The Next Step In Manufacturing: Industrial Automation

Long ago manufacturing was done through skilled individuals to develop tools and items for selling, or bartering. These days the term artisan for developing such items has been replaced by industries setting up specific facilities to manufacture products. This is still the norm in today’s industry for developing consumables for customers. But, the next set in manufacturing evolution has developed the use in lights-out facilities. This also goes by the alias of industrial automation. 

Industrial automation is a term coined for facilities to operator virtual without the need for human interaction. The process is still developing, but more and more facilities are turning to these systems for its presented benefit. 

· Lower Implementation Costs and Operating Expense

· Improved Productivity and Efficiency

· Reduced Cycle Time and Work-In-Process ~ Increased Inventory Turns

· Reduction in On the Job Injury

· Manage Facility Energy Usage Accurately

· Increase Equipment Efficiency to Maximize Production 

The list goes on and on. The idea of full automation is still under-development and there are still activities that require human attention until the industrial automation process is a well-known standard. 

Originally the purpose of automation was to increase productivity due to integrated manufacturing facilities able to function twenty four hours a day, and reduce cost associated with human operators. However, the quality of production has been a focal point for competitive industries and utilizing automation for validation and verification tests has grown considerable. The idea of a flexible manufacturing process has given rise to the lights-out facilities as the production can be generated based on when the order is received and reduce the volume of standing inventories. 

To Automation or Not to Automate?

Full on industrial automation is expensive and requires large amounts of resources to convert any facility. The best idea is to build a facility from the start with complete integrated control systems for an automated manufacturing facility. First thing to understand is when considering automation is to reflect on current operations and develop solutions that this idea could be used for. Here are the main reasons for utilizing automation are reducing cost, improving quality, reducing inventory, and improving response time.

· Reducing Cost

Reducing direct labor is a primary to reducing cost. Eliminating  direct labor results in reducing cost only if the manpower costs more than the automation operational costs. The reduction in manpower decreases cost along with indirect cost associated with employees. Reduction of in-process inventory is another savings that happens when replacing batch operators. Another benefit is scrap reduction based on automated inspection conducted by the machinery. Cost of training is essential reduced with less manpower.

· Improving Quality

This is done through machinery inspecting parts and the use of in-process testing. Often industrial automation will verify that the product is of good quality before having it sent out. Also the added benefit of elimination of piece part rejects. The sorting of quality goods will improved for finished production. When automation is used to validation products, the parameters must be quantified in order for the products to be accepted or rejected. This eliminates operator error, which is presented with manually inspections. 

· Inventory Reduction

Reduction of inventory with industrial automation is similar in manner as lean manufacturing. Since production flow is based on station to station activity, instead of piling up at each operation, the work-in-process is reduced. Additional, finished goods inventory is reduced because automation allows you to make products when they are as needed.

· Improved Response Time

Response time is related to manufacturing cycle time and is based from the point when an order is received to the final product shipment. Manually operators usually sit on products waiting for added value work to be performed. Automation will improve response time through each operation. Sub-assemblies can be integrated into the automation line to eliminate individual workstations. Automation can handle surge orders and improve response time through programmable changeovers.

        Industrial automation has several advantages that make it ideal for the next stage in manufacturing. With so many features that allow it to perform precise and accurate tasks, the dedication and engineering going in it must be extensive and difficult.