Industrial automation what is it? A comprehensive guide for business

Estimated reading time: approx. 8 minutes

TL;DR:

• Industrial automation increases productivity and reduces production costs
• This translates into higher quality and repeatability of products
• At Michale, automation is the cornerstone of manufacturing growth
• Industry 4.0 combines automation with IoT, AI and data analytics
• Successful implementation depends on a detailed process analysis and the selection of a proven partner

Table of contents

Introduction
What is industrial automation?
Main areas of application for industrial automation
Components of industrial automation systems
The role of industrial automation in modern business
Automation versus robotisation or are they always the same thing?
Industry trends and Industry 4.0
How do you prepare your company to implement industrial automation?
Example of application at Michale Automatics
Summary and conclusions
FAQ

Introduction

Industrial automation what is it and why has it attracted so much interest among manufacturing company representatives in recent years? With the development of new technologies, more and more companies are beginning to see the benefits of automation. Thanks to it, it becomes possible not only to increase process efficiency, but also to improve product quality or reduce manufacturing costs. In this article, we explain what industrial automation is, what its key elements are and why, at Michale Automatika, we consider this area to be fundamental to the development of the manufacturing industry. You will also learn how to implement selected solutions and what to look for when planning automation in your plant.

What is industrial automation?

Industrial automation is a field that deals with the design, implementation and maintenance of systems that enable automatic control and supervision of production processes. The aim is to reduce human intervention in repetitive, time-consuming or hazardous activities. In practice, this means introducing machines, controllers and robots that autonomously take action on the basis of data provided by sensors and software.

From a business management perspective, the most significant effects of automation are:

• Increasing the efficiency of production lines.
• Reduce operational costs associated with staffing.
• Improved product quality and repeatability by eliminating human error.
• Increased occupational safety and reduced risk of accidents.

At Michale Automatika, we see automation as a direct response to rapidly changing market realities, where agile adaptation to new customer needs and industry trends matters.

Main areas of application for industrial automation

Industrial automation today is not just limited to large plants in the automotive or electronics industry. Thanks to falling component prices and the increasing availability of technological solutions, smaller companies are also opting for automation. Interestingly, an increasing number of industries - from food to pharmaceuticals to the packaging sector - are implementing automation and robotisation systems. For many plants, however, the key factor is to properly design the production line and match the level of automation to the size of the plant.

Examples of implementation

Below is an overview of some typical examples of industrial automation applications:

• Robotised assembly lines in the automotive industry, where robots precisely join together individual body components.
• Automatic packaging systems in the food industry, where sensors verify, for example, the weight and dimensions of packages.
• Product sorting lines in logistics warehouses, where vision systems recognise products and direct them to the appropriate collection zones.
• In the chemical and pharmaceutical industries - automatic mixing of substances and continuous monitoring of temperature and pressure.

In each of the aforementioned examples, industrial automation achieves high repeatability and precision, resulting in significant savings and higher quality of the final product.

Components of industrial automation systems

To understand process automation in practice, it is useful to look at the key components that make up a typical industrial automation system. These most commonly include PLCs, SCADA systems, sensors and actuators, and industrial robots.

PLC and SCADA controllers

PLCs (Programmable Logic Controllers) are responsible for managing the operation of machines and other equipment in the production process. These can range from simple to very sophisticated algorithms executed in real time. The PLC is usually complemented by SCADA (Supervisory Control and Data Acquisition) systems, which allow remote viewing of process parameters, recording data and responding to emergency situations.

Sensors and actuators

Industrial automation systems rely on data provided by a wide range of sensors (e.g. optical, pressure, temperature or vision sensors). This information is transmitted to the controller, which, if necessary, issues commands to the actuators (e.g. pumps, valves, electric motors) to correct the process flow accordingly.

Industrial robots

Robots play a special role in industrial automation. At Michale Automatika we are the official distributor of SIASUN brand robots. These robots can be implemented in various areas such as welding, packaging or sorting. If you are interested in which models might work best for your plant, check out our range (e.g. SIASUN Robot SR25A-12-2-01) and consult our team.

The role of industrial automation in modern business

Against the backdrop of ever-increasing competition, industrial automation allows companies to grow in areas where they have hitherto been either at a loss or unable to match the largest players in the market. These include speeding up lead times, reducing labour costs and lowering product defect rates.

Impact on costs and efficiency

• Effectiveness: The uninterrupted operation of the machines increases the production rate and shortens the cycle of each process.
• Costs: Lower consumption of raw materials and energy translates into a faster return on investment. Many tasks that are difficult or inconvenient for humans to perform are handled automatically.

Importance for product quality and safety

• Quality: Modern industrial automation systems react in real time to deviations in the production process and prevent defective products from reaching subsequent stages.
• Safety: Thanks to the use of automation, workers do not have to perform the most tedious and potentially dangerous tasks. Many processes are under constant surveillance by sensors that monitor the risk of failure or collision.

Automation versus robotisation or are they always the same thing?

Although the terms automation and robotics are sometimes equated in colloquial speech, they are not synonymous. Industrial automation refers to a much broader spectrum of solutions, including process control algorithms, monitoring systems (e.g. SCADA) or machine operation by PLCs. Robotisation, on the other hand, is the introduction into plants of autonomous units (robots) capable of performing repetitive tasks in a fully or partially autonomous manner.

Robots can be part of an automation system and are thus one of its most important components, influencing the efficiency and speed of production. However, automating a production line does not always have to mean implementing robots. Sometimes, suitably configured controllers and actuators operated by a small number of operators are sufficient.

Industry trends and Industry 4.0

Industrial automation is an integral part of Industry 4.0, which is increasingly heard about in the context of the revolution in the manufacturing sector. The fourth industrial revolution combines classic automation technologies with the concepts of the Internet of Things (IoT), artificial intelligence (AI) and advanced data analytics. This provides us with the opportunity to:

• Ongoing monitoring of all processes on the production line.
• Predictive maintenance (failure forecasting).
• Integration of robotic systems with ERP/MES databases to fully automate reporting.
• Creating digital twins, allowing virtual testing and optimisation of processes.

For example, at Michale Automatyka, when we implement new robotic workstations, we often use simulation tools. This allows us to detect potential conflicts in production line layouts early on and optimise every robotic movement.

How do you prepare your company to implement industrial automation?

Deciding to start automating production is an important step that, with the right planning, can ensure a quick return on investment. Below are some of the key steps.

Process analysis and planning

Before you start implementing automation solutions, it is worth carefully analysing your company's current processes. Find out which process is most prone to human error and which generates the most costs or involves staff shortages. Carefully define your objectives: do you want to increase productivity, reduce downtime or perhaps improve employee safety?

It is also important to calculate the return on investment (ROI) for each phase. If you are interested in detailed calculations, see our ROI calculator for welding robotisation, available on the website. Although it focuses on a specific area (welding), it can serve as a reference for general calculations.

Selection of a technology partner

In order to implement automation successfully, it is necessary to work with an experienced supplier or system integrator. At Michale Automation, we specialise in the design and commissioning of robotic production lines, as well as the integration of external devices such as vision systems and cobots. If you are looking for a comprehensive robotisation service, visit our services department and see how we operate step by step.

Example of application at Michale Automatics

The Michale Automatics team recently carried out a project to modernise the production line at a plant that assembles small components for the white goods industry. The customer's problem was insufficient precision in manual assembly and a high number of quality defects. After a thorough analysis, we proposed robotic workstations in which SIASUN SR25A-12-2-01 robots working with PLCs played a key role.

As a result:

• The number of defections has been significantly reduced - from more than 5 per cent to less than 0.5 per cent per month.
• Production cycle times have been reduced by around 20 per cent.
• It has been possible to relieve staff of monotonous assembly tasks, which has increased staff satisfaction and commitment.

The implementation was preceded by a testing and simulation phase (the so-called digital twin), so that the line worked stably almost from the first commissioning. In the future, the customer is planning further expansion - adding more real-time quality test stations and extending SCADA monitoring.

Summary and conclusions

Industrial automation what is it? It's not just about machines and controllers. It is also a business philosophy focused on increasing efficiency, quality and safety while reducing costs. In today's competitive market environment, it is increasingly difficult to find a company that is not considering automation at least to some extent. The benefits of implementing automation systems - from precision and repeatability to rapid return on investment - cannot be overstated.

Key recommendations and conclusions to bear in mind:

• Carefully analysing production processes and identifying the areas most prone to human error is fundamental when planning automation.
• Industrial automation does not always require the purchase of expensive robots. Sometimes appropriately configured PLC-controlled devices will suffice, although industrial robots are the most effective form of automation in many industries.
• Industry 4.0 solutions (e.g. IoT, AI, digital twins) provide a broader perspective and facilitate the creation of integrated systems spanning manufacturing, logistics and reporting.
• Choosing an experienced partner - such as the Michale Automatics team - is crucial to make automation a success.
• Investment costs can be predicted using ROI estimation tools.

We encourage you to visit our services page for more detailed information on the benefits of robotisation. If you are also interested in servicing and maintaining existing workstations, see our offer.

It is worth remembering that every production process is different and requires a customised approach. Whether your company needs to automate a simple packaging step or integrate a complex production line with ERP systems, there are solutions to suit your budget and your specific business.

We hope the above guide has helped you understand what industrial automation is, how it translates into process efficiency and the benefits you can expect from implementing it. If you would like to learn more, we encourage you to contact us. At Michale Automation, we help entrepreneurs build and modernise production lines, implement modern workstations and integrate vision systems.

Thank you for reading and we invite you to read other articles on our blog where we share the latest trends and good practices in the world of automation and robotics. You can also subscribe to our newsletter and keep up to date with interesting case studies, tutorials and information about our new partnership with SIASUN.

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.