As covered in our previous blog post, Demand-Side Trends and Digital Manufacturing Technologies, automation is poised to play a pivotal role in the future of manufacturing. In a space where employment rates are falling steadily, automation can, in fact, help increase retention and attract top talent back to the industry.
In this post, we’re going to be looking at the different types of manufacturing automation–from exoskeleton vests to carbon-consuming concrete and 3D-printed leathers–and how likely they are to shape the future of manufacturing.
This is what we’ll cover:
3 Types of Manufacturing Automation
7 Use Cases for Manufacturing Automation and the Benefits they Bring
- Automation and Robotics
- Factory Digitization
- Improving Workplace Safety
- Advanced Predictive Analytics
- Real-Time Product and Materials Tracking
- Bringing Machine Vision to Life
- 3D Printing
Why the Future of Manufacturing Automation is Rich with Real-World Applications
3 Types of Manufacturing Automation
First, let’s cover what the three types of manufacturing automation are. This list isn’t restrictive so much as it is a reasonable way to draw lines around automation. It’s useful for understanding automation and how to invest strategically in it.
- Fixed automation – ’Fixed’ refers to any type of automation that’s hard-coded. That means that software and hardware are designed to solve a specific problem or create a specific product. Fixed automation can be found everywhere in a manufacturing center: automated machinery, conveyor systems, and automatic painting processes are all examples of fixed automation.
- Programmable automation – Manufacturers can customize programmable automation to complete a given task. A 3D printer, for instance, is an example of programmable automation–it only does one type of task (printing), but can be programmed to do nearly infinite versions of that task. Programmable automation works well for batch manufacturing, where each batch is similar yet unique, with repetitive and non-repetitive aspects.
- Flexible automation – This is the most versatile type of manufacturing automation. It’s able to be programmed to a high degree, producing different products and/or accomplishing different tasks interchangeably. Flexible manufacturing automation is arguably the most complex and slow to implement, generally requiring a bespoke solution and programmer know-how to operate. The positive impact of flexible automation on profitability, however, can be profound.
7 Use Cases for Manufacturing Automation and the Benefits They Bring
Now that we’ve covered the different types of manufacturing automation, it’s time to explore the various use cases for automation in the manufacturing space. We’ll not only be looking at different examples of automation at work but also their benefits and results.
Automation and Robotics
You can’t talk about manufacturing automation without discussing robots.
Given there’s a labor shortage within the manufacturing sector, the importance of robotics automation is at an all-time high. Simultaneously, prices are coming down, which is good news for smaller manufacturers, who have previously been priced out of the market.
The factory of the future may well be “lights-out”–free from human workers. But until then, we’ve got:
- Modular Robots: Unlike standard robotic arms, modular robots have swappable parts and can be programmed to build an array of products off the same production line. Companies like RobCo are at the forefront in this space with their modular robot kit that offers a cost-efficient automation solution.
- Cobots: Cobots or collaborative robots work with humans and one another to perform complex tasks, learning by studying and mimicking the actions of those around them.
This new wave of intelligent robotics is enabling traditional manufacturers focused on mass production to shift to mass customization, tailoring their output to each individual customer’s sky-high expectations without sacrificing margin.
Factory Digitization
Factory digitization refers to the process of turning traditional factories into “smart factories.” World manufacturing sites are working at just 60-85% of their theoretical capacity, meaning there’s a huge opportunity to streamline processes and unlock production potential.
In a smart factory, more processes are digitized and handled by machines without human intervention, speeding up productivity. KPMG reports that a South Korean mushroom-farming operation–one of the largest in the world–saw a 30% increase in output from their already impressive 23 million kilograms of mushrooms a year, all from giving manual tasks across the farming, sorting, and packaging system a digital transformation.
And with technologies like IIoT (Industrial Internet of Things)–which 59% of an IDC survey’s respondents said they’d be investing in–connectivity can be used to bring more data to manufacturers. This rich data creates new opportunities, which we’ll explore further in some of the points below.
Improving Workplace Safety
This point touches on robotics automation as well as manufacturing digital transformation as a whole. Passing off work from humans to machines creates a safer space for workers in a field that is generally risk-prone.
This is great news for all involved parties. It means less assumed risk for your workers (making manufacturing work more desirable) and fewer chances for human error to become a factor. It can also lead to a saving in resources, as the time and money otherwise spent on workplace accidents can be diverted elsewhere.
But it’s not just robotics adding Health and Safety value in the factories of the future. The early adoption of exoskeleton technology–essentially a wearable device that supports, covers, and protects a human worker–has proved to be very effective indeed.
The EksoVest, from Ekso Bionics, decreased workplace injuries by 83% in a Michigan Ford assembly plant back in 2017. Fast forward to 2022 and exoskeleton technology is being developed by 80 different providers, leading to a potential market valuation of $1.8 billion in 2025. The ‘Chairless Chair,’ another example of manufacturing wearables, is helping mitigate one of manufacturing’s biggest Health and Safety issues: back pain, which costs $100 billion annually.
Advanced Predictive Analytics
While a less exciting form of manufacturing automation on the surface, predictive analytics is one of the most potent technologies for manufacturing. This is particularly true in a period plagued by supply chain disruptions, where manufacturers are looking to prepare for the next great disruption.
Fortunately, data is here to help. As mentioned a few points ago, IIoT is poised to bring new levels of data richness to the manufacturing sector. This data includes tracking, maintenance, and availability stats from across your supply chain–and this data will be delivered to your desk daily.
This trend looks to be more of a future-facing change, though. Today, the use of advanced predictive analytics has reached close to 25% according to MHI’s 2022 Industry Report with Deloitte. We’re surprised this number isn’t higher, due to the value this manufacturing automation can add. Lack of clear business case, lack of adequate knowledge in-house, and uncertainty around making investments in the current economic client are all barriers to entry for predictive analytics, according to MHI.
Real-Time Product and Materials Tracking
Another way that IIoT is set to affect manufacturing automation is through real-time product and materials tracking. Currently, this is something that needs to be done manually, and as a result, it sometimes isn’t done at all.
This leads to a poorer experience for manufacturers and consumers alike, as there is less information on the status of goods and materials. With IIoT devices, however, monitoring can be vastly improved.
Technologies like RFID tags and scanners can be used to automatically track items as they move through your supply chain and warehouse. Syngenta uses RFID tag technology to streamline its production of agricultural chemicals across the world. Each of the 10,000 bags produced each year is fitted with an RFID tag to be tracked at every stage of the production process, providing a simple and real-time update of every asset. With data automatically uploaded to Syngenta’s system, the in-house personnel is free to focus on high-value tasks, instead of data collection. This has reduced the risk of errors and enhanced production efficiency.
And with computer vision–another emerging AI-led manufacturing automation trend–IIoT monitors can keep an eye on your inventory without the need for built-in tracking devices.
Bringing Machine Vision to Life
Machine vision is one of those technologies that’s been a hazy pipe dream for decades. Recent advancements, however, are beginning to make it a tangible reality.
Machine vision refers to a computer’s ability to take in visual input and identify elements and objects within this input. It’s what’s allowing for self-driving vehicles–including autonomous industrial vehicles. And it will create new manufacturing opportunities and possibilities, performing work that was previously only possible under human supervision.
Instrumental, Landing AI, and even Google are all examples of businesses bringing machine vision technology to the manufacturing space, covering use cases including predictive maintenance, packaging inspection, component assembly, as well as the autonomous vehicles mentioned above. The application of machine vision prevented 72 component failures during an 18-month trial for one automotive manufacturing company and increased defect detention by 50% at another.
3D Printing
For a simple technology, 3D printing has come a long way in a relatively short time. While it started as a way to machine complex shapes and designs out of plastics and metals, it’s beginning to be used in organic matter, an area that will open up possibilities that are nearly impossible to imagine.
New venture, Modern Meadow, is experimenting with 3D printed leather and has recently closed on $130 million of Series C funding to continue its development.
The Future of Manufacturing Automation Is Rich with Real-World Applications
It’s always exciting to ponder the future impact of technology. With manufacturing automation, though, this is truer than ever. There are so many possibilities just around the corner, and manufacturers are already beginning to get a taste of what these solutions will be capable of–both to replace and augment human workers.
It’s a bright future to be sure, especially for those who invest in these developments early.