Robotics in Manufacturing: Transforming Production
Explore the role of robotics in manufacturing as well as its applications and impact on efficiency. Learn how robots are reshaping the future of production!
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Key Points
- Automation uses technology such as industrial robots, programmable logic controllers (PLCs) and computer numerical control (CNC) machines to make performing tasks more efficient.
- Automation has touched various industries, including healthcare, food service, electronics, pharmaceutical and manufacturing.
- There are four main types of automation: fixed, programmable, flexible and industrial.
- The best type of automation depends on an industry or business' specific needs and goals.
Automation uses technology to perform tasks that would otherwise take valuable employee time. It leverages various control systems such as machines, computers and robots to optimize processes.
Automation has touched various industries, including healthcare, food service, electronics, aerospace, automotive, pharmaceutical and manufacturing - the most automated sector. Most of these industries rely on one or a combination of four different automation types. In this blog post, we’ll walk through the main types of automation, including common uses, pros and cons.
What Are the Four Types of Automation?
The four types of automation include fixed, programmable, flexible and integrated.
1. Fixed automation
Fixed automation, also known as hard automation, is designed for high-volume production. It involves setting up specialized equipment to perform a specific set of tasks repeatedly. While convenient, it has limited flexibility.
Fixed automation is widely used in manufacturing industries, particularly in the production of automobiles, chemicals and food processing.
Mechanized assembly lines, transfer lines, conveyor belts and material handling within warehouses and distribution centers are examples of fixed automation.
Pros:
- High production rates.
- Low unit cost.
- Efficiency in repetitive tasks.
Cons:
- Inflexible, limited to specific tasks.
- High initial setup cost.
- Difficult to modify once set up.
2. Programmable automation
Programmable automation allows for the reconfiguration of equipment to handle different tasks, making it suitable for batch production. This type of automation often uses PLCs, industrial robots and CNC machines.
- PLCs are programmable computers that perform specific actions according to the input they’ve received.
- Industrial robots can learn to perform time-intensive tasks. Some have a programming language that a robotics technician will have to learn. However, recent advancements are making programming robots easier through simpler methods like offline simulation, online programming, teach pendants and lead-through demonstration.
- CNC machines are directed by pre-programmed software that directs the movement of machines and factory equipment.
Industries like electronics, aerospace and custom manufacturing benefit from programmable automation due to its adaptability for different production batches.
Pros:
- Flexibility in handling different tasks.
- Suitable for medium-volume production.
- Lower setup cost compared to fixed automation.
Cons:
- Slower production rates than fixed automation.
- Requires reprogramming for each new task.
- Complexity in operation and maintenance.
3. Flexible automation
Flexible automation, or soft automation, offers a higher level of adaptability. It allows for quick changeovers between tasks without significant downtime, making it ideal for environments requiring frequent adjustments.
Manufacturing systems that produce a variety of products, such as automotive parts, consumer electronics and medical devices use flexible automation.
Robot arms are a classic example of flexible automation because they can perform diverse tasks, such as welding, painting and screwing.
Pros:
- Quick changeovers.
- High flexibility and adaptability.
- Reduces downtime between tasks.
Cons:
- Higher initial investment.
- Complex setup and maintenance.
- Requires skilled automation technicians.
4. Integrated automation
Integrated automation combines various automation types into a single cohesive system. It aims to automate entire production processes, from material handling to quality control, using advanced technologies such as artificial intelligence and the Internet of Things (IoT).
Many integrated automation systems are used in “lights-out manufacturing.” Meaning, that production can continue without human involvement. Industries like pharmaceuticals, logistics and large-scale manufacturing benefit from integrated automation.
Computer-aided process planning (CAPP) is an example of integrated automation. CAPP uses computer technology to create process plans with step-by-step instructions on how to produce a part. The plan covers what tooling is needed, the dimensions of the part, set-up directions, quality assurance checkpoints and more.
Pros:
- Seamless operation across multiple processes.
- Improved efficiency and productivity.
- Enhanced data collection and analytics.
Cons:
- High implementation cost.
- Complex integration process.
- Significant training required for staff.
Types of Automation FAQs
What are the benefits of using automation in manufacturing?
The different types of automation in manufacturing can offer numerous benefits, including increased productivity, reduced labor costs, improved quality control and enhanced safety. Automated systems can operate continuously without breaks, leading to higher output levels. Additionally, automation reduces the risk of human error, ensuring consistent product quality.
What are the challenges of implementing automation in manufacturing?
Implementing automation in manufacturing comes with its challenges. The initial setup cost can be high, and integrating new technologies into existing systems can be complex. Additionally, hiring employees with a robotics and automation education requires time and resources. There may also be resistance from workers who fear job displacement due to automation.
What’s the best automation type?
The best type of automation depends on an organization's specific needs and goals. Fixed automation is ideal for high-volume, repetitive tasks, while programmable automation suits varied production needs. Flexible automation offers adaptability for frequent changes in product design, and integrated automation provides seamless connectivity and efficiency across complex systems.
Learn About the Different Types of Automation at Universal Technical Institute
As automation continues to evolve, so does the need for people with applicable skills. You can gain these skills at Universal Technical Institute’s 12- to 18-month (depending on program and campus) Robotics & Automation Technician program where students get hands-on with industrial robots, PLCs, conveyor belts, programming software and more.
Upon graduation, they’re prepared to pursue entry-level roles within the industry.1 Request more information to get started!
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1 ) UTI is an educational institution and cannot guarantee employment or salary.
2 ) For program outcome information and other disclosures, visit www.uti.edu/disclosures.
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