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How is Industrial Automation Reshaping Smart Manufacturing?

Explore the evolving landscape of industrial automation as it leads the manufacturing industry into an era of strategic growth and automation trends. The shift towards smart factories, driven by Industry 4.0, integrates artificial intelligence, data analytics, and the Internet of Things into production.

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Industrial Automation checks out the trends and opportunities leading the industry into an era of automation and strategic growth.

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Industrial automation is a potent strategic tool. Image by storyset on Freepik

The manufacturing industry has undergone a tremendous transformation over the last few years. The industry has significantly moved towards smart factories, driven by Industry 4.0 and industrial automation (IA). By incorporating artificial intelligence (AI), data analytics, and the Internet of Things (IoT) into the production ecosystem, smart manufacturing goes beyond traditional automation.

This amalgamation has created a new era of smart manufacturing, where industrial automation plays a pivotal role. According to The Insights Partner, the global industrial automation market is forecast to reach US$322.67 billion by 2023, up from US$171.23 billion in 2022. The market is growing at a CAGR of 8.2% during the projected period.

 

The core components of industrial automation

Industrial automation refers to the automation of industrial processes. It uses computers, communication systems, and process operators. The IA technology helps enhance the productivity and quality of products while simultaneously lowering the production cost. Industrial automation has various core components for effective industrial processes, which are discussed below:

 

Sensors and actuators

In industrial automation, sensors serve as the eyes and ears. They gather information from the production setting, keeping an eye on things like machine status, pressure, and temperature. On the other hand, actuators make sure that the manufacturing processes follow predetermined parameters by acting in response to the data they collect.

 

Programmable logic controllers (PLCs)

PLCs control and coordinate different aspects of the manufacturing process, acting as the brains behind industrial automation. These programmable controllers serve as the brains of the system, coordinating the data and command flow to guarantee smooth functioning.

 

Human-machine interface (HMI)

Human operators can monitor and control machinery with the help of HMIs, which provide a visual representation of the manufacturing processes. Efficient human-machine communication is made easier by intuitive interfaces, which also improve system performance.

 

Communication networks

The various parts of the automation system are connected by strong communication networks, which are frequently built on protocols like MQTT or OPC UA. Owing to the real-time data exchange made possible by these networks, the manufacturing ecosystem is synchronised and responsive.

 

How can industrial automation be used as a strategic tool in manufacturing?

In the manufacturing sector, industrial automation is a potent strategic tool offering numerous benefits that directly support the accomplishment of corporate goals. To fully realise the potential of industrial automation in manufacturing and its observable benefits for business growth, strategic utilisation of this technology is essential.

Several strategic approaches are available to effectively harness industrial automation in manufacturing, some of which are mentioned here:

 

Comprehensive process analysis

Manufacturers must find automation opportunities. They should perform a comprehensive examination of production procedures in order to pinpoint jobs and procedures that would profit from automation. They must give top priority to areas where automation can result in notable improvements in quality, cost savings, or efficiency.

 

Strategic goal alignment

Industry leaders must align their strategies with their business objectives. They should ensure that the adoption of industrial automation is in line with the overall goals and expansion plans of the company. Automation should be a strategic enabler, regardless of the objective—raising production capacity, enhancing product quality, or reaching a wider consumer base.

 

Modular automation integration

Businesses should take a modular approach. They must take into account integrating automation in a modular fashion. The automation process can be implemented incrementally, causing less disruption to current operations and offering flexibility for future expansions, by breaking it down into modular components.

 

Data-driven decision-making

It is essential for companies to collect data in real time from different manufacturing stages by utilising industrial automation. To gain practical insights for process optimisation, predictive maintenance, and well-informed decision-making, they must use data analytics tools.

 

Flexible and adaptive systems

It is important to put in place automation solutions that can be quickly and easily adjusted to accommodate modifications in the demands of production. This guarantees that the production process can react swiftly to changes in consumer demand, product modifications, or unplanned interruptions.

 

Investment in workforce training

Investing in developing workforce skills through workforce training initiatives is imperative that will provide workers with the know-how to run and maintain automated machinery. The smooth integration and best possible performance of automation technologies are guaranteed by a workforce with proper training.

 

End-to-end integration in supply chain

Businesses need to automate every step of the supply chain, from obtaining raw materials to distributing them. This cuts lead times and bottlenecks while ensuring a coordinated and effective flow of materials.

 

Investment in emerging technologies

Businesses must investigate emerging technologies and keep themselves informed about cutting-edge technologies like the Internet of Things (IoT), machine learning, and artificial intelligence. They should think about how these technologies can increase productivity and creativity, in addition to industrial automation.

 

Strategic asset utilisation

Making use of industrial automation to make the best possible use of labor, energy, and machinery is crucial. By ensuring that resources are used effectively, this strategic approach helps to lower costs and increase profitability.

Apart from these, scalable solutions for growth, cybersecurity measures, strategic vendor partnerships, regular performance evaluation, regulatory compliance, clear communication channels between different stakeholders, including management, engineers, and operators, benchmark performance, and intuitive design are some other strategic approaches.

Adopting these approaches will help manufacturing businesses harness the full potential of industrial automation to drive growth, boost competitiveness, and position themselves as leaders in the ever-evolving landscape of modern manufacturing.

 

Do we need to automate everything, or are there limits?

It is no wonder that automation can significantly enhance productivity by eliminating the need for manual labor and accelerating processes. However, the decision to automate must be determined by a strategic evaluation of the specific needs, challenges, and goals of a business.

Since industrial automation offers a wide range of advantages to businesses and society at large, it also brings certain challenges. The first and foremost challenge is job displacement and unemployment. When industries begin to use machines and robots to increase productivity, the unemployment rate will surge, especially in low-skilled or repetitive roles.

This is where individuals are required to upskill themselves to adapt to the world of machines and operate them efficiently. Other challenges include initial implementation costs, technical challenges and limitations, reduced human interaction and customer experience, and dependency and loss of skills.

 

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Automation can significantly enhance productivity Image by Lifestylememory on Freepik

Future opportunities of industrial automation in smart manufacturing

The future of industrial automation in smart manufacturing holds enormous opportunities for innovation, efficiency, and competitiveness. A number of significant opportunities are expected to influence the path of industrial automation in the coming years as technology progresses. Some of these are as follows:

  • Integration of digital twins

  • Edge computing for real-time processing

  • Advanced robotics and cobots

  • Integration of AI and machine learning algorithms

  • 5G Connectivity for enhanced communication, and

  • Human-centric automation design.

 

The final thought

Industrial automation is about enabling businesses to innovate and empowering workers to collaborate seamlessly with technology. With a lot of advancements in industrial automation and smart manufacturing, Industrial Automation believes that the final act is yet to unfold, and the possibilities are as endless as the ingenuity that drives us forward.

 

References

1. https://www.rockwellautomation.com/en-us/capabilities/smart-manufacturing.html

2. https://www.themanufacturer.com/articles/what-is-the-role-of-industrial-automation-in-a-smart-factory/

3. https://www.simplilearn.com/advantages-and-disadvantages-of-automation-article

 

For a deeper dive into the dynamic world of Industrial Automation and Robotic Process Automation (RPA), explore our comprehensive collection of articles and news covering cutting-edge technologies, roboticsPLC programmingSCADA systems, and the latest advancements in the Industrial Automation realm. Uncover valuable insights and stay abreast of industry trends by delving into the rest of our articles on Industrial Automation and RPA at www.industrialautomationindia.in