What is automation and is it a new technology? Automation as a concept is not new. Humans have been automating tasks for centuries. In modern times, automation is the process of controlling equipment using sensors and IoT technology to create automated services, manufacturing processes, and more using machines.
Currently, 31% of all businesses have automated at least one task. Automation also helps eliminate boring and monotonous tasks. Due to the automation of manual tasks, 65% of knowledge workers are less stressed. From SMBs (small and medium-sized businesses) to large corporations and manufacturing companies, automation helps every industry.
Table of Contents:
What is Automation?
In modern times, automation is at the forefront of technological development. From factories to healthcare systems, automation is rapidly reshaping industries. Before discussing its types, benefits, and future, let’s understand what automation is.
Definition of Automation
Automation is the process of making machines operate automatically with minimum human input or intervention. It uses modern technology such as sensors, IoT, algorithms, robotics, and often Industry 4.0 platforms to control and automate machines and machinery processes.
Any industry or workplace that has repetitive tasks can be automated. Automation across industries is becoming robust with the rapid technological advancement of sensors, AI, and Machine Learning.
History and Evolution of Automation
Automation technology has evolved from mechanization, which occurred during the Industrial Revolution. Mechanical dolls, power looms, and spinning wheels are all examples of early automation.
However, the true revolution in automation began in the late 20th century. With the help of computers, microprocessors, sensors, software, and modern technology, a transformative wave of automation began. As the technology advanced, the use of PLCs also made automation robust.
With the help of Machine Learning (ML) and Artificial Intelligence (AI), automation is changing manufacturing processes and industrial systems on a large scale. Automation makes industrial systems more efficient and helps automate the repetitive tasks.
Types of Automation
Automation is now spread across industries and sectors, and it’s essential to understand that it comes in many different forms. Each form is tailor-made for specific operational needs. Exploring the various types of automation will provide critical insight into how automation is implemented across sectors and its impact on productivity, safety, and efficiency.
Below are seven different types of automation we mainly see today:
- Fixed Automation
- Programmable Automation
- Flexible Automation
- Industrial Automation
- Integrated Automation
- Office Automation
- Home Automation
Fixed Automation
Fixed automation is a type of industrial automation in which the process remains fixed as it was configured in terms of shape, size, and consistency. It follows a fixed sequence of processes. Fixed automation can be seen in most manufacturing processes.
Flow production, in which products are continuously being made following a sequence of actions, is an excellent example of fixed automation. Fixed automation helps with consistency and can produce large amounts of products at a low per-product cost. However, it is challenging to accommodate frequent changes after the initial setup.
This type of automation is suitable for high-demand products that do not require any changes. Coca-Cola uses fixed automation in its factories.
Programmable Automation
Programmable automation is the type of automation that allows the equipment and automation to change according to needs. This process is done by programs that program the system so that the automation process can change the sequences if required. This type of animation is suitable for batch productions.
Factories use programmable automation to change products or create different varieties. The system allows them to develop products in batches, which can be anywhere between a dozen and a few thousand. This type of automation is more flexible for creating different varieties and batch production. However, making changes might be time-consuming.
Flexible Automation
Flexible automation, also known as “soft automation,” is similar to programmable automation but more complicated. This type of automation allows you to create different products by making minor changes without losing time when reprogramming.
A flexible automation system can create different products without separating them in batches. This type of automation’s most significant advantage is that it creates different products and does not waste time while making changes. However, flexible automation setups are more expensive than others.
Industrial Automation
Industrial automation is the process of controlling and operating industrial machines using technology without human intervention. Any type of automation used in industrial processes can be considered industrial automation.
Large companies automate the product creation, packaging, and storing process. Technologies such as machine learning, supervisory computers, and autonomous robots are used in Industrial automation.
Industrial automation is used across industries, including electronics, pharmaceuticals, and food and beverage processing sectors. It helps companies increase productivity and resource efficiency and reduce product costs, generating more profit.
Integrated Automation
Integrated automation is the process of completely automating a manufacturing plant or automation system using computers and software without human intervention. Once the parameters are set, the software controls the automation process, and the automation system operates independently.
Integrated Automation Platforms, or IAPs, are technology infrastructures that allow systems to integrate with each other. The benefits of integrated automation are the same as those of industrial automation. However, integrated automation requires even less human input.
Office Automation
Office automation is the process of automating everyday tasks with software and computer programs. It helps collect, store, transfer, and modify data with the most minor human input.
In short, office automation manager data. This type of automation helps store, filter, and transfer data without human intervention, which communicates and minimizes the chances of human error. The Applicant Tracking System, or ATS, is an example of an office automation tool that handles the recruitment process.
Email management tools, document management tools, payslip generation tools, and ATS are all examples of office automation.
Home Automation
Home automation is the process of automating the systems in your home. It can control your entertainment, security, and electronics devices and modify your windows, doors, and smart appliances.
With the availability of IoT devices and smart appliances, home automation is no longer rocket science. Some companies are making home automation smart switches well below INR 1000.
Benefits of Automation
Automation benefits manufacturing and other industries by eliminating the need for human intervention. Implementing automation gives companies that rely on industrial systems multiple benefits at once. Let’s understand all the benefits we can get from automation.
Benefits of Automation –
- Increased Efficiency and Productivity
- Cost Reduction
- Improved Quality
- Enhanced Safety
- Scalability
Increased Efficiency and Productivity
Automation helps increase productivity by completing tasks faster than humans can. Because machines do not require breaks, automating these machines to run on minimum human input increases the total output. With the help of automation, companies can produce more with the same amount of resources.
Machines can work around the clock. By implementing IoT systems, companies can monitor the health of the machines and even predict failures and malfunctions early enough to stop the accident from happening. This cuts down significantly on the downtime of those machines, boosting productivity directly.
Cost Reduction
Automation can reduce costs by eliminating the need for human intervention. Completely automated processes require minimal human input and can often be overseen by a single human operator.
Some forms of automation, such as integrated automation, have removed the need for human intervention. With the help of software and computers, they can independently run sequences, maintaining workflow and production. Once the parameters are set, no human interference is required.
Improved Quality
Automation systems can run the machines in sequences, automating repetitive tasks. Since machines and automation systems are configured with set parameters before starting production, the system helps with consistency and precision.
By removing the need for human input and setting fixed parameters, we can ensure 100% precision and consistency in product quality, shape, and size.
Enhanced Safety
Industrial automation can save lives by removing the chance of human error in hazardous situations. In chemical plants and factories, automation can ensure that spills or leaks do not make the working environment hazardous. Even when handling dangerous materials, robots are a safer option.
Automation in specific sectors can reduce exposure to harmful chemicals, high temperatures, and other hazardous conditions. For example, factories can move and store super-hot elements using robotic arms, removing any risk for human workers.
Scalability
Industrial automation or other automation systems can quickly scale up or down according to production and operational needs. When markets are dynamic, scalable automation helps businesses stay agile and adapt to changing needs.
Automation systems are made of smaller parts that are reusable, easy to maintain and replace, and work independently. This reduces the complexity and dependency, increasing maintainability and reusability.
Importance of Automation
Automation affects businesses, the economy, the competitive market, innovation and technology, and even the planet. While businesses can see the impact of automation almost immediately, we can see it impacting the world around them over the years.
Among many, there are four significant reasons why automation is important. Those reasons are:
- Economic Impact
- Competitive Advantage
- Innovation and Development
- Sustainability
Economic Impact
Automation boosts efficiency and productivity and saves production costs. It allows industries to handle large amounts of production and packaging with minimal human input and time loss. Due to sensors and IoT technology, machine malfunctions can be predicted early, avoiding downtime.
The other economic impact we often hear about is job displacement. Implementing automation can cause job displacement, but the automation industry is also creating new jobs that didn’t exist before. Companies can train their existing workforce in specific skills to coexist and boost productivity.
Competitive Advantage
Automation provides competitive advantages to businesses by increasing their productivity and product quality. When it comes to repetitive tasks, automation is the most precise and seamless option. It provides consistency, improving quality and customer experience.
Besides seamlessly upscaling production processes, automation also helps with data management. Combined with Machine Learning, automation systems can gather, store, organize, and analyze data with greater precision and consistency.
Innovation and Development
Automation also helps with innovations and technology development. Due to its high precision and consistency and almost no downtime, it can speed up development processes, allowing faster development of technology and prototypes.
Combined with AI, automation systems can now start immediate automation based on real-time data. Companies can use more advanced automation systems to not only complete repetitive tasks but also learn, adapt, and make decisions and real-time changes based on real-time data.
Sustainability
Automation also significantly contributes to sustainability. Robots can gather, sort, and handle waste better than humans, with fewer chances of contamination. With the help of AI, systems can learn from patterns and predict waste generation, making it easier to handle.
Automation can save energy, detect energy loss and consumption patterns, and predict future events if implemented in energy management and renewable energy projects. Automation combined with IoT can also control devices and systems remotely.
Challenges and Considerations
In AI, ML, and Industry 4.0, automation is now necessary for most companies and large businesses. While some sectors use automation as a tool in production, others use it to manage their offices, recruitment processes, and even workflows. Everything is part of the automation technology, from industrial automation systems to automated visual assistants in the office.
Implementing automation from scratch can be scary, but it is worth the hassle in the long run. Below are some key factors we should consider before deciding to implement automation.
- Initial Investment
- Maintenance and Upkeep
- Security Concerns
Initial Investment
The initial cost of implementing new technology can be high, especially for small and medium-sized businesses. However, in the long run, this investment yields higher ROI (return on investment).
A company must also invest in either training or hiring employees who can operate the automation systems. A mix of both approaches usually provides the best long-term benefits, building teams with expertise.
Maintenance and Upkeep
Automation will become much more complicated if you are not ready for maintenance and upkeep. While automation can handle your repetitive tasks consistently without error and with maximum precision, it is your responsibility to ensure the machines and system software are up to date.
With automation systems and IoT devices, system maintenance becomes a lot easier. However, it still needs monitoring and maintenance from time to time. With the help of IoT and sensors, you can easily predict a system or machine malfunction and avoid unnecessary downtime by solving the issue early.
Security Concerns
When you use the Internet and cyber technology to make your system more robust, you also open it up to more cyber security risks; thus, securing your automation system is essential.
With the help of a robust cyber security system, you can prevent data breaches, data manipulation, and manipulation of automated functions to avoid disruption of any functions. If the base of a building is not strong, the entire structure can collapse. Cyber Security ensures the base of your automation system is not at risk.
Future of Automation
We have already discussed automation’s benefits, importance, and risks. Now, we will explore its near future. Automation has evolved over the years, but where is it going? What can we expect in the next few years? Let’s take a look.
Trends and Innovations
Regarding future trends and innovations, Artificial Intelligence plays a significant role in automation. With the advancement of AI technology and machine learning, we can now witness automation systems learning independently from patterns and then making decisions based on those patterns or real-time data.
Machine learning and AI make automation systems more dependable, accurate, and smarter. The implementation of IoT has not only made appliances smart but also boosted the automation industry. Systems can now determine their health and notify the operator if a part is damaged or requires attention.
In fact, with the help of IoT, systems can now predict downtimes and alert the operator so issues can be solved before they occur. We can expect to witness more robust and smart automation systems.
Global Adoption
Automation is accepted globally, and almost all businesses will use it soon. Eighty percent of all companies already use some form of automation. From manufacturers to marketers, everyone relies on automation to get the job done. Top automation companies are also not slowing down.
As AI-powered tools like ChatGPT or AI Image Generator tools get famous, even small and medium-sized businesses (SMBs) can use automation in their daily operations. With the help of AI, IoT devices, sensors, and various forms of automation, technology companies are inventing new automation systems for multiple industries.
Conclusion
Automation is rapidly growing and will be the future for all industries and sectors. From manufacturing to packaging to marketing, everything can be and is being automated. In the future, we will see rapid adoption of automation across industries.
In this article, we have discussed what automation is, what types of automation we can see, its importance, and its benefits. We have also discussed its challenges, things you should consider before implementing it, and the future of automation as an industry.
FAQ
Q. What is automation in simple words?
A: Automation is the technology that makes machines work with minimum human intervention. Self-driving cars and large industrial manufacturing systems are all examples of automation.
Q. Why is automation used?
A: Automation increases productivity, worker safety, consistency of quality, and efficiency and reduces operational costs. For these reasons, automation yields a good return on investment across industries.
Q. What is the automation system?
A: An automation system has many parts, including sensors, actuators, and controls, which help operate machines with minimum human input.
