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Factory Automation
Introduction
A description of factory automation with a list of companies that provide, implement, and plan it
You will learn:
- What is Factory Automation?
- The Types of Factory Automation
- How Factory Automation is Planned and Implemented
- Equipment for Factory Automation
- And much more …
Chapter 1: What is Factory Automation?
Factory automation involves integrating advanced technology processes to boost productivity, elevate manufacturing output, and significantly improve production efficiency. Through a seamless set of operations, products are manufactured, assembled, packaged, and made ready for distribution and shipping. The core of factory automation depends on computer programming to manage each processing and production phase efficiently.
The rapid expansion of factory automation stems from rising global market competition. To retain a competitive edge, businesses are adopting factory automation to optimize operations, cut costs, and enhance productivity. Factory automation enables continuous 24-hour production with minimal errors, reduced waste, and outstanding product quality.
Factory automation includes extensive technology systems regulated by distributed control systems (DCS) or supervisory control and data acquisition (SCADA) systems. Programmable logic controllers (PLCs) and remote terminal units (RTUs) strategically placed throughout the factories take signals from the system to direct equipment in executing tasks. PLCs and RTUs are tailored to fit the specifications of products and processes. Crucial components of a factory automation system comprise PLCs, advanced solutions, cybersecurity measures, and operational technology (OT). Each element is integrated into the system to oversee and manage factory operations effectively.
Chapter 2: Types of Factory Automation
Factory automation plays a pivotal role in modern industrial manufacturing and smart factory operations. As manufacturing processes have evolved, automation has enabled facilities to improve efficiency, productivity, and product quality—all while reducing operational costs. Defining factory automation is challenging due to its diverse applications across industrial sectors, from automotive manufacturing and electronics assembly to food processing and pharmaceuticals. Depending on the specific product requirements and production environment, each automation system is tailored to meet unique client needs, leveraging various technologies such as robotics, industrial control systems, programmable logic controllers (PLCs), and artificial intelligence (AI).
The concept of automation often conjures images of autonomous machines and industrial robots working in harmony to achieve seamless mass production. While this image may seem futuristic, advances in automation engineering, machine vision, and industrial IoT (Internet of Things) have made such visions an everyday reality for many manufacturers. Today’s factory automation systems are at the forefront of Industry 4.0, driving transformations in industrial manufacturing through data-driven, interconnected, and self-optimizing solutions.
Factory automation systems range from those that require significant human-machine interaction (HMI) to fully autonomous solutions with minimal human intervention. Many production plants deploy collaborative robots (cobots) that work safely alongside people—combining the strengths of human operators with the precision and speed of automated equipment. The choice between automated and manual processes depends on required throughput, product variability, quality standards, and scalability.
The rapid expansion of automation technology, fueled by advancements in robotics, machine learning, and cloud-based production monitoring, is transforming factories worldwide. The global factory automation market is projected to reach $400 billion by 2030, reflecting the widespread adoption of automation solutions across industries seeking to optimize production throughput, workplace safety, and resource utilization.
There are four primary types of factory automation systems: fixed automation, programmable automation, flexible automation, and integrated automation. These categories are distinguished by factors such as production volume, workflow flexibility, system complexity, programming capabilities, and degree of human involvement. By understanding the strengths, limitations, and best-fit applications for each type, manufacturers can select the optimal automation system to achieve their operational goals.
Fixed Automation
Fixed automation, also known as hard automation or special-purpose automation, is commonly used for high-volume, mass production of a single product. These systems are designed and configured for dedicated processes, such as repetitive assembly line operations, where minimal variability is required. Once set up, fixed automation systems are inflexible and cannot be easily reprogrammed or repurposed for other products. The initial engineering and installation require substantial capital investment, making these systems cost-effective only when operating at scale with predictably high demand over time. Due to their durability and throughput capability, fixed automation solutions are popular in sectors like automotive manufacturing, electronics, and industrial component production.
Despite their rigidity, fixed automation employs advanced technologies, such as automated handling equipment, machine vision systems, and custom tool integration that deliver consistent, high-precision output. The costs associated with these assets are typically amortized over their long operational lifespan, making them a cornerstone of lean manufacturing environments focused on continuous, reliable output.
Examples of Fixed Automation Systems
- Automated Assembly
- Web Handling
- Converting Systems
- Chemical Processes
- Conveyor Systems
- Transfer Lines
- Paint Processes
- Coating Processes
Programmable Automation Systems
Programmable automation offers manufacturers the flexibility to switch between different products or product variants by simply updating system instructions and control programs. Often implemented with CNC (computer numerical control) machines, PLCs, PACs (programmable automation controllers), and even industrial robots, programmable automation supports batch manufacturing and mid-volume production runs. This flexibility is particularly valuable in industries with variable demand, frequent product changeovers, or customization requirements such as electronics, aerospace, and consumer goods.
In programmable automation environments, reconfiguring production lines is as simple as uploading or modifying software programs—eliminating the need for manual tooling changes. Such systems excel at producing small to medium batches of similar products, supporting agile manufacturing strategies and just-in-time production approaches. While initial costs and technical expertise can be barriers to entry, programmable automation significantly reduces labor costs, increases product consistency, and minimizes downtime related to product transitions.
Key examples include CNC machining centers, robotic welding cells, pick-and-place robots, automated guided vehicles (AGVs), and advanced warehouse automation systems. Modern programmable automation often incorporates IoT sensors and manufacturing execution systems (MES) for real-time process monitoring and optimization.
Automation Production Lines
Automated production lines are the backbone of many industrial automation environments, enabling high-speed, repeatable manufacturing through a series of interconnected workstations. Similar to the historic production innovations of Henry Ford, today’s automated production lines deploy sophisticated transfer systems—such as conveyor belts, linear actuators, or robotic transporters—to move parts between work cells. Each station is typically programmed to complete specific tasks in a predefined sequence, utilizing smart controllers, PLCs, and industrial network protocols (like Ethernet/IP or PROFINET) to ensure precision and synchronization.
These production lines are extensively used in the automotive sector, electronics manufacturing, packaging, and consumer products. Human workers might still monitor processes, handle exceptions, or conduct quality assurance tasks, but the automation system handles the bulk of repetitive labor. Enhanced by sensor technology and data analytics, modern automated lines support predictive maintenance, improve OEE (overall equipment effectiveness), and reduce product defects.
End-to-End Automation (E2E)
End-to-end automation delivers a fully automated manufacturing process from raw material intake to final product packaging and distribution. This holistic approach is enabled by interconnected hardware and software solutions that span the entire workflow, including ERP (enterprise resource planning), SCADA (supervisory control and data acquisition), and MES integration. The lights-out factory or dark manufacturing environments exemplify E2E automation, where operations continue uninterrupted around the clock with limited human supervision. Such advanced systems drive substantial productivity gains, reduce risk of human error, enhance traceability, and create resilient supply chains.
As manufacturers strive to implement Industry 4.0 and smart factory technologies, E2E automation leverages robotics, AI-powered quality control, predictive analytics, and seamless data exchange for real-time optimization. Typical E2E solutions may include automated material handling, robotic process automation (RPA), machine learning for predictive maintenance, autonomous mobile robots (AMRs), and integrated cloud dashboards for plant-wide visibility.
Successful implementation of end-to-end automation relies on robust OT (operational technology) and IT architecture. It is often paired with lean manufacturing and Six Sigma methodologies to achieve cost reduction, increased throughput, enhanced profitability, and world-class product quality.
Flexible Automation (FA)
Flexible automation, or soft automation, is designed to adapt rapidly to changing production requirements, supporting high-mix, low-volume manufacturing and multiple product variants. Unlike fixed automation, flexible systems can accommodate frequent changeovers with minimal downtime due to their reliance on programmable technologies, robotic arms, and AI-driven control platforms. FA bridges the gap between programmable automation and full integration by allowing the reconfiguration of both equipment and software to handle customized orders, variable lot sizes, and shifting customer demands.
Flexible automation solutions are highly valued in industries such as automotive, electronics, medical devices, and assembly operations where unique or complex products are required. These systems optimize throughput and operational efficiency while maintaining exceptional quality standards. Robots, CNC machinery, and collaborative automation tools can be re-tasked quickly by adjusting program codes or process logic—empowering manufacturers to bring new products to market rapidly and cost-effectively.
In addition to production adaptability, flexible automation enables rapid prototyping, concurrent engineering, and streamlined customization—supporting industry trends toward mass personalization and agile supply chain strategies.
Integrated Automation
Integrated automation (often described as Computer-Integrated Manufacturing or CIM) brings together all manufacturing operations—including design, procurement, production, quality management, and distribution—into a seamless, digitally-connected ecosystem. These advanced systems deploy a combination of industrial robotics, automated inspection, real-time data analytics, and centralized control dashboards. Integrated automation creates closed-loop feedback that facilitates continuous improvement, traceability, and end-to-end process optimization.
Common components of integrated automation include distributed control systems (DCS), fieldbus communication protocols, IIoT (Industrial Internet of Things) sensors, and advanced MES platforms. The result is synchronized operation of all automation assets, from CNC machines and robotic arms to AGVs and automated storage and retrieval systems (AS/RS). These solutions minimize errors, reduce manual touchpoints, and accelerate time-to-market, delivering competitive advantage in fast-paced industrial markets.
Integrated automation supports digital transformation initiatives, scalable smart manufacturing, and sustainable production practices. Automated monitoring software, cloud-based analytics, and cyber-physical systems ensure higher reliability, enhanced security, and predictive decision-making across the value chain.
As evidenced by these automation types, the landscape of factory automation is multifaceted and continues to evolve rapidly. Related concepts and terminology often used interchangeably include industrial automation, process automation, artificial intelligence manufacturing, robotics integration, 3D printing, additive manufacturing, and digital twin technology. Each of these approaches represents a pathway toward achieving greater efficiency, scalability, and competitiveness in modern manufacturing settings.
Factory Automation Category List
Chapter 3: Factory and Industrial Automation Tools
The tools of factory automation are advanced technological controls, industrial management systems, and automation devices specifically designed to eliminate human error, reduce operational costs, and drastically shorten production cycles. As Industry 4.0 continues to transform manufacturing, more production facilities are turning to factory automation solutions because of their enhanced efficiency, system reliability, precision, and ability to maintain tight tolerances. Core to factory automation is the integration of digital, computer-controlled, and mechanical technologies that work together to optimize and streamline complex manufacturing processes.
Leading industrial and factory automation companies excel in providing tailored strategies for implementing automation tools and smart manufacturing solutions that radically improve profitability by minimizing labor expenses and optimizing production output. Every automation system is engineered to address the unique requirements of both the product and the operational environment. As smart factories and automated manufacturing systems gain traction, custom automation enables seamless scalability and adaptability for diverse applications and industries.
Supervisory Control and Data Acquisition (SCADA)
SCADA, or Supervisory Control and Data Acquisition, is an essential industrial automation system composed of software platforms and hardware components installed on centralized computer networks that act as interfaces between industrial equipment and plant operators. SCADA systems empower manufacturers to collect, visualize, and analyze production and process data in real time, support remote monitoring, and ensure effective process control. Operators use human-machine interfaces (HMIs) to enter instructions, adjust parameters, and closely monitor factory processes, all from a single, centralized dashboard.
Through the integration of SCADA, production teams achieve access to real-time manufacturing data from anywhere in the world, enhancing operational visibility and control. SCADA efficiently collects data from programmable logic controllers (PLCs) and remote terminal units (RTUs), ensuring supervisors and plant managers can make informed decisions that boost efficiency, increase safety, and drive continuous process optimization. By seamlessly interfacing with equipment, robotics, and machinery across manufacturing lines, SCADA not only enhances production oversight but also assures regulatory compliance and the highest standards of equipment safety.
The primary components making up a SCADA system are programmable logic controllers (PLCs) and remote terminal units (RTUs)—microcomputers that communicate with process machinery, HMIs, industrial sensors, and other automation devices. SCADA platforms are highly adaptable to any industrial application, including discrete manufacturing, power generation, utilities, oil and gas processing, chemical plants, water treatment facilities, and more. The use of robust SCADA architectures reduces downtime, lowers maintenance and operating costs, and ensures smooth, predictive, and failsafe operations across all industrial equipment.
When a malfunction or anomaly occurs, embedded industrial sensors transmit data through the SCADA network to relevant personnel via alert notifications or automated work orders. While SCADA and the Industrial Internet of Things (IIoT) both monitor and control connected equipment, IIoT excels in offering cloud-based data storage, remote analytics, and cross-platform integrations. By leveraging IIoT and SCADA together, businesses can unlock powerful predictive maintenance and advanced diagnostic capabilities for preventing unexpected failures and maximizing asset uptime.
Programmable Logic Controller (PLC)
PLCs (Programmable Logic Controllers) are rugged industrial computers engineered for real-time automation, sequencing, and process control. These controllers—vital for process automation—are equipped with specialized hardware and software to interpret inputs, execute control functions, and produce precise outcomes, thereby increasing manufacturing efficiency and productivity. PLCs are used to automate electromechanical processes in diverse industries, such as automotive assembly lines, food and beverage manufacturing, packaging, and even in amusement parks for ride control. The two central components of PLCs are the Central Processing Unit (CPU) and the Input/Output (I/O) interface.
- Central Processing Unit (CPU) – The CPU is the program execution engine that coordinates system activity, leveraging its processor, system memory, and integrated logic circuits. It includes a microprocessor, memory chip, and communication modules for interfacing with both field devices and higher-level network controls. The CPU can shift between programming mode (for updating logic or ladder diagrams) and run mode, where it executes instructions and remotely manages process operations. Data acquired from industrial input devices (e.g., switches, sensors, and actuators) is processed for real-time decision-making. Program scan cycles occur rapidly—often in milliseconds—enabling the CPU to efficiently respond to changes in manufacturing conditions and production demand.
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Input/Output (I/O) Interface – The I/O system bridges external industrial devices and the PLC’s CPU, accepting status updates from input sources and relaying control signals to output actuators or end devices. The CPU processes incoming data and dynamically adjusts output operations based on the custom logic programmed by engineers. All PLCs essentially follow three major functional cycles:
- Input Scan – Constantly monitors and updates status from all field input devices.
- Program Scan – Interprets and implements user-defined logic and sequencing instructions.
- Output Scan – Transmits real-time responsive signals to all connected output hardware.
PLCs are configurable to meet the specialized needs of different manufacturing and processing industries, such as pharmaceuticals, batch processing, water resource management, and discrete manufacturing. Custom software solutions and data handling protocols are adjusted to fit the application, enabling maximum operational flexibility.
The most widely used PLC programming languages, as recognized by the International Electrotechnical Commission (IEC 61131-3), include ladder logic diagrams, structured text, function block diagrams, sequential function charts, and instruction lists. Selection of the optimal language depends on user competency, specific application demands, and ease of troubleshooting during system maintenance. Each language offers unique strengths for particular industrial automation tasks, ensuring robust performance and simplified diagnostics.
To standardize PLC hardware and software globally and ensure high levels of automation safety, the International Electrotechnical Commission (IEC) introduced comprehensive standards that cover equipment design, programming interfaces, communication protocols, and cybersecurity measures. With these evolving standards, PLCs remain at the forefront of modern industrial automation and smart manufacturing initiatives.
Remote Terminal Units (RTU)
Remote Terminal Units (RTUs) are intelligent field devices integral to distributed industrial automation systems. RTUs gather data from sensors, instruments, and actuators in the field and transmit that data—either wirelessly or via wired networks—to centralized SCADA platforms for further analysis and response. In addition to data collection, RTUs support bidirectional communication by executing control commands, generating alarm notifications, and offering seamless integration with other plant automation hardware.
RTUs, also called remote telemetry units or remote telecontrollers, process signals from industrial field devices and communicate operational information for critical processes like oil and gas pipeline monitoring, power grid management, water and wastewater treatment, and mining operations. Modern RTUs have evolved to include programmable automation controller (PAC) features, rivaling the capabilities of PLCs at a lower cost for certain applications.
Configuration of RTUs can be accomplished using intuitive web-based interfaces or dedicated setup software, supporting popular programming languages such as Basic, Visual Basic, and C#. This adaptability ensures compatibility across a broad range of communication protocols, field devices, and network topologies. Their durable, robust construction makes RTUs suitable for deployment across geographically dispersed, harsh, or remote environments—sometimes hundreds of miles from the central SCADA monitoring station—facilitating critical data acquisition and remote process control in real time.
Distributed Control Systems (DCS)
Distributed Control Systems (DCS) serve as centralized brains for overseeing, coordinating, and optimizing complex industrial process operations in large-scale manufacturing environments. These advanced process automation platforms orchestrate subsystem activity using sensors, process controllers, actuators, field devices, and software, enabling real-time monitoring of production trends and seamless command issuance to controllers and equipment—including thousands of networked PLCs.
DCS architectures minimize single points of failure by distributing control logic across multiple redundant nodes, greatly improving plant efficiency, process safety, and reliability. This decentralization supports superior fault tolerance and system resilience, which is vital for 24/7 continuous operations in sectors such as petrochemical manufacturing, power plants, and large-scale batch production facilities.
The core components of a DCS system are:
- Control Nodes – Perform distributed control and decision-making functions
- Human Machine Interface (HMI) – Provides operators with user-friendly dashboards and visualization for interacting with processes
- Data Communication Network – Facilitates high-speed, secure data transfer between distributed devices, controllers, and HMIs
- Field Instruments – Includes industrial sensors, process actuators, analyzers, and other automation end devices
A crucial advantage of DCS is integrated data management. DCS platforms can consolidate plant floor operational data with business systems (such as ERP and MES databases), offering comprehensive insight into manufacturing activities and supporting data-driven decision-making. Advanced DCS solutions enable predictive maintenance, process optimization, intelligent supply chain integration, energy management, automatic quality control, safety compliance, batch tracing, remote process monitoring, advanced alarm management, and direct Industrial Internet of Things (IIoT) connectivity for future-ready smart factories.
Robotics
Robotics are a cornerstone of modern factory automation, driving unprecedented levels of speed, consistency, and operational efficiency in manufacturing. Industrial robotic systems—such as multi-axis robotic arms and automated guided vehicles (AGVs)—handle a variety of material handling, pick-and-place, machine tending, and repetitive assembly tasks, often far faster and with greater accuracy than manual labor. The widespread deployment of robotics in manufacturing lines reduces cycle times, boosts throughput, and ensures uniform product quality, making them indispensable for high-volume production.
Engineers program these robots to perform complex operations such as lifting, orienting, assembling, and packaging workpieces using sophisticated industrial control software. Robotics systems leverage advanced programming languages, vision systems, and sensor integration, allowing for heightened flexibility and precision on the factory floor. Robots’ ability to adapt to different product types and production requirements makes them ideal not just for repetitive high-volume applications, but also for specialized processes requiring sensitivity and careful handling—such as electronics assembly or pharmaceutical manufacturing.
However, successful robotics integration depends on careful evaluation of workflow requirements, production volume, and system compatibility. Not every automation project benefits from robotics—for low-volume, custom, or delicate production processes, other automation tools or collaborative robotics (cobots) may provide better value. Proper application of robotics leads to optimized productivity, improved plant safety, and a rapid return on investment for manufacturers investing in industrial automation and smart factory technologies.
Chapter 4: Software for Factory Automation
The complexity of factory automation requires innovative and technologically advanced computer software in order to oversee the thousands of actions and tasks performed by equipment. The discussion of software for industrial and factory automation covers a wide swath of technological solutions. Each type of software has aspects that are specifically honed for a particular product or industry.
As every person, manager, and business owner knows, the term computer software covers a long list of solutions. Although this is true, the types of software used for SCADA and DCS is complex, intuitive, and exceptionally technical due to the processes it is designed to oversee. Automation software is designed for business record keeping, customer orders, shipping, the operation of equipment, and production scheduling. Fortunately, industrial automation designers and solution providers have the tools and technology to assist their clients in choosing the perfect software.
Siemens
Siemens, a German company, provides a full spectrum of automation solution software from PLCs to all encompassing factory wide software systems. Part of their software includes virtual simulations that allow the testing of automation processes before implementing them.
Advanced Integration Technology (AIT)
AIT offers custom solutions for the complete integration of automated systems. They program and tailor their software to the type of product and includes material handling and quality control inspection devices. A feature of AIT systems is their Scorpion Vision Machine that performs high speed inspection of production lines.
Rockwell Automation
Rockwell specializes in PLCs, HMIs, and complete solution industrial software. The company is well known for its integration of specialized forms of equipment, which is a necessity in modern manufacturing. Rockwell’s Allen-Bradley ControlLogix can be scaled for small machines and factory wide complex production.
ABB
ABB, a Swiss automation control company, offers robots, PLCs, drives, motors, and software for specialized applications. The main focus of ABB is robots for manufacturing and logistics. An important part of the services that ABB offers is their collaborative robots.
Honeywell
Honeywell specializes in factory wide solutions by offering hardware and software. A key to Honeywell’s software package is their advanced security solutions to safeguard control systems.
Emerson
Emerson provides sensors, valves, actuators, and software for process control. The company’s DeltaV is a DCS system known for its flexibility and scalability for process industries.
The few software solutions listed above are a sampling of the many worldwide solutions that are available from France, Japan, the United States, and Germany. The types and sizes of companies that provide industrial automation solutions come in many sizes. The girth of industrial automation companies is due to the rapid and ever growing use of factory automation systems. As every automation solution company will say, it is essential to work closely with an expert when making the choice of factory automation solution.
Leading Manufacturers and Suppliers
Chapter 5: Factory Automation Equipment
As can be interpreted by the plethora of information regarding factory automation, there are several types of equipment that are used to complete tasks commanded by factory automation control systems. Although specialized types of equipment are common for factory automation, there are certain forms that are applicable for all systems.
Computer Vision
Computer vision is an artificial intelligence (AI) tool that gets information from images, videos, and objects, identifies them, and stores the data or sends it to a HMI. They use input to learn. Computer vision runs on algorithms that have data or images saved in the cloud. When computer vision recognizes a pattern, it uses the pattern to decide the content of other images.
Images captured by sensing devices, such as cameras, imaging methods, or other devices, are analyzed by the system. During analysis, the image is broken down and compared to patterns in the computer vision’s library. Users receive information about an image by requesting it.
Collaborative Robotics
Collaborative robotics is a blending of manual labor with automated devices. Often referred to as cobots, collaborative robots are designed to work safely with humans. They complete repetitive, menial tasks as their human partner works on more complex, thought provoking, and intricate activities. The basic design of collaborative robots is to complement and support the work of their human partner.
The work of collaborative robots and humans expands the number of applications that can be performed, resulting in increased productivity and efficiency. Part of the safety aspects of collaborative robots is their ability to lift and move workpieces too heavy or difficult for humans. Collaborative robots can position such a workpiece and adjust it in different positions for easy access.
Industrial Robotics
A rapidly growing part of product production is industrial robotics, which are a key part of end-to-end automation. Industrial robots are a step up from collaborative robots and are able to complete mundane repetitive tasks thousands of times a day. The use of industrial robots is beginning to find a footing in product production. The full capabilities of these technological wonders are constantly expanding and being examined.
Industrial robotics consists of multiple machines with robotic arms that operate on three or more axes. They are commonly used in warehousing and assembly lines due to their ability to repeat repetitive tasks quickly, efficiently, and accurately with exceptionally high precision. The number of industrial robots presently in use in the world is close to four million and rising. Tasks normally completed by industrial robots include assembly, material handling, spot welding, and applications requiring extreme precision.
Autonomous Guided Vehicles (AGV)
AGVs, also known as Autonomous Mobile Robots (AMRs) or Intelligent Autonomous Vehicles (AIVs), are material transport vehicles that use a guidance system to move about an industrial facility. The main uses for AGVs are in warehouses for moving goods, on assembly lines for supplying raw materials, and at the end of assembly operations for moving completed products to storage.
Initially powered by wires buried in the floor of a facility, modern AGVs use different navigation methods. They are a time saving device that removes the need for workers to transport materials and supplies.
Chapter 6: The Advantages of Factory Automation
Factory automation is an advantageous method for economically and efficiently producing high quality products. In essence, it takes mundane, boring, repetitive, necessary tasks, and bundles them together under a precision control system that oversees every aspect of an operation from raw materials to final product. The choice of using factory automation is dependent on several factors that have to be carefully researched and examined.
Planning
The data provided by SCADA and DCS systems assists management in making production and delivery decisions. Production volumes are easily controlled and manipulated in relation to customer requirements. In process decisions are made according to system data. Each step of a production process is visible, adjustable, adaptable, and accessible providing real time information.
Operating Costs
There are multiple cost benefits when using factory automation, which can perform the work of several people, depending on the task, quickly and efficiently. The removal of the human factor from assembly operations eliminates the need for heat to keep workers warm. In addition, labor costs are radically reduced.
Safety
A consideration that is often overlooked when assisting the benefits of factory automation is safety. All forms of automated devices are programmed with limitations that prevent them from harming workers. Most of the restrictions are in regard to sensing people in a workspace and stopping in such circumstances. The use of factory automation enhances worker safety and nearly eliminates any adverse effects to workers.
Quality
The use of automation in place of manual labor radically reduces the number of defective, imperfect, or poor quality products. The different methods that factory automation uses to check the quality and performance of processes and the compliance of final products with design specifications nearly eliminates low quality products.
In normal manual operations, each assembly line has a quality checker who randomly removes parts and products to examine them for adherence to quality standards. The process is inefficient and frequently misses errors and flaws. Such circumstances are not possible with factory automation, since every product and part is electronically examined.
Productivity
Factory automation systems can work 24 hours a day every day of the week without tiring or needing a break. The continuous operation of equipment increases productivity and ensures the fulfillment of orders. Every element of a factory automation system from the SCADA to the PLCs and RTUs works continuously to produce high quality products.
Waste Reduction
One of the calculations that is intermixed with production operations is a determination of waste that is produced by a process, which is due to several factors. The efficiency and control factors of factory automation nearly eliminates waste concerns since quantities, amounts, and materials are carefully monitored.
Footprint
With the removal of waste, the use of streamlined equipment, and the use of less energy, factory automation reduces a company’s environmental footprint. Since stored materials are timed and used efficiently, restocking is more coordinated removing the need for warehousing and assembly line storage space.
Reduces Outsourcing
Since cells have limitless capacity, parts can easily be produced in house to meet production requirements without the need for additional equipment, which is another factor that reduces costs.
System Integration
Every aspect of manufacturing is contained in one combined system that provides easy access. Hardware, software, and controls are housed in a single system that can be adjusted and changed using a set of commands. System integration and the ease of use are one of the main reasons that companies switch to factory automation.
As production needs change, the system can be retooled and repositioned. Robots, bar feeders, and APLs are repositioned and deployed to meet the needs of an application or part. In addition, the volume of production can be adjusted and switched between products without having to rebuild production lines. Adjustments to grippers and vision tools can be changed over in accordance with part sizes and shapes.
The central factor to system integration is the ability of robots to learn and adapt to new processes. This reduces changeover time and makes it easy to adjust to changing demand requirements.
Chapter 7: Factory Automation Implementation
When companies begin the process of investigating factory automation, they have researched, studied, and examined a variety of alternatives that meet their production needs. In most cases, they have assessed the objectives of the use of a system as regards product outcomes. Their diligent and meticulous research leads them to meeting with an industrial automation provider in order to plan factory automation implementation.
In many cases, automation experts recommend automating a small portion of production to get the feel of a system. Such a plan makes it possible to examine a system and become familiar with a system’s various aspects. Starting small and building helps reduce costs, which can be financially beneficial.
Knowledge
A complete and total understanding of every step of the production process is a necessity. Each step of production should be studied, examined, and monitored down to the smallest detail. Included in this learning process are suppliers, a time table for implementation, and an inventory of available resources.
Installation
Since the implementation of a factory automation system is a major time consuming process, in order to avoid production shutdowns, implementation schedules should include a reference to slow production times or production dark periods.
Integration
Elements that are part of existing operations have to be included in the change over to a factory automated system. This necessitates communication between the system and the existing elements. Adapting these components helps in saving time and streamlines the transition process.
Execution
As excited as people are about the installation of something new, it is important to be aware of adjustments that have to be made to conform to product requirements. Every factory automation system requires programming that meets the demands of a product. This includes tweaks and minor changes that increase efficiency.
Maintenance
Regardless of being a technological wonder, factory automation systems are huge pieces of equipment that are monitored for potential failures and problems. As part of installation, a maintenance and upkeep plan is developed to ensure peak performance and limited stoppages.
Training
One of the defining concepts of every factory automation system manufacturer is their dedication to providing the necessary knowledge to be able to operate the system. The objectives of such training vary depending on the technical sophistication of personnel, since some companies already have technical processes while others are taking steps in a new direction. The successful operation of a factory automation system is directly related to the capabilities and knowledge of the personnel that run it.
Chapter 8: Industries that Use Factory Automation
The use of factory automation is rapidly increasing as companies discover the profitability of its use and its efficiency. Although not all manufacturing can use factory automation, certain industrial processes are ideally suited for its use. Factory automation companies work closely with all forms of manufacturers to assist them in choosing a system that best fits their needs and requirements.
Automotive Systems
Henry Ford introduced the assembly line that increased the number of cars that could be produced per day. Each of the components for his cars were produced in small factories located in the Detroit area and shipped to an assembly plant. Ford’s invention has progressed over the years to today’s technologically advanced factory automation systems that have taken Henry’s ideas and brought them into the 21st century.
The range of parts, components, and assemblies produced for the auto industry using factory automation include engine blocks, transmissions, seats, dashboards, and bodies. Systems consist of a central controller that links all equipment to the system. Each machine is capable of producing different types of parts by simply changing the programming, removing Ford’s many little factories. Changes can be made quickly by adjusting the parameters of the system.
The process for producing a part begins with a design that is uploaded into the system that generates instructions for machines to produce the part. The central control system oversees the process and monitors production.
Aerospace
Factory automation is ideal for the aerospace industry, which requires exacting tolerances, exceptional dimensional accuracy, and high-quality parts. Engines, landing gear, and avionics systems are produced using the factory automation process. The complexity of aerospace parts demands precision programming and close attention to details. A key factor that makes factory automation ideal for aerospace is its ability to adapt to changes and quickly respond.
Electronics
A component that is produced for electronics using factory automation is printed circuit boards (PCBs) that necessitate proper positioning of minute components. The development of factory automation has made the production of PCBs easier, less time consuming and far more accurate. Like automobile components, the design of a PCB is downloaded into the central system that programs equipment and tools for producing the PCB.
Medical Instruments
As with aerospace parts, medical instruments require precision and accuracy that cannot be achieved by manual workers. The implementation of factory automation makes it possible to manufacture the most delicate and sensitive forms of medical tools, such as surgical tools, implants, diagnostic equipment, and artificial limbs. The necessity for hygienic conditions increases the desirability of factory automation for the production of medical instruments.
Food Production
The use of factory automation for food production is due to the processes ability to change from one food product to another with minimal adjustments. Unlike other industries, food producers manufacture a wide assortment of products using the same equipment. Similar to the medical instrument industry, food production requires antiseptically clean conditions to meet Food and Drug Administration standards, which makes factory automation an ideal process.
Conclusion
- Factory automation involves an array of tools, processes, and technologies that are combined and integrated to produce a product or perform an application.
- The key to factory or industrial automation is its programming that is designed to take in data and output instructions.
- The many benefits of factory automation include cost savings, improved product quality, high volume production, and on time deliveries.
- In most cases, factory automation is customized to fit the needs and requirements of the products being produced and the environment of production.
- Factory automation and industrial automation specialists work with their clients to design systems that match a client’s needs. The collaboration of supplier and client has led to years of success and profitability.
