Factory automation has dramatically changed since its introduction in the 18th and 19th centuries. The mechanical devices of those times, like the power loom and steam hammer, have been replaced by electronics ranging from programmable logic controllers to industrial AI box PCs. The goal of factory automation has never changed, though, aiming to bring increased efficiency, productivity, and worker safety to factories while reducing costs.
What Is Factory Automation? Understanding the Fundamentals
Simply, factory automation uses technology to operate the factory’s various devices and machinery. Hydraulic and pneumatic systems are examples of factory automation.
Most factory automation technologies today have the following components:
- Control Systems: The “brains” of factory automation, control systems or controllers coordinate and manage a factory’s machines, mostly without human supervision. Examples of control systems include programmable logic controllers (PLCs), rugged mini PCs, and artificial intelligence.
- Industrial Robots: Industrial robots are machines directed by control systems to perform specific production-related tasks automatically. Collaborative robots or cobots, which work closely with humans, and robotic welders are examples of such machines.
- Sensors: From cameras to temperature detectors, sensors gather data for the control systems to record and react to.
- Automated Guided Vehicles (AGV): Some factories use AGVs to collect and transport products around the factory floor, all of which is done without or with minimal human guidance.
Exploring Factory Automation in Action: Key Types & Real-World Examples
The types of automation found in factories are numerous, with factory automation ranging from simple mechanical aids to highly sophisticated systems managed by AI.
Automated systems are usually broken up into the following types:
Manual / Minimal / Partially Automated Systems
These automation systems are used for simple tasks or to aid human workers. Examples using these systems include vehicle display testing and customer complaint management. The common factor with these systems is that it is the human worker, not the system, that has the final say on how the particular task is to proceed.
Automated Single Machine Systems
Also called automated assembly machines and special-purpose machines, automated single-machine systems are set up to perform one specific, repetitive task, like:
- Cutting material
- Feeding materials or parts
- Handling parts or other systems
- Making a visual inspection
- Packing products
- Rotating parts
- Welding parts together
CNC machines, automated inspection systems, and 3D printers are examples of automated single machines. Many require human workers to manually insert and position material into the systems, which then promptly execute their specific tasks automatically.
Automated Production / Assembly Lines
This type of automation places automated single machines into workstations and links them together. At each station, the product is processed in a specific order before being sent to the next station. The process is repeated until the product is completed and accepted. Painting a new car on an assembly line is a well-known example of this type of factory automation.
Human workers may be found on assembly lines and workstations, performing manual tasks, using partial automated systems, or working with special-purpose machines like cobots.
End-to-End Automated Factories / Smart Factories
The ultimate in factory automation, end-to-end automated factories or smart factories run entirely on their own without any onsite human workers. Cutting-edge technologies from AI to digital twins run the assembly lines 24 hours a day, 7 days a week, 365 days a year. Humans monitor factory activities remotely through industrial computers.
Smart factories in the real world are few and far between. The most well-known example is by the Chinese electronics company Xiaomi, which unveiled the newest version of its smart factory in 2024.
The Business Impact: Top Benefits of Implementing Factory Automation
The benefits of factory automation to companies are numerous, mostly centering around increasing efficiency and product quality, all at lower costs.
- Reduce costs by using less time, effort, and material to manufacture the finished product(s).
- Increase production output without sacrificing quality, since machines can operate 24/7 while maintaining a consistent output.
- Enhance worker safety by automating tasks in hazardous environments and performing repetitive tasks.
- Increase flexibility and adaptability of factory operations by adding (or shutting down) automated machinery to meet changing demands (scalability)
How to Choose the Right Factory Automation Equipment for Your Operation
The priority for businesses adding automation to their factories should be finding a system that suits their specific needs and goals. Companies should ask themselves:
- What pain points are you trying to solve? Factory automation works best on those issues that are repetitive, time-consuming, prone to errors or are bottlenecks in production.
- Which automation devices and machinery best address the pain point? Example: Rail-mounted gantry robots are best when space is limited in the factory and speed is a necessity. Cobots are more useful (and safer) in those spots where humans work closely with automated systems.
- Will the new factory automation systems work with your current ones? You’ll want to make sure they’re compatible with each other. For example, check to see if the industrial computers used have legacy ports, which can bridge the gap between newer and older systems. An original equipment manufacturer (OEM) can be a tremendous aid in answering this question, along with failure rates, support, etc.
- What’s the Return on Investment? Finally, you should look at the long-term ROI when comparing all the costs involved in factory automation, such as hardware and software, versus its benefits (higher quality, error reduction).
Automate Your Factories With Cybernet Computers
Factory automation replaces routine and hazardous tasks and processes that human workers once performed with machines. The benefits are numerous, ranging from greater consistency of products to lower expenses to worker safety.
Contact an expert at Cybernet if your factory is looking for industrial computers to work or even manage your factory automation systems. We’re an OEM with years of experience in the industrial sector, with mini box PCs, all-in-ones, tablets, and even AI computers, built from the ground up to handle the sometimes punishing work environment. And if you can’t find what you’re looking for among our pre-builts, we’ll happily customize one(s) to meet your exact wants and needs.