into account, computers perform better.
Improved repeatability: Production lines are efficient because the repetitive sequence of movements is somehow "programmed" into the operators performing the work. This requires a minimum of decision making, where the operations are largely controlled by a specific set of pre-determined instructions. These repetitive motions can be broken down into simple translations and rotations that can be programmed into the robot. Repeatability is improved because the actuator is designed to have a nearly constant range of motion.
Precision and Accuracy: As mentioned earlier, actuators are designed to perform a constant range of motion. The characteristics of the actuator motion do not change unless there is a feedback signal or a change in the control variable. Automation systems can be calibrated to provide the same output with minimal or no deviation.
Improved Product Quality: With automation systems, products can be created consistently. Human error and lapses in subjective judgment are avoided. Automated systems operate on logic and evaluate whether a condition meets the desired output. Continuous validation can be done through a feedback system that is more effective than humans.
Better working conditions: Processes involving extreme temperatures, overpressurization, high forces, rapid movements and toxic substances can pose safety hazards to personnel. Automation allows robots to perform unsafe tasks, thereby eliminating injuries and even death.
Reduced operating costs: In addition to additional profits due to better quality and consistently higher productivity, other economic benefits can be gained from less raw material waste and lower labor costs. Reduced material waste is ensured through the use of automatic feeding systems that ensure consistent raw material usage. Optimizing the amount of feed material can be easily and effortlessly done through programming. In terms of labor savings, one robot can perform the work of multiple personnel. In the long run, these benefits will offset the high investment costs of installing an automated system.
Disadvantages:
High investment cost: High investment cost is the main factor that prevents process owners from setting up automation systems. In addition to sensors, controllers and actuators, an automation system consists of different auxiliary systems, such as power supplies, compressed air systems, hydraulics and lubrication systems. Robotic systems can cost around hundreds or even millions of dollars, depending on the complexity of the automation required.
Extra maintenance is required: Automation systems may not experience the same fatigue as human operators, but continuous operation leads to inevitable wear and tear of components. To maintain its optimal performance and longevity, regular maintenance is required to check for or prevent any issues that could lead to unplanned downtime.
Less versatile: Most automation systems cannot be easily reconfigured. Modularity and programmability are additional features that increase the cost of the equipment. Additionally, because robots operate only on specific instructions, any conditions outside of their programmed range can lead to unpredictable output or sudden system failure. A human operator can analyze these conditions and act accordingly.