What is Industrial Automation
According to the dictionary, Industrial Automation (IA) is the use of technology to control processes in the industry.
Industrial Automation is the process of running/operating machines and other industrial equipment with the help of computers & software programs.
Note that, here, “Machine” can refer to anything from a motor to a drill to a conveyor belt.
IA reduces/eliminates human intervention in various decision making and machines as well as overall engineering process execution.
It is helping manufacturers in responding better to various issues, like labor supply, machine execution & predictive maintenance.
Also, it is helping in overall supply chain consolidation resulting in a good balance between quality and cost.
With powerful data analytics and the associated insights, manufacturers can integrate automation solutions seamlessly into their industrial processes to help reduce costs, improve efficiency, enhance safety, and boost productivity.
What is Industrial Automation:
Industrial automation allows manufacturers to increase productivity through computerized technologies and applications.
So, the, repetitive/mechanical tasks associated with one person in production and manufacturing processes are replaced by automation.
Automated devices can be programmed to control processes.
Automating industrial processes involves the use of robots, control systems, and computers.
In addition to saving time and effort, Automation also improves the accuracy of a task.
An industrial automation system uses established technologies and automatic control devices to automate industrial processes.
This leads to reduced human involvement, resulting in improved performance over manual control.
Background of Industrial automation
Earlier, in factories/ industrial plants, the overall production process was dependent upon shop floor factory workers (in terms of execution of a machine, coordinating the output of one machine as input to next machine, overall machine maintenance etc.).
Though earlier, the implementation of automation in a production process was focused on replacing a human worker with an independent machine, these independent machines required a human supervisor for a smooth production process.
So, in this phase, Industries implemented automation to increase productivity and reduce costs related to employees, their benefits, and other associated expenses, while increasing precision and flexibility.
With the Industrial Revolution came mechanization, which brought cheaper and more plentiful goods.
Generally, the mechanical processes in industries were faster and produced greater quantities of goods but still required skilled workers.
But now with technological developments in analog and digital control systems, microprocessors and PLCs (Programmable Logic Controllers) and various sensors, it has become very easy to synchronize several independent machines and processes.
Recent advancements in automation in industrial production are focused on flexibility and quality.
Industrial automation allows for monitoring and controls locally & remotely.
With these increasingly advanced control mechanisms, industries can operate 24 hours a day.
Industrial automation provides, lot of flexibility to manufacturers.
This flexibility helps in bringing out more product types.
Also, it allows, consumers to order customized products that are automatically produced.
So Industrial automation is helping us achieve a lot more, by harnessing the power of sensors, actuators, computers, data & analytics.
Types of Industrial Automation:
An automated system’s level of complexity and degree of human engagement vary depending on the application.
Even though industrial automation systems have many uses, they all fit into one of these categories: fixed, programmable, flexible & Integrated automation.
Each of these forms of industrial Automation is described in greater detail below.
1. Fixed Automation –
Fixed Automation is an automation that is set up to do the same tasks over and over again, with little to no variation in what it does. Imagine installing a cash register at a store.
The cash register will do the same thing every time someone comes up to it.
It will take the customer’s money, scan the product, tell the customer how much they owe, and give them their change.
The register does this over and over again. The cash register has very little variation in what it does.
Fixed Automation is very common in many different industries.
This type of Automation is less versatile than others; it is typically used to automate repetitive operations using dedicated equipment in order to enhance production efficiency and throughput rates.
2. Programmable Automation – This sort of Automation is ideal for batch production. When the system’s instruction set changes based on what’s being made, a new control program may be created for each batch based on the supplied requirements and processing tasks.
It is frequently used for medium volumes, although it may also be utilized for low or high volumes where economics justify it.
3. Flexible Automation– As with programmable Automation, it allows for product changes. But this is much more than ‘programmable automation’
Inflexible Automation, it is possible to change products rapidly and automatically via the control system, which eliminates the need to reconfigure the equipment between batches.
4. Integrated Automation – This method does not require human involvement in comparison to the other three.
A single control system handles and synchronizes all connected machinery, processes, and data with this technology.
Advantage of Industrial Automation:
The main benefits of industrial automation are
- Streamline equipment and processes for greater efficiency and increased quality
- Reduction of human interaction from production lines. This, in turn, increases productivity, output, accuracy, and safety.
- Reduction in cost. This is achieved by reducing human cost as well as reducing the waste/slack in the system.
- Efficient use of raw material, input material as well as better utilization of energy.
- Ability to maintain consistency in quality (and continuously improve the quality of output).
- Now, Human interaction is shifted to new areas of expertise in design, operations, installations, and maintenance of automated machinery, robotics, equipment, and plant operations
- Creation of a safe environment for all. Also, reduction in environmental pollution. Automation can avoid harmful manufacturing conditions with severe temperatures, pollutants, intoxicating elements, and radiation-containing materials
- Reductions in system failure and downtime
- Greater flexibility as well as control over the manufacturing process. This helps in quick adaption/ customization of processes as per the need. New innovative & improved designs can be quickly introduced & integrated in the current system.
Points to watch out for:
1. It’s quite expensive to install an automated system from the beginning.
2. For maintenance and servicing, it is always necessary to have a team of skilled individuals.
Conclusion: What is Industial Automation
Industrial Automation is an economical, efficient, and flexible process, which has been used in industry to achieve higher-quality standards, lower production costs, and the removal of labor.
It’s is the control of machinery and processes used in various industries by autonomous systems through the use of technologies like computer software & Internet of Things, cloud & robotics.
The need for automated devices, software, and equipment will stay strong as long as the industrial automation industry develops.
Globally, this technology has proven to be a helpful tool for organizations, especially in an age when consumers have become used to fast transactions.
