Manufacturing Automation: The Essential Guide for All Manufacturers

For decades, manufacturing automation was considered a “nice to have” for many manufacturers. Automating parts or all of a manufacturing floor offered benefits such as improved productivity, enhanced quality, and cost reduction. However, the technology wasn’t required to be a profitable business.

Today, the manufacturing industry landscape has changed. No longer a “nice to have,” automation in manufacturing is now a “must have” for those aiming to compete in a highly competitive market. As labor shortages persist and quality demands intensify, manufacturers can no longer afford to remain on the sidelines.

Fortunately, as the manufacturing industry has evolved, so has automation technology. In recent years, there has been a surge in accessible, user-friendly, and affordable technology in robotics and manufacturing automation platforms. Manufacturers who previously found automation out of reach now have the opportunity to adopt industrial automation solutions and enjoy the benefits larger manufacturers have been experiencing for years.

In this guide, we’ll discuss manufacturing automation, its benefits for your business, how to get started, and some key technologies you should know about.

What is manufacturing automation?

Manufacturing automation, also known as “industrial automation,” is the use of technology, machines, equipment, and systems to automate production processes in manufacturing. The primary goal of manufacturing automation is to streamline operations, reduce dependency on human labor, and ultimately improve the bottom line.

Manufacturing automation encompasses a wide variety of disciplines, including:

• 3D design: Using digital models to design industrial equipment, automated machines, and robot cells.
• Robotics: Employing robots to perform tasks such as palletizing, assembly, welding, and more.
• Programming: Writing code to control machines and automate workflows.
• Artificial intelligence (AI) & machine learning: Utilizing AI for generative design, motion control, and analyzing data to optimize processes, detect anomalies, and improve quality control.
• Remote monitoring: Using sensors and cameras to monitor equipment, performance, health, and processes in real-time.

Manufacturing automation projects vary in complexity. Some involve automating multiple interconnected processes, while others focus on simpler tasks, such as moving a box from one location to another. No matter the complexity, integrating these technologies can be transformative for a business.

What are the benefits of introducing automation to manufacturing?

Amid ongoing labor shortages, rising labor costs, and increasing quality demands, the time to automate is now. By reallocating human workers from repetitive, dull, and dangerous tasks to more high-value activities, both businesses and workers benefit.

Here are seven key benefits of introducing automation to manufacturing:

• Increased productivity: Operate continuously without breaks, leading to higher production rates and improved labor productivity.
• Enhanced quality: Reduce the likelihood of human error and ensure greater consistency and precision in manufacturing processes.
• Reduced costs: Perform repetitive and labor-intensive tasks more efficiently than human workers and minimize waste by optimizing the use of materials.
• Reduced lead times: Streamline production processes by reducing the time required to move products from order to delivery.
• Improved workplace safety: Enhance worker safety by automating hazardous or physically demanding tasks.
• Mitigation of labor shortages: Address the challenges posed by labor shortages, particularly in industries where skilled workers are difficult to find.
• Higher employee retention rates: Develop a more engaged and productive workforce by automating routine and repetitive tasks. This way, employees can focus on more strategic and high-value activities.

Each manufacturer is unique and will have a different reason for introducing automation. Many use a combination of these benefits to justify the investment.

What are the types of manufacturing automation?

There are two fundamental approaches to manufacturing automation: fixed automation and flexible automation. Each approach offers unique advantages and is suited to specific types of applications. Understanding these is crucial for businesses aiming to optimize their operations and stay ahead in the ever-evolving industrial landscape.

Fixed automation

Fixed automation, also known as hard automation, refers to systems designed to perform a specific set of operations with little flexibility for variation. These systems are typically used for high-volume production of standardized products. For example, a servo motor ice cream cup-filling machine is a fixed automation application because it can’t be repurposed for different tasks.

Flexible automation

In contrast, flexible automation refers to systems that can be programmed to handle a variety of tasks and products. This approach allows for greater adaptability to changing production needs. Most applications that utilize a collaborative robot (cobot) are examples of flexible automation because they are suited to many different tasks and are easily programmable and reprogrammable.

Which industries use industrial automation?

Industrial automation has seen widespread adoption across various manufacturing industries. Specifically, it has transformed processes in metal machining, rubber and plastics manufacturing, wire production, healthcare and pharmaceutical manufacturing, consumer goods manufacturing, and food processing and packaging.

Automation in pharmaceutical manufacturing

Pharmaceutical manufacturing, also known as lab automation, involves completing repetitive tasks with complete accuracy, making it an ideal candidate for manufacturing automation. Robotic systems can replace manual tasks such as pipetting, dispensing, sample preparation, and assay development, significantly expediting workflows, streamlining processes, and increasing production.

Sunset Resources, a Vention Automation Partner, is a leading biotech and automation company that is revolutionizing advanced robotics solutions for the pharmaceutical industry.

Automation in automotive manufacturing

At a time when a lot of industries are just becoming more comfortable with automation, the automotive industry has been automated for decades. At nearly every phase of the vehicle production process, you’ll find at least one robot performing tasks such as assembly, welding, and painting and coating. Automated systems (without robots) are also common for quality control, inspection, and supply chain management.

Automation in aerospace manufacturing

The aerospace industry requires manufacturing automation to create advanced technology for airplanes and turbine engines. Robots assemble large and complex components, such as fuselages, wings, and tail sections, which require precision and consistency. To meet stringent quality standards, automated vision systems conduct detailed inspections.

Automation in food processing manufacturing

Food processing manufacturing is the preferred method to ensure consistent quality, improve food safety, and enhance outputs. Robots and automated systems can easily handle repetitive tasks such as sorting, peeling, picking, and cutting to increase speed and consistency. One of the most popular industrial automation solutions is robotic palletizing, designed to optimize the process of stacking and organizing products onto pallets.

Sager Foods, a Vention client, utilizes two Vention cobot palletizers to alleviate manual, monotonous tasks at their food oil bottling plant.

How are robots used in manufacturing automation?

Robot arms, defined as programmable mechanical devices that mimic human arm functions, are the basis for industrial automation equipment and automated manufacturing processes. They automate labor-intensive and repetitive tasks with precision and speed, significantly reducing production time and labor costs.

There are different types of robot arms to be familiar with. To ensure you pick the right type of robot, explore how they’re used in manufacturing automation.

Collaborative robots (cobots)

Collaborative robots, also known as cobots, are named for their ability to work in close proximity with humans. The built-in sensors and safety features allow for closer human-robot collaboration without the need for safety enclosures. They are easily programmable, can be quickly repurposed for different tasks, and are a lower-cost alternative compared to traditional robotics, making them ideal for small and medium-sized manufacturers (SMMs) that need to adapt to changing production requirements. Cobots are the top choice in flexible automation solutions and are used across multiple sectors, including manufacturing, logistics, healthcare, food and beverage, and more.

Industrial robots

Compared to a cobot, industrial robots offer a higher payload and faster cycle times. This makes them the optimal solution for heavier and larger materials, such as those used in large-scale manufacturing like automotive manufacturing. Unlike cobots, industrial robots require a safety enclosure to operate safely around humans and have less flexibility to adapt to different tasks. Because industrial robots perform highly precise and consistent tasks, such as welding, painting, and assembly, programming and re-programming can be complex and time-consuming. Industrial robots are common in fixed automation solutions,

Gantry robots

Gantry robots, also known as Cartesian robots, are a type of robotic automation system that operates along a three-axis Cartesian coordinate system. They feature linear actuators that move the robot along the X, Y, and Z axes. Compared to cobots and industrial robots, gantry robots are known for their large workspace, high payload capacity, and rigidity. They are commonly used in industries such as large-scale material handling, automated assembly lines, automotive manufacturing, logistics, and warehousing.

How do I get started with manufacturing automation?

With all the technological developments in recent years, manufacturing automation has become increasingly within reach for SMMs. However, getting started with manufacturing automation can still be overwhelming. There are some key steps to follow to ensure a successful automation project and lay the foundation for success and profitable results.

Kickstarting your industrial automation journey

To support manufacturers through their first automation project, Vention experts with decades of experience in designing, programming, and deploying automation projects have compiled a guide on kickstarting your industrial automation journey. This guide includes setting clear objectives, appointing a technical champion, starting with low-risk projects, securing top-down support, and more. Follow these recommendations to ensure a smooth and successful automation journey.

Choosing which manufacturing process to automate first

One of the most challenging tasks for any manufacturer starting their manufacturing automation journey is deciding which process to automate first. There can be numerous contenders, all vying for the boost in productivity and efficiency that automation can bring. However, you shouldn’t start with just any process on your manufacturing floor—you need to find the one that is just right. Follow this guide on which manufacturing process to automate first for key factors to consider.

Building an Advanced Manufacturing Team (AMT)

An AMT is an internal group dedicated to driving industrial automation initiatives across one or more manufacturing plants for the company. Although reliance on external system integrators is likely to remain for automation projects requiring deep process expertise, AMTs are well-suited to drive entry-level and intermediate projects where agility and a limited budget are needed to have an impact. Read this guide for five key benefits of establishing an AMT.

Structuring an Advanced Manufacturing Team for manufacturing automation

An AMT provides benefits in increased speed, reduced CAPEX investment, and workforce upskilling. To structure an effective AMT for robotics and industrial automation, there are some recommendations to consider, including assembling a cross-functional team, establishing a project management framework, investing in simulation and testing, and more. This article contains comprehensive guidance on how to effectively structure an AMT.

Calculating return on investment (ROI) for robotics and industrial automation

Calculating ROI is crucial for demonstrating the long-term value of an industrial automation project and securing management approval. However, achieving an accurate ROI calculation can be cumbersome due to the numerous factors involved in such projects. This guide outlines the essential components necessary for calculating ROI and provides instructions on how to use the Vention ROI calculator.

What is the end-to-end manufacturing automation workflow?

While each manufacturing automation project will vary, there are four key phases to the end-to-end workflow that all manufacturers should be knowledgeable of: design, automate, deploy, and operate.

The Manufacturing Automation Platform (MAP) was created for a single mission—navigating users through each phase of creating automated equipment. This powerful yet intuitive platform seamlessly integrates engineering software and modular hardware into a unified digital environment, bridging the gap between the digital and physical worlds.

MAP empowers manufacturing professionals across all levels of expertise, from novices in automation to advanced integrators, enabling them to automate factory operations efficiently and profitably.

Designing

After completing each step in the ‘Kickstarting Your Automation Journey’ series, it’s time to begin with the first phase of an automation project: design. Within MAP is MachineBuilder, a 3D CAD software built exclusively for the factory floor. This AI-driven tool enables the rapid creation and design of automated equipment, robot cells, and tooling directly in the web browser. MachineBuilder is free to use and designed to cater to manufacturers of all experience levels.

Automating

Each design completed in MachineBuilder generates a digital twin, a near-perfect digital replica of the physical machine. These digital twins play a crucial role in MachineLogic, where users can program and simulate automation sequences. For beginners in automation, there’s a user-friendly no-code interface available as an alternative to traditional PLC and robot programming. Advanced users can leverage native Python integration for more sophisticated programming needs.

Deploying

Once the design and programming are verified through simulation, the next step is deployment in MachineCloud. Thanks to thorough verification during the simulation stage, deployment becomes streamlined with a simple one-click process. Users can effortlessly transfer programs and machine configurations from the digital twin to a physical machine, all directly from the web browser.

Operating

With the physical machine assembled and fully deployed, it’s time to begin earning a return on investment. MachineAnalytics maximizes machine uptime and optimizes performance through real-time remote monitoring. Track the machine through data and analytics, while also seeing it run live with RemoteView. For unexpected downtime or machine malfunctions, Remote Support is available on-demand for troubleshooting and issue resolution.

With these four automation stages contained within a single, easy-to-use platform, manufacturers are empowered to drive industrial automation projects forward. With the do-it-yourself capabilities MAP provides, manufacturers can reduce labor costs and shorten project timelines so that you can automate 3x faster and with up to 40% less cost.

How is AI used in manufacturing automation?

The use of AI has been rapidly evolving over the last decade. In manufacturing automation, AI has been used for years to analyze data from production or supply chains, optimize processes, and carry out quality controls and maintenance.

Recently, new developments in AI, particularly generative AI, have opened new possibilities within manufacturing automation. We’ve organized them into three major trends:

• Programming co-pilot: Using prompt-based coding to enable natural language commands, enhancing communication and efficiency. This can be done via models such as ChatGPT.
• Real-time adaptive path programming: Operating robots with minimal human intervention for maximum programming accuracy and autonomous adaptability. Requires machine vision and mission-based programming to be successful.
• Synthetic training of robot cells: Utilizing virtual environments for the training and debugging of robotic systems. An accurate digital twin is required to simulate scenarios, detect issues early, and innovate rapidly, leading to enhanced accuracy during the deployment process.
  
  

NVIDIA, a leader in AI, recently announced its partnership with Vention to create near-accurate digital twins significantly faster so manufacturers can test their projects before they invest. Areas of development include generative designs for robot cells, co-pilot programming, physics-based simulation, and autonomous robots.

What are the risks involved with manufacturing automation? And how do you mitigate them?

Implementing manufacturing automation offers numerous benefits, but like any process, it also entails risks. These risks can generally be categorized into two main areas: technology risk and process risk. Understanding these risks and effectively mitigating them is crucial for long-term success in adopting automation within manufacturing operations.

Technology risk

Technology risk is the challenge of successfully integrating all components within an automation project to achieve the desired performance. The only way to ensure that a robot cell will perform at the intended level is to purchase all the components, design and build the robot cell, and then test it. Unfortunately, it often doesn’t work as intended, leaving manufacturers to bear significant financial and operational risks.

With recent technological advancements, there are methods to eliminate technology risk. Some industrial automation and manufacturing robotics providers now offer productized “out-of-the-box” solutions. These solutions are pre-designed, pre-configured, and often even pre-assembled, so they are ready for immediate use with minimal setup or customization. This shift toward productized manufacturing automation projects is leading to more reliable machines that are simpler to maintain.

Process risk

Process risk refers to the capability of chosen technology to consistently perform at desired levels despite significant variations in inputs from one unit to another. Historically, managing process risk has been challenging because traditional technologies weren’t able to handle large variations in processes. Moreover, committing to CAPEX without the ability to validate a system disproportionately affected SMMs.

In recent years, cloud robotics and AI have significantly mitigated process risk. The development of highly accurate digital twins and the virtualization of machine design allows manufacturers to de-risk automation projects before making any CAPEX investment. By integrating digital twins and virtualization with the capability to share and reuse manufacturing apps, programming functions, and libraries, manufacturers no longer need to start from scratch with each project.

Stories from real manufacturers thriving with manufacturing automation

Manufacturing automation is powerful enough to change the trajectory of a factory floor. With its ability to increase productivity, enhance product quality, reduce lead times, improve workplace safety, and more, automation is essential for manufacturers big to small. Discover customer stories from real manufacturers who saw measurable success after introducing automation.

Safari Sun

Safari Sun is a family-owned and operated apparel manufacturer. They sought to automate their manual hat-picking process due to limited floor space and picking errors. Beginning with a simple sketch, Safari Sun and Vention crafted a fully automated gantry system in just eight weeks. The system was designed in MachineBuilder and self-programmed using Python in MachineLogic. With this solution, Safari Sun minimized its footprint, reduced picking errors, and upskilled employees to more fulfilling tasks

Edwards Vacuum

Edwards was moving into a new facility and needed to outfit it with modular and ergonomic industrial equipment. With a one-week lead time, Vention deployed over 165 pieces of industrial equipment, ensuring Edwards’ new facility was up and running on time. Using MachineBuilder to design the equipment and collaborate as a team, Edwards is able to quickly upgrade and modify existing equipment instead of decommissioning it.

Classic Woodwork

Classic Woodwork is a bespoke woodworking manufacturer that was looking to improve efficiency but struggled to attract additional talent during the labor shortage. They also believed you could not automate the production of tailor-made items. Working with Vention, Classic Woodwork had a fully operational robotic sanding machine, featuring a Universal Robots UR10e on a Vention timing belt 7th axis, in just 10 weeks.

Sager Foods Inc

Sager Foods, a food processing manufacturer, was looking for a way to move employees off palletizing, a very manual and physically demanding task. To combat this, they introduced two cobot palletizers serving three production lines. After a two-day commissioning and training period, the palletizers were fully operational, so Sager Foods could start earning its one-year ROI.

The future of the manufacturing automation industry

The future of the manufacturing automation industry looks promising. According to a survey from Persistence Market Research, “the demand for industrial automation is expected to grow by 9.3% per year to reach USD 307.7 billion in 2030, a significant increase from the 2023 value of USD 165.1 billion.” This data shows that industrial automation is not only here to stay but is also predicted to experience exponential growth in the years to come.

Emerging trends such as the productization and platforming of manufacturing automation, along with AI and machine learning, are reshaping manufacturing processes, making them smarter, more interconnected, and more accessible. Robotics are becoming integral in enhancing productivity while ensuring safer and more flexible work environments.

As automation technologies become more accessible and adaptable, manufacturers across various sectors are poised to leverage these innovations to achieve unprecedented levels of efficiency, scalability, and competitiveness in the global market landscape.

Ready to start your automation journey? We’re here to help.