Industrial automation what is it? A comprehensive guide for manufacturing companies

Estimated reading time: approx. 10 minutes

TL;DR:

• Industrial automation is the engineering of automatic control of production and technological processes
• Implementation of automation improves efficiency, security i repeatability processes
• The most common drivers used are PLC, works industrial, SCADA and MES software
• Investment in automation often pays for itself within a 1-3 years
• The key is needs analysistechnology selection and support from an experienced integrator

Table of contents

• Introduction
• Definition of industrial automation
• Benefits of implementing industrial automation
• Areas of application for industrial automation
• How do you start implementing industrial automation in your company?
• Costs and return on investment (ROI) in industrial automation
• Is industrial automation right for every business?
• Examples of trends and challenges in industrial automation
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Industrial automation is a concept that is increasingly emerging in the context of the development of modern manufacturing companies. The growing demand to increase the efficiency, repeatability and safety of industrial processes is causing many companies to consider what exactly industrial automation is and how to implement it effectively. If you have the question "industrial automation what is it?" in your mind, this article will give you all the information you need. Michale Automation (also often referred to as Michale Automation) specialises in machine building and robotic production lines, so we are happy to share our knowledge on the subject. After reading, you will understand what industrial automation is all about, learn about its most important components and benefits, and find out how you can approach the implementation of automation in your industrial plant.

Why is the topic of industrial automation so important today?

• Rising human labour costs and staff shortages.
• The requirement for continuous improvement in the quality and repeatability of the products produced.
• The need to adapt to increasing production volumes.
• Pressure from dynamic market changes and the need to react quickly.

To turn all these challenges into a competitive advantage, consider implementing industrial automation. In the following sections, you will learn exactly what industrial automation is, what advantages it has and how the process of integrating it into existing production lines works.

Definition of industrial automation

Industrial automation is a branch of engineering that deals with the design, implementation and maintenance of systems and equipment for the automatic control of production and technological processes. Its main objective is to reduce human involvement in repetitive activities with a high risk of errors or accidents. In practice, industrial automation combines many disciplines, such as electronics, mechanics, computer science or robotics.

Fundamentals of industrial automation

Automation in a production plant means using, among other things:

• Programmable Logic Controllers (PLCs).
• Machines and systems equipped with sensors, actuators or power systems.
• Management and process monitoring software (SCADA, MES).
• Industrial robots or cobots that collaborate with humans.

As a result, these systems independently coordinate the production flow and respond to changes in real time according to the settings.

Key elements of industrial automation

1. PLCs - the basic 'brains' of automation systems, which make control decisions based on input signals (e.g. from sensors).
2. Industrial networks - enable data exchange between machines and higher-level systems (e.g. SCADA).
3. Industrial robots - are able to perform activities such as welding, packaging, palletising or internal transport with precision and repeatability.
4. Human-Machine Interfaces (HMI) - operator panels that allow the operator to monitor the process and make changes to operating parameters.
5. Vision systems - Quality control, identification of objects and product positions on the belt.

Benefits of implementing industrial automation

Implementing industrial automation can bring tangible results for a company. Here are the most important of these:

Increased productivity and repeatability

Fully automated workstations are able to continuously repeat tasks with high accuracy. Industrial robots or PLCs do not get tired, do not make mistakes due to human factors, and once set, parameters can be maintained for any length of time (taking service and maintenance into account, of course). As a result, the production cycle becomes shorter and productivity sometimes increases by several tens of per cent.

Improving quality and safety

In many industries, such as automotive, food and pharmaceuticals, stable quality and safety of the final product is crucial. Automation minimises the risk of defects caused by human factors and allows better control of processes while increasing employee safety. Hazardous tasks, such as welding at high temperatures or handling heavy moulds, are being taken over by robots.

Reduction in operating costs

While the initial investment in automation systems may be felt in the budget, putting them in place translates into lower operating costs in the long term. Automation reduces production errors, reduces material waste and improves energy efficiency. Reducing the cost of human labour allows the company to focus resources on strategic activities - just an important advantage especially in an era of rising labour costs.

Scalability and flexibility

Modern industrial automation systems can be easily expanded as required and modified for new products. This allows the company to respond to market changes without having to completely redesign the plant. And if the need arises to run an additional line or increase capacity, a properly configured automation system will facilitate such upgrades.

Areas of application for industrial automation

Contrary to appearances, automation is not just for large factories. It will work just as well for smaller companies looking to improve productivity and reduce costs. Here are some examples of industries and processes where industrial automation plays a key role:

Welding and metalworking

Examples include welding stations equipped with robots that perform joints with repeatable quality. Automation in metalworking often also includes cutting, bending or grinding processes, where tasks are repetitive and require precision to be maintained over long periods of time.

Packaging and palletising

Many manufacturers use robots to automatically pack and palletise goods at the production line. These machines handle heavy loads effortlessly, minimising the risk of injury to workers and allowing higher volumes to be handled with increasing orders. With vision systems, the robot can be adapted to recognise products of different shapes or sizes.

Assembly applications in the electronics and automotive sectors

When electronic parts such as PCBs are manufactured or automotive components are assembled by robots, automation ensures high accuracy and repeatability. This is extremely important in the production of electronic circuits, where errors in soldering or assembly can doom an entire batch. In cars, on the other hand, every component must be closely matched and assembled according to safety standards.

Storage systems and logistics

Automated materials handling systems (AGVs) are becoming a standard feature in modern distribution centres. Robots responsible for order picking or sorting goods in the warehouse reduce the number of errors and speed up shipment. Solutions using artificial intelligence to optimise the flow of goods are also becoming more common.

How do you start implementing industrial automation in your company?

Getting started with automation can seem complicated, especially if you do not have the in-house resources and expertise of robotic systems integration specialists. Here are some steps to consider before starting the project.

1. Process analysis and identification of needs

The first step is to carefully analyse the current production system and identify the areas where automation can bring the greatest savings. Internal and external audits are used for this. It is worth paying attention to processes that are repetitive, have a high risk of errors or accidents or generate high costs due to low productivity.

2. selection of appropriate technological solutions

Depending on the specific plant and type of production, some solutions will be better than others. For example, in the food industry, vision systems for product recognition and selection on the belt are important. In the metal industry, on the other hand, welding robots or automated machining centres may be key. If you want to find out what a robotic line tailored to a variety of applications looks like, see our offer on the robotisation page.

3. selection of a technology partner and testing

Implementing industrial automation often requires working with an experienced integrator. Michale Automation offers comprehensive services from audit and consultancy, through design, to implementation and service of robotic workstations. As an official distributor of SIASUN SR25A robots we can select a robotic arm that meets the performance and safety requirements of specific applications. It is best to start with a smaller pilot project to test how automation will affect performance and what challenges may arise.

4. installation, configuration and training

Once the design is approved, specialists install the appropriate systems and equipment, either integrated into the existing production line or created from scratch. Tests are then carried out to verify correct operation in terms of efficiency, safety and quality of the products produced. It is also very important to train the workforce so that they know how to operate the new stations.

5. service and maintenance

Once a line is up and running, regular maintenance and monitoring of key components is essential. A proactive approach to service and maintenance minimises unplanned downtime and extends the life of the equipment. If you are interested in the topic of professional post-implementation support, we recommend servicing and maintenance of stations.

Costs and return on investment (ROI) in industrial automation

One of the most important questions entrepreneurs ask themselves before investing in automation is: "When will it pay for itself?". A thorough ROI (Return on Investment) analysis is key to assessing profitability, and includes:

• Cost of purchasing robots, controllers and software.
• Integration, audit and training expenses.
• The subsequent cost of service and maintenance.
• Increased productivity and reduced material losses.
• Greater stability of product quality and possibly lower claim costs.

In practice, depending on the industry and the scale of the investment, the payback can be within 1-3 years. Take the robotisation of welding in the metal industry as an example. Where a welder works a limited number of hours and tires on a complex series, a robot can continuously perform identical operations with high precision. The higher initial costs will soon be matched by savings in terms of man-hours and lack of errors. If you are considering calculating the cost-effectiveness of a project, use the ROI calculator welding robotisation.

Is industrial automation right for every business?

Automation is a broad field that can be adapted in almost any manufacturing sector. However, the profitability of such an investment may depend on several factors:

Size of plant and scale of production

Large companies tend to benefit more quickly from automation, not only because of the scale of their operations, but also because of their more complex processes and the ability to spread costs over more products. Smaller companies, however, increasingly benefit from automation to a certain extent - for example, in selected critical processes that generate the highest costs or require the highest repeatability.

Type of processes

Some manufacturing tasks are easier to automate due to their repeatability and complexity (such as packaging, simple assembly, batch welding), while others may require more engineering work (e.g. precise manipulation of irregularly shaped parts with the support of vision systems). Hence, it is crucial to identify which processes in a given company will yield the fastest return on investment.

Level of organisational readiness

The implementation of industrial automation involves the need for staff training and cooperation between different departments (engineers, operators, IT department). A company that is unwilling or unable to make changes to its organisational structures may find it difficult to exploit the full potential of automation. It is advisable to plan process changes in advance and train staff so that they can freely use the new technologies.

Examples of trends and challenges in industrial automation

Today, industrial automation is becoming increasingly complex. Here are some of the trends that are shaping its future.

Integration with IoT and Industry 4.0

Automation enters a new level when devices are networked and able to transmit data in real time (Internet of Things). This enables centralised control and optimisation of processes across the entire plant, rather than just one production line.

Collaborative robots (cobots)

Robots designed to work side-by-side with humans without the need for a separate safety area are becoming increasingly popular. With built-in sensors and advanced safety systems, cobots are proving their worth in processes where the flexibility of working with operators is required.

Artificial intelligence and machine learning

AI and machine learning allow processes to be automatically fine-tuned and optimised in real time. Machines are able to learn from historical data and draw conclusions on an ongoing basis regarding, for example, quality or efficiency.

Cyber security

With the increasing number of networked systems in industry, the threat of cybercriminal activities is also growing. Manufacturers are therefore focusing on introducing solutions to protect production lines from unauthorised access or hacking attacks. This is a challenge that will only grow in importance.

Practical conclusions and recommendations

1. Start with a needs analysis: Determining which processes generate the greatest costs and the most quality problems will help to select areas for automation.
2. Tailor technical solutions: The choice of properly configured robots and control systems is crucial to the profitability of a project.
3. Take advantage of integrator support: If you don't have enough engineering background, trust a company that has experience in automation projects. Michale Automation offers complete solutions - from consultancy to design to service.
4. Plan for long-term development: Consider how to later incorporate vision systems, cobots or digital analysis of production line data so that the organisation can continuously improve efficiency.
5. Implement a culture of innovation: Automation is not just about turning on a plug; it requires a change in mindset. It is worth ensuring that employees are trained and motivated so that they are not afraid of the new working model.

Summary

"Industrial automation what is it?" is a question that more and more Polish manufacturing companies are asking themselves. Thanks to automation, the efficiency, repeatability and safety of manufacturing processes can be radically improved. However, good identification of needs, reliable selection of components and planning integration with already existing systems are crucial. Michale Automatyka offers turnkey support in this regard - from design, robot fitting (e.g. SIASUN), to training and long-term service.

If you want to find out more:

• About the possibilities of robotising various processes in your company - visit our robotisation page.
• About the service and stand maintenance offer - feel free to browse the dedicated subpage.
• About specific SIASUN machines and robots - check out the product catalogue on our website.
• And if you are wondering about calculating the profitability of a project - use the ROI calculation tool.

We also encourage you to check out our other articles on our blog, where we cover the topics of robotics, production line system integration and Industry 4.0. We would be happy to answer your questions - you can ask them in the comments or contact us directly. Thank you for reading and we hope that you now find the concept of industrial automation much clearer and more inspiring.

FAQ

How long does it take to implement automation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.