5 Types of Automation (Benefits, Pros & Cons, Examples)

Do you want to increase your company’s efficiency and productivity to better compete with your competition and earn more revenue?

The adoption of cutting-edge and efficient automation systems is a necessity if you want to compete in many industries. Statista shows that the global industrial automation market will be worth $265 billion by 2025.

Many industrial manufacturers and business owners understand the need to adopt industrial automation systems for fast business growth. However, only a few know which automation system is best for their different needs.

This article explores the five different automation systems and how you can apply them in manufacturing.

Let’s get started.

Types of Automation Systems in Production

Automation systems comprise distinct technologies designed to optimize, control, and streamline business process automation. Different types of automation systems are specific to the production process, each designed to minimize human intervention.

A majority of the processes that require automation systems are repetitive or mechanical tasks or a combination of the two.

Here are the five types of automation systems in production and what they offer to the industrial automation market:

1. Fixed Automation

A fixed automation system works on finishing a single set of tasks many times over. You carry out these sets of tasks without deviation, and the manufacturing process remains fixed. Another name for this system is the hard automation system,

In a fixed automation system, the entire automation process repeats the same task with the same automation equipment. This type of automation system is peculiar to discrete mass production and continuous flow systems.

A fixed automation system offers immeasurable advantages to a business aimed at reducing labor costs and time in the installation process. This system helps businesses stay competitive and increase their profit margins.

A practical example of a fixed automation system is an automated conveyor belt, which helps move goods from one point to another with ease. The setup of an automated conveyor belt is to perform fixed and repetitive tasks that guarantee high levels of production.

Image of an Automated Conveyor Belt

Companies that are involved in repetitive manufacturing also use fixed automation systems that allow for variation in the manufacturing process.

Food packaging companies and the textile manufacturing industry are popular companies that use fixed automation systems to carry out repetitive manufacturing.

2. Programmable Automation

Programmable automation is a type of automation system that runs based on commands delivered by a computer program. A set of codes controls this automation, allowing for changes in the sequencing process at any time.

In a programmable automation system, robotic equipment controls the entire batch production linked to a computer program. You can easily make changes to this automation type because it only requires the modification of the control program.

The initial cost of setting up a programmable automation System is high. But in the long run, since the processes are continuous and unchanging, the initial high-cost balances over time.

Programmable automation systems are common in systems that produce similar product types and use similar tools.

A practical example of a programmable automation system is the automobile and machine manufacturing industry. Companies in this industry produce the same products over a long period in large batches.

Programeble Automation — **Source:** **SlideServe**

3. Flexible Automation

A flexible automation system allows for flexible production systems. You can also call it soft automation.

This type of automation System is common among computer-controlled flexible manufacturing systems where every piece of equipment gets instructions from a human-controlled computer.

Similar to a programmable automation system, the flexible automation system gives no room for manual changeover in its process and procedure.

Example of A Flexible Automation Production System

The goal of a flexible automation system is to provide greater flexibility, ensuring a greater production rate with minimal downtime. Without the need for complex reprogramming, you can produce different product types with a flexible automation system.

A practical example of a flexible automation system is in paint manufacturing and steel rolling mills, where you can produce different product types from a single system.

Soft automation systems are helpful in distinct manufacturing processes, including continuous process manufacturing, batch process manufacturing, and discrete mass production systems.

The Evolution of Automation — **Source:** **Valin**

4. Integrated Automation

An integrated automation system is a comprehensive automation framework that involves the total automation of a manufacturing plant.

Unlike other types of Automation Systems, an integrated automation system requires minimal human involvement, entirely handled by control processes and computers.

Similar to a flexible automation system, an integrated automation system is compatible with both batch process and continuous process manufacturing.

Unlike other types of Automation Systems, the Integrated Automation System takes a holistic approach to industrial automation, working under a single command system. It unifies data, independent machines, and processes under one control system.

The main aim of an Integrated Automation System is to minimize the complexity of independently automated work processes. This system achieves this aim by effectively streamlining the communication between the different sections of the automated processes.

Some practical examples of automation technologies that use integrated automation systems include automated material handling systems, automatic assembly machines, and computer-aided manufacturing.

Solving Integrated Automation — **Source:** **Futuriom**

5. Process Automation

Process automation involves the use of technology based on data and system integration to automate manual processes with minimal human input. This encompassing type of automation system combines all other types of automation into one universal type.

The scope of a process automation system tends to be broad, and businesses stick to automating their processes in bits. Some businesses limit their automation needs to more complex processes, where the need for process automation is easily visible.

One of the standout benefits of using process automation in your processes is how it helps improve your business productivity and efficiency.

Process automation systems help provide valuable insights about your business processes, helping to proffer solutions to your business challenges.

This type of automation is common among businesses that use software programs and apps to execute a diverse range of tasks.

Practical examples of processes that use process automation systems are process mining workflow automation and warehouse automation.

An Example of A Fully Automated Warehouse

Pros and Cons of Industrial Automation

Industrial automation offers several benefits to independent automated work processes, reducing the need for human intervention. As with any emerging technology, there are disadvantages to opting for this system and process in continuous process manufacturing.

Pros of Industrial Automation

Increased Productivity: Industrial automation speeds up processes by eliminating the need for human intervention. This act leads to a significant increase in productivity, increasing output, and reducing production cycles.
Scalability and Flexibility: This automation offers adaptability that helps businesses stay competitive and effectively meet their customers’ demands. Businesses can respond better to fluctuations in market demands with an automated system in place.
Cost Savings: You can optimize and streamline processes with industrial automation, thereby reducing the wastage of time and valuable resources. By streamlining processes, businesses save costs through reduced labor costs and minimized operational expenses.

Cons of Industrial Automation

Job Displacement: Industrial automation involves reducing the need for human labor by using machines and robots to perform tasks and processes. This act harms a social scale as humans tend to lose their jobs to these improved models.
Reduced Human Interaction: One of the notable disadvantages of industrial automation is how it reduces human interaction, leading to a reduction in the customer experience as the human factor is removed from the equation.
High Initial Implementation Cost: In the long run, industrial automation is an excellent tool for manufacturing companies to save costs. But in the short term, the initial cost of setting up automated systems is high and poses a huge challenge, gulping up a significant amount of the capital.

Understanding Automated Production Lines

An automated production line comprises several workstations linked by a transfer and electronic control system. Every automated production line comprises people, data, robots, and industrial equipment.

A typical example of a sophisticated manufacturing system, automated production lines automate manufacturing tasks with little or no human intervention. It integrates tools, machines, equipment, and programmable automation technology to help automate sequences.

Automated production lines can be the specific routes that every product passes through during production. Usually, these routes consist of several production processes, including processing, transportation, assembly, and control of batch processes.

Practical examples of automated production lines include automatic processing lines, assembly lines, spraying lines, and welding lines, among other types. Each of these automated production line examples is unique to different industries and their automation system processes.

An Example of Automated Assembly Lines

Here are some of the features of automated production lines:

Numerical or Computer Control Function: This feature refers to the moving parts of the automation equipment controlled by digital signals. Via codes, the upper computer receives processing information that controls the automation process.
Variability: Automated production lines exhibit a high level of variability, allowing them to adapt to changes in the production process.
High Production Efficiency and Integration: In automated processing lines, the process equipment has high production efficiency and integration. This feature helps it meet the need for automation equipment in modern production processes.

Automation Applications in Manufacturing

In manufacturing processes, automation involves the process of using production management software, robotics, or other automation tools to operate a production line.

The goal of automated manufacturing systems is to increase efficiency, productivity, and accuracy in the manufacturing process, minimizing the need for human intervention.

Manufacturing is one of the important areas of automation applications, helping to automate complex processes and improve productivity.

You can build automation applications in manufacturing through the use of programmable devices, systems, and tools, including computer-controlled machines, AI, and robots.

Automation in the manufacturing process is popular for carrying out repetitive or dangerous tasks. This action helps free up time off human labor, allowing them to focus on other highly skilled manufacturing processes.

6 Benefits of Automated in Manufaturing — **Source:** **Conure**

Automation in manufacturing can occur in different forms, from increasing the turnout of ordinary processes to a complete overhaul of the process.

Whatever form of automation you use for manufacturing, the best way to get maximum results is to understand which option suits your business best.

Here are some practical examples of automation applications in manufacturing.

Use of Robots: Robots are pre-programmed to carry out tedious and repetitive tasks in manufacturing, such as stacking, painting, welding, labeling, and assembly. Companies like Tesla and Amazon use robots in their manufacturing plants for different purposes.
3D Printing: This task uses a machine that follows a computer design to print materials in physical form. L’Oreal and Volkswagen are top companies that adopt the use of 3D printing in their manufacturing process.

FAQ

What Is Industrial Automation?

Industrial Automation uses control systems, machines, and robotics to perform repetitive tasks previously assigned as human labor. It aims to increase productivity, quality, and safety in industrial manufacturing processes without the need for human intervention.

What Are Industrial Automation Systems?

Industrial automation systems are systems that use industrial robots, machines, and control systems to carry out manufacturing automation. It comprises several distinct technologies and techniques designed to streamline, control, and optimize industrial processes.

What Is Computer Automation?

Computer automation is the use of instructions or software to control repeated processes, replacing the need for an IT professional. In computer automation, computer-controlled devices carry out the tasks of manual work in data centers and cloud deployments, guaranteeing an increase in efficiency.

What Is the Purpose of Automation?

Automation is a key criterion in business management, helping increase competitiveness, efficiency, and value customers derive from control processes. The main goal of automation is to increase efficiency, accuracy, and speed in business processes, ultimately guaranteeing increased productivity to the overall manufacturing automation system.

What Is Automation Used For?

Automation serves different purposes in different industries. In manufacturing processes, automation necessitates using a control system and production equipment that minimizes human intervention. For IT-based systems, automation helps replace IT professionals' manual work through the use of instructions that create a repeated process.

What Are the Latest Automation Technologies?

Artificial Intelligence, Robotic Process Automation, Industrial Internet of Things, and Chatbots are some of the latest automation technologies. While each serves different specific functions, they are similar in how they assist manufacturing operations to learn from data and optimize processes.