Automation is the use of automated technologies and machinery in operations such as manufacturing to eliminate the need for additional labor. In this blog, we tell you about the various types of automation.
Benefits of Automation:
- Human labour requirements are reduced.
- Quality consistency means fewer chances of human error.
- Health and safety have been improved.
- Enhanced efficiency
Automation, on the other hand, can:
- It could be a pricey initial investment.
- Require some manual labour, such as observation and programming.
- Failures may result in temporary production downtime.
Types of Automation
- Fixed automation
- Flexible automation
- Programmable automation
- SCADA and MES systems
Fixed automation
It is a type of automation in which the production process remains fixed due to the way it is configured, following a fixed sequence of automated procedures. Flow production, in which things are continuously manufactured, is an example of this. This is often referred to as “hard automation.” Fixed automation might be costly to set up at first due to the equipment necessary, but it gives high production rates in return. It is, however, relatively rigid when it comes to making adjustments to the product.
This is pretty handy for many businesses that employ automation to produce food goods of a single type and version. It enables them to efficiently create and package that item in mass. Foods that require chemical processes, for example, may employ this to assure chemical process consistency.
The following are some of the benefits of fixed automation:
- High amounts of output
- Consistent production quality
- Low cost per unit manufactured
- Fixed automation has the following drawbacks:
- High initial investment
- Changes are difficult to accommodate.
This form of automation is best suited for: high demand and generic products that do not require modification.
Programmable Automation
Programmable automation enables industrial equipment and automation to be adapted to changing requirements. This is accomplished by controlling the automation using a program that can be coded in specific ways for the automation to change the sequence of automation. It is more typically utilized in low to medium levels of manufacturing and is often best suited for batch production.
Factories that produce many food varieties will frequently use programmable automation. This enables them to produce batches of a single product in quantities ranging from a few dozen to perhaps thousands. If the product has to be modified, it only needs to be reprogrammed.
Among the benefits are:
- The ability to switch products as needed
- If batch production is necessary, this option is ideal.
Among the disadvantages are:
- Expensive in terms of equipment.
- Reduced output levels.
- Changing items is frequently time-consuming.
Flexible Automation
Flexible automation, sometimes known as “soft automation,” is comparable to programmable automation but slightly more complex. Essentially, flexible automation allows for the creation of a variety of items without the need for time-consuming reprogramming. A flexible automation system may efficiently create multiple product combinations without needing to segregate them into different batches, as batch production requires. This form of automation typically produces at a medium level of output.
Among the benefits are:
- Product adaptability
- There is no time lost due to new manufacturing adjustments.
Among the disadvantages are:
Costly custom machinery/automation
Increased unit cost
SCADA and MES (man-machine-interface) systems
SCADA (supervisory control and data acquisition) is a computer system-based tool. It collects and analyses real-time data and is used to monitor, control, and manage equipment.
These are installed in manufacturing plants to monitor equipment such as telecommunications, water, gas, and trash. If there is a problem with these, such as a telecommunications equipment failure, the SCADA system provides information on where the problem occurred as well as the criticality of the failure.
Similarly, an MES (Manufacturing execution system) is a system that can be used to supervise. An MES, on the other hand, is used to monitor and track production operations in a factory. It enables you to see how effective production is at any given time by obtaining real-time production statistics.
Both of these systems may be integrated into your manufacturing process to verify that your factory equipment is operating properly, reducing potential downtime and providing the greatest quality product with the least amount of waste.
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