Target audience:
Decision makers (Program Managers, Directors, CEOs) of manufacturing & allied firms, management consultants, manufacturing consultants, business strategists, innovators, and curious people.
Reading time:
5-10 min.
Introduction
Automation constitutes a major transformation that is reshaping the landscape of industries, organizations, and daily operations. It encompasses the utilization of technology—from basic machinery to sophisticated artificial intelligence systems—to execute tasks with minimal reliance on human involvement. This comprehensive guide examines the definition, historical development, categories, practical applications, advantages, challenges, and prospects of automation, offering a thorough analysis of its influence and potential.
Understanding Automation: Definition and Core Concepts
In simple words, automation is the application of technology, including software, robotics, and systematic processes, to perform tasks with limited direct human involvement. This field includes a vast range of solutions, spanning from foundational mechanical devices to advanced artificial intelligence systems. The principal objectives are to enhance efficiency, accuracy, and productivity while mitigating operational costs and reducing human error. Today, automation plays an integral role across diverse sectors, supporting manufacturing operations, IT infrastructures, household appliances, and business processes. [IBM]
A Brief History of Automation
The roots of automation trace back to the Industrial Revolution in the 18th century when mechanization began to replace manual labor. Key milestones include:
- Early Mechanization: Introduction of power-driven machines in textile and manufacturing industries.
- Assembly Lines: Henry Ford’s 1913 assembly line revolutionized mass production.
- Numerical Control (NC): The 1940s saw the development of NC machines for precise manufacturing.
- Programmable Logic Controllers (PLCs): Introduced in the late 1960s, PLCs automated complex industrial processes.
- Robotics and IT Integration: The 1980s and 1990s brought robotics and computer integration, enabling more complex automation.
- Industry 4.0: The 21st century ushered in digitalization, IoT, AI, and machine learning, creating smart factories and intelligent systems. [Wevolver]
Types of Automation
Automation can be categorized based on flexibility, complexity, and application:
1. Fixed Automation
- Description: Designed for high-volume, repetitive tasks with minor variation (e.g., automobile assembly lines).
- Pros: High efficiency, low unit cost.
- Cons: Low flexibility, high initial investment.
2. Programmable Automation
- Description: Equipment can be reprogrammed for different tasks, suitable for batch production (e.g., robotic assembly).
- Pros: Greater flexibility, adaptable to product changes.
- Cons: Lower production rates than fixed automation, requires skilled programming.
3. Flexible Automation
- Description: Systems can quickly adapt to changes in product design or volume, ideal for dynamic markets.
- Pros: High adaptability, supports customization.
- Cons: Higher complexity and cost.
4. Integrated Automation
- Description: Combines various automated systems into a cohesive unit, optimizing entire production processes.
- Pros: Maximizes efficiency and productivity.
- Cons: Requires advanced integration and management. [Wevolver]
Key Technologies in Automation
- Robotics: Machines capable of performing complex, repetitive, or hazardous tasks.
- Artificial Intelligence (AI): Enables systems to learn, adapt, and make decisions.
- Sensors and Actuators: Collect data and execute physical actions.
- Control Systems: Manage and regulate machinery and processes (e.g., PLCs).
- Software Automation: Includes business process automation (BPA), robotic process automation (RPA), and workflow automation.
- Internet of Things (IoT): Connects devices and systems for real-time data exchange and control.
Benefits of Automation
- Increased Productivity: Machines operate continuously, boosting output.
- Cost Reduction: Lower labor costs and minimized waste.
- Improved Quality: Consistent, precise operations reduce defects.
- Enhanced Safety: Automation handles hazardous tasks, reducing workplace injuries.
- Scalability: Easily ramp up production or services to meet demand.
- Reliability: Automated systems perform tasks consistently, reducing human error. [Red Hat]
Challenges and Risks
- Job Displacement: Automation can reduce demand for certain manual jobs, raising concerns about unemployment.
- High Initial Investment: Advanced automation systems require significant upfront costs.
- Complexity: Integrating and maintaining automated systems can be challenging.
- Cybersecurity: Increased connectivity exposes systems to potential cyber threats.
- Skill Gaps: Demand for new skills in programming, maintenance, and system integration.
The Future of Automation
Advancements in technology strongly influence the future of automation:
- AI and Machine Learning: Systems will become more autonomous, capable of complex decision-making.
- Collaborative Robots (Cobots): Robots working alongside humans, enhancing productivity and safety.
- Hyperautomation: Combining multiple automation tools for end-to-end process automation.
- Smart Factories: Fully connected, self-optimizing production environments.
- Sustainable Automation: Focus on energy efficiency and environmental impact.
While automation will continue to transform industries, it also necessitates a focus on reskilling the workforce, ethical considerations, and robust cybersecurity measures. [Fiberroad]
Case Study: Emerson’s RPA Program
Emerson, a Fortune 500 company, offers industrial solutions including actuators, control systems, measurement instruments, and asset management. Key industries served by them include—chemicals, mining, automotive, energy, and more, Emerson also provides modernization, migration, consulting, training, and project services. [Global Data]
Emerson selected a first-generation robotic process automation (RPA) provider several years ago as their automation platform and subsequently automated numerous mission-critical processes, such as financial operations, complex order management, and supply chain tasks subject to stringent service level agreements (SLAs). The SLA deadline was set to be a maximum of five hours. [Robocorp]
The Problem: There was a delay in processing customer quotations due to a bottleneck of automation tasks at the server during peak business hours and underutilization during non-peak hours if additional servers and licenses were to be added to the existing system (one license per server).
The main reasons included:
- Rigid server architectures and restrictive licensing models.
- Difficulty handling spikes in computing loads leading to underutilized capacity.
- Significant limitations in accelerating processes and achieving their internal SLAs.
The Solution: To address the RPA system deadlock, Emerson hired Robocorp, an RPA provider that:
- Is built on an open-source automation framework.
- Scales automations on-demand through cloud orchestration.
- Offers a straightforward consumption-based pricing model.
The Results:
- Achieved 100% SLA compliance with reduced downtime and faster customer quoting.
- Cut infrastructure by 75%, running 16+ sessions on one Gen2 RPA server instead of 16 servers and licenses in Gen1.
- Improved processing speed by 72% through parallel operations and optimized cloud use.
Conclusion
Automation is a cornerstone of modern progress, driving efficiency, innovation, and competitiveness across the globe. As technology evolves, its role will only expand, offering new opportunities and challenges. Understanding automation—its types, technologies, benefits, and risks—is essential for individuals and organizations aiming to thrive in an increasingly automated world.
References
- https://www.buildingradar.com/construction-blog/what-is-automation-in-technology-applications-and-benefits
- https://www.isa.org/about-isa/what-is-automation#:~:text=The%20dictionary%20defines%20automation%20as,delivery%20of%20products%20and%20services.%E2%80%9D
- https://www.britannica.com/technology/automation
- https://www.ibm.com/think/topics/automation
- https://fiberroad.com/resources/new-trends/what-is-industrial-automation-a-comprehensive-overview/
- https://smythos.com/managers/ops/what-is-automation/
- https://www.redhat.com/en/topics/automation
- https://www.wevolver.com/article/understanding-industrial-automation-a-comprehensive-guide
- https://southshorecontrols.com/the-different-types-of-automation-systems-and-how-they-can-benefit-you/
- https://www.progressiveautomations.com/blogs/news/the-evolution-of-automation
- https://www.spiceworks.com/tech/artificial-intelligence/articles/what-is-automation/
- https://publications.robocorp.com/hubfs/Case%20Studies/Case-Study-Emerson.pdf
- https://www.hfsresearch.com/research/emerson-cuts-costs-and-scales-complex-automation-with-python-powered-robocorp/
- https://www.globaldata.com/company-profile/emerson-electric-co/