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 the technological controls, management tools, and devices that remove any concern for human error, help decrease costs, and substantially save production time. So much of manufacturing is moving to factory automation due to its efficiency, reliability, precision, accuracy, and high tolerances. Factory automation uses digital, computer, and mechanical technologies to smooth and streamline manufacturing processes.
Industrial and factory automation companies provide clear outlines of how to custom plan automation tools that can radically change and improve profitability by lowering labor and production costs. Every automation system is custom built to meet the needs of a product and the environment.
Supervisory Control and Data Acquisition (SCADA)
SCADA is a central system of software installed in a computer system to act as an interface between industrial equipment. It allows users to compile data regarding equipment, enter commands, make changes, and adjust parameters for production improvement. Data from PLCs and RTUs is fed to the SCADA system. Human machine interfaces (HMIs) are used to enter commands, make adjustments, and monitor processes.
Using a SCADA system, real time data can be accessed anywhere in the world. The collected data enables managers and supervisors to make decisions regarding various aspects of a process. SCADA interfaces with production equipment and machinery to provide data regarding manufacturing processes and their status.
The components of SCADA are programmable logic controllers (PLCs) and remote terminal units (RTUs), which are microcomputers that communicate with machines, HMIs, sensors, and other devices. SCADA systems are adaptable to any form of industrial operation from energy and food production to the biochemical industry and waste water management. The wide use of SCADA systems saves time, money, and ensures smooth and safe operations of equipment.
If a piece of equipment malfunctions, sensors on the equipment send data through the SCADA system to an end user in the form of a work order. SCADA is often compared to the industrial internet of things (IIoT), since both are used to monitor and control equipment. One of the differences between the two systems is IIoT’s ability to store data on site or in the cloud in various formats. The data is used as a diagnostic tool for predicting equipment failures.
Programmable Logic Controller (PLC)
PLCs are industrial computers that have hardware and software for control functions. They monitor inputs to generate appropriate outputs to make production operations efficient and productive. The main function of PLCs is for industrial electromechanical automation of assembly lines, amusement parks, and food processing. The sections of PLCs are the central processing unit (CPU) and the input/output ((I/O) interface.
- Central Processing Unit (CPU) � The CPU controls system activity using its processor and memory system. It consists of a microprocessor, memory chip, and integrated logic control circuits, monitoring, and communications. The different operating modes of a CPU are programming mode and run mode. The programming mode accepts changes to the downloaded logic while the run mode executes the program and operates processes. Data from field devices, such as switches and sensors, are processed, and the CPU performs the commands of the control program. The cycles of the program happen very quickly at about 1/1000th of a second. A CPU’s memory stores the program, holds the status of the I/O, and offers a method for storing data.
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Input/Output (I/O) Interface � The input output system is directly connected to equipment and provides an interface with the CPU’s information providers (inputs) and controllable devices (output). The CPU processes input and makes required output changes executing user programming. PLCs are constantly performing three processing steps, which are:
- Input Scan � Detects the status of devices
- Program Scan � Implements programmed logic
- Output Scan � Changes the status of connected devices
The processes of PLCs differ in accordance with the industries they serve. As with all forms of factory automation, PLCs are customized to meet the requirements of the products being produced. Software and data handling methods are adjusted to fit the needs of a platform.
The most popular programming languages for PLCs are structured text, sequential function charts, ladder logic diagram, function block diagram, and instruction list, which are recognized by the IEC. PLC programming languages can be selected for their appropriateness for the applications they control. As with all forms of industrial tools, programming languages have their advantages, disadvantages and weaknesses.
In order to establish some form of controls for PLCs, the International Electrotechnical Commission (IEC) created a standard for the appearance of PLCs that includes types of equipment, software, communications, safety measures, and many other aspects of programmable controllers. Since 1982, when the first five part standard was introduced, the IEC standard has changed and developed with the present version having 9 parts with a 10th part being developed.
Remote Terminal Units (RTU)
RTUs collect data from field devices and relay the data wirelessly or by fixed communications to the SCADA platform. The other functions include controlling equipment, providing alarm notifications, and integrating with other automation systems. Traditionally, RTUs were less advanced than PLCs. With technological advances and innovations, modern RTUs have the same or similar capabilities to that of PLCs.
Remote terminal units, also known as remote telemetry units or remote telecontrollers, collect and process data from sensors, various devices, and actuators. Like PLCs, RTUs are used to monitor industrial operations and send commands. They can operate like a computer, which is unlike PLCs and are less expensive.
RTUs can be programmed using a simple web interface or using their setup software to configure input and output streams. The languages that can be used with RTUs are Basic, Visual Basic, and C#, which require special skills to set up. The durability of RTUs makes it possible to use them in extremely remote locations that can be hundreds of miles away from the SCADA system.
Distributed Control Systems (DCS)
A DCS system is a central brain that coordinates and controls process subsystems of industrial operations. The system controls complex and intricate processes for large manufacturing factories. The subsystems of DCS, such as sensors and data collection devices, communicate with the DCS, which interprets production trends and sends instructions to controllers, actuators, equipment, and PLCs located in the factory. Unlike PLCs that oversee a few production processes, DCSs send instructions, commands, and output to thousands of PLCs that are monitored, supervised, and controlled by a DCS. Thousands of applications, including production schedules, maintenance scheduling, and information exchange are controlled by a DCS system.
The distribution of control of DCS systems across several nodes minimizes single point failures, which helps improve efficiency.
The components of a DCS system include:
- Control Nodes � Execute control functions
- Human Machine Interface (HMI) � How operators interact with the system
- Data Communication Network � Transfers data between nodes and HMI
- Field Instruments � Sensors, actuators, and data collection devices that execute commands
A key part of DCS functions is data integration, which allows for the smooth flow of information from sources, controllers, and equipment. To function properly DCS systems have to be integrated with other business data systems to have a complete overview of manufacturing operations. The capabilities of DCS include predictive maintenance, process optimization, supply management, energy management, quality control, safety monitoring, batch processing, remote monitoring and control, data reporting, and IIoT integration.
Robotics
An essential element of factory automation is robotics, processes that are used in multiple ways to enhance efficiency and increase the speed of production. The use of robotics has been associated with replacing manual labor for repetitive processes. As essential as robotics may be, they are only one part of the larger factory automation process. Three or six axis robotic arms do material handling, pick and place, and complete mundane tasks faster than workers.
The use of robotics for repetitive processes improves production volume. Engineers program robots for lifting, placing, and orienting workpieces using technology that allows them to determine the motions of a robot due to program choices and the flexibility and adaptability of robots for different applications.
Although robots are valuable tools, they do not fit into every type of factory automated system. An initial definition of the production problem helps to determine if robotics are applicable to the conditions. Robotics are commonly used for low volume and sensitive production processes.
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.