Factory automation, smart technology, robotics, AI, oh my! It’s undeniable how rapidly manufacturing technology is evolving. And what’s more, it will only increase in speed as time goes on.
So how can you stay ahead of your competitors? You need to adapt just as quickly.
Fortunately, factory automation is an investment that will launch your manufacturing business into the age of Industry 4.0, paying for itself in short time. In this article, we’ll explain what factory automation means and how you can use it to get ahead of your competitors and delight your customers.
What Is Factory Automation?
Factory automation is the use of control systems to automate different processes and machinery in an industrial setting. The goal of factory automation is to reduce human intervention, increase efficiency, and improve product quality.
Factory automation incorporates various IIoT technologies like programmable logic controllers (PLCs), human-machine interfaces (HMIs), industrial control systems (ICS), and computer numerical control (CNC) machines to create a streamlined and highly efficient manufacturing process.
In other words, factory automation transforms traditional manual operations into automated systems where tasks are performed precisely and consistently. By integrating these advanced technologies, manufacturers can rest assured that their manufacturing process is adaptable and scalable to meet the ever-evolving demands of the industry.
Benefits of IoT and Factory Automation
The integration of the Internet of Things (IoT) with factory automation is revolutionizing manufacturing. Smart factories have innumerable benefits. Here are a few.
Improve Efficiency
When we talk about efficiency, we are referring to all aspects of your manufacturing: workforce, production processes, equipment use, data collection and analysis.
Smart factories use IoT devices that collect and analyze data in real-time, giving your team the information they need to optimize production and assembly processes. You can use this data in the moment to pivot operations on a dime or better understand performance over months or years.
Predictive Maintenance
Gone are the days of wasteful scheduled maintenance and unexpected machine failures. Factory automation uses IoT sensors to monitor the health of equipment and predict failures before they occur. In other words, smart factories remove the guesswork around machine maintenance.
Having a proactive and automated approach to maintenance means fewer unexpected breakdowns, lower maintenance costs, and more reliable operations.
Better Product Quality Control
IoT devices not only monitor the health of your equipment; they also ensure optimal performance. IoT sensors can measure performance metrics like temperature, pressure, speed, velocity, and accuracy of machine components. If there’s a variation from the norm, an alert is sent to your team so they can fix it immediately.
This ensures that you can catch defects early and maintain high standards of production. It also means happy customers.
Enjoy Cost Savings
While the upfront cost of upfitting your factory to a smart factory can feel like a serious investment, the ultimate cost savings just a couple of years down the line make up for it in a big way.
Automation reduces the need for manual labor, resulting in lower labor costs overall. It also helps you manage resources better by minimizing waste and maximizing the use of materials. Your team can leverage IoT devices to more accurately track inventory and materials, allowing you to lean down and save on warehouse costs by stocking only what you need. And factory automation offers your business analysts a wealth of data so they can make smarter decisions and make sure your business is always growing.
Key Technologies in Factory Automation
So, what exactly is involved in factory automation? What makes a factory a smart factory? Here are some of the most popular technologies that you can implement to improve your competitive edge.
Artificial Intelligence (AI) and Machine Learning (ML)
Artificial intelligence and machine learning are no longer industry buzzwords; they’re reality. IoT platforms use AI and ML to enable predictive maintenance, process optimization, and quality control by analyzing vast amounts of data and providing actionable insights to teams.
AI and ML can identify patterns and make data-driven decisions that improve manufacturing efficiency at a moment’s notice.
Robotics
Large and small robots are used in manufacturing to assist and reduce your workforce. Many types of robots are used in manufacturing.
For example, articulated robots are anthropomorphic robots that can perform complex tasks like welding, machining, and assembly. SCARA robots are compact robots that automate assembly and material handling with speed and precision. Cartesian robots operate in a cartesian coordinate system (think X, Y, and Z axes) and are commonly used in 3D printing and CNC machines.
Programmable Logic Controllers (PLCs)
Programmable logic controllers (PLCs) are used to control machinery, robots, and processes. They offer flexibility and scalability in automation and are the backbone of any automated factory. They ensure different components work together seamlessly.
Human-Machine Interfaces (HMIs)
Human-machine interfaces (HMIs) are user-friendly dashboards that allow operators to interact with automated systems. They allow users to operate and monitor machinery from a safe distance and make it easier for human operators to control complex processes.
Digital Twins
Digital twins are virtual replicas of physical systems like factory equipment or assembly processes. You can use digital twins to test the performance of equipment without real-world consequences. Use digital twins to help identify potential issues, enact testing situations, and make better decisions in manufacturing.
Edge Computing
Edge computing is when IoT devices communicate with each other without first having to communicate with the main server or IoT platform. Devices equipped with edge computing capabilities can be programmed to make lightning-fast decisions and kick them into action in fractions of a second.
The Role of IoT Platforms in Factory Automation
While factory automation refers to everything that goes into a smart factory, from robotics to IoT devices to sensors to network solutions, IoT platforms are just one component. However, it’s the piece that completes the puzzle.
All the data collected by IoT devices and all the coding that controls robotics start and end with your IoT platform. IoT software is responsible for parsing and analyzing data, ensuring that devices are properly and securly connected, and effectively integrated with legacy systems.
The best IoT platforms are also scalable. Be sure to invest in IoT systems that are frequently updated so you know you’ll continue to get top-of-the-line service as your business grows.
Factory Automation Services
Services you need when updating your factory include:
- Consulting and assessment
- Integration with your existing systems
- Training and technical support
- Maintenance and upgrades
- Customized automation solutions
How to Get Started with Factory Automation Systems
To get started with factory automation, make sure you know your needs. Evaluate your current processes and gather feedback from users to understand your strengths and weaknesses. This will help you understand where factory automation can help most.
At the same time, research all available automation technology and find out which are the most common and simplest solutions. These are likely the technologies your competitors are already using. Figure out how to get on par with them, then advance even further to maintain your competitive edge.
Next, hire an IoT consultant. Automation consultants like the experts at ProphecyIoT can help you streamline research, implementation, and training processes. Experts will make sure you avoid common pitfalls and make the implementation process smoother and faster overall.
Together, develop a plan for implementation that includes timelines, budgets, and resource allocation.
Begin training early and often. Identify a few key stakeholders and turn them into subject matter experts who can disseminate training to the rest of your workforce. As implementation rolls out, questions will arise.
Monitor implementation and always be looking for opportunities to optimize. Schedule regular reviews and updates. Factory automation is an ongoing process. As you implement changes, more opportunities for improvement will present themselves. Take advantage of each one for continued growth.
Questions About Factory Automation?
The experts at ProphecyIoT understand how daunting change can be. From unplanned downtime to training a reluctant workforce, we’ve seen it all. If you still have questions about factory automation, IoT platforms, or where to begin, contact us today.
