What You Should Know About Process Manufacturing Automation
Manufacturers are constantly looking for methods to reduce costs and increase production without losing quality, no matter what they produce at the end of the line. It all boils down to automation — automated manufacturing procedures that employ intelligent equipment on the production floor to drive operational operations with minimum human interaction.
Fast ahead to today's "new normal." We're in the midst of a crisis that no one predicted, with manufacturers suddenly needing to rethink their operations, focus on remote working, and change their procedures and staff to regain and maintain business continuity. This has pushed manufacturers across all industrial sectors to automate part or all of their workflows, while others are focusing on integrating automated processes into their company's business management system.
What is Process Manufacturing Automation?
The use of intelligent technology to industrial processes in order to replace manual, monotonous, repetitive operations with highly efficient and automated workflows is known as manufacturing process automation. Enterprises can operate quicker and smarter with industrial automation and control, decreasing operational costs and minimising waste.
Plant operators must physically and manually check performance metrics and output quality to find the ideal settings to run the production equipment in the absence of process automation.
Sensors, automated control devices, computer technology, and software engineering are used in Manufacturing automation systems to simplify and manage these operations. Thousands of sensors at various points across the facility capture data, which is then saved and processed on a computer. Every process and machine in a control room may be watched and managed through a huge screen. The computer software utilises measurements to demonstrate not just how the plant operates, but also to simulate several operating modes and determine the best strategy for the facility. It can forecast patterns, which helps to reduce response time to changing situations.
By boosting standardisation, speed, and conformance to design criteria, manufacturing automation increases overall performance. It also lowers day-to-day running costs and the possibility of human error.
Manufacturing Automation explained by Manish Arora, Founder at Maximl
WHY IS AUTOMATION REQUIRED?
The necessity for automation is well recognised. The use of automation in manufacturing has several indisputable benefits. The most notable are:
Automation decreases labour expenses since most manual operations are mechanised. AI and data analytics contribute to lower manufacturing costs by giving insights and data that allow for prompt and educated decisions. Lower operational expenses result from less mistakes and waste. Furthermore, automated preventative maintenance extends the life and performance of machines, increasing asset value.
Improves quality: The automated system aids in increasing and maintaining consistent output quality. The margin of error is as low as 0.00001 percent. Monitoring, inspection, and real-time data assist in checking every stage of the production process to decrease error margins.
Increases productivity: Automated lines are made up of workstations connected by transfer lines; each workstation handles a different aspect of the manufacturing process. Many human acts can be replicated with robotics. Automation boosts productivity by enabling continuous manufacturing 24 hours a day, seven days a week.
Greater adaptability: In a typical manufacturing process, implementing a new task or adjusting modifications might require hours or days of user training. Reprogramming a machine or robot is straightforward, rapid, and reliable using industrial automation.
Traceability is a significant aspect not just in the food and pharmaceutical sectors, but also in other industries. Automation assists in tracing and tracking a product's complete lifespan, from raw material to the end destination where it is sent. Tracing makes mapping and root cause analysis easier, allowing for more effective control and development.
Monitoring Equipment: Sensors, cameras, and smart devices in the automation network observe and monitor the operation of all machines in the production unit. They aid in the diagnosis of problems and provide alerts for prompt action.
Predictive maintenance: Industrial process automation continually monitors production lines and floors, measuring temperature, acoustics, time, frequency, oil pressure, and other factors. When the sensors detect a change, they quickly send an alarm, allowing personnel to take rapid action. Thus, possible issues may be avoided, and repair/maintenance expenses can be reduced.
Industrial safety: Industrial automation contributes to workplace safety. In the industry, industrial automation and robots (particularly in hazardous areas) lower the risk of accidents. Workers are not allowed to approach assembly lines, and any hazards, such as temperature spikes, are quickly discovered and highlighted so that safeguards may be taken to protect the safety of everyone on the shop floor.
Accurate Data: Automation facilitates the collection and analysis of trustworthy data. When precise information is employed in the manufacturing process, precise outcomes are obtained. AI and ML systems are scalable and self-learning, ensuring consistent accuracy. The database serves as a continuous resource as well as a searchable platform for better and faster decision-making.
What sorts of manufacturing automation are there?
The manufacturing process is quite varied. As a result, numerous forms of factory automation exist to address various concerns. These are some examples:
1. Fixed Automation
Fixed automation is also known as hard automation. It is often a system in which factory automation is configured to create a specific product and inside individual machines. Fixed automation is used to produce big volumes and has a high barrier to entry. Many sequences and industrial procedures are combined in hard automation. As a result, once the equipment is in place, altering production techniques is exceedingly difficult. Even more so when you consider the significant initial expenditure required for developing and engineering it.
Examples of fixed automation include:
- Chemical manufacturing procedures
- Production lines
- Conveyor systems for materials.
2. Automated Programming
As the name implies, programmable automation is a manufacturing system that is controlled by a programme. The programme is a collection of instructions that the system reads, understands, and executes.
The ability to modify is a major element of programmable automation. It can support several product combinations or utilise a different sequence. You may also create new items by entering a new programme. Batch production can benefit from programmable automation.
Programmable automation examples include:
- Robots in the workplace
- Machine tools that are numerically controlled (NC)
- PLCs are programmable logic controllers.
3. Adaptable Automation
Flexible automation is comparable to programmable automation in several aspects. Its architecture enables it to adjust swiftly to manufacturing changes, such as product quantity. Personnel programme computerised systems to operate the equipment in order for them to function. They can also employ Human Machine Interfaces (HMIs).
A central computer system manages the production and material-handling systems in this configuration. As a result, flexible automation is appropriate for batch manufacturing. Furthermore, it is an excellent choice if you wish to make many product varieties at the same time.
Flexible automation examples include:
- Lines of production
- Robotics
- Material handling equipment
How to Begin with Automation
How can you get started automating operations in your business? The first step is to link your equipment so you can gather data, process it, and make choices. Only then will you be able to get insight into operational performance of both your equipment and your employees, allowing you to automate procedures and drive improved efficiency throughout the shop floor.
Learn how Maximl can assist you in swiftly connecting your equipment, collecting data, and automating operations. Get quick insights into the operation of your equipment and processes, drive predictive maintenance plans, and more:
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