Earlier the purpose of automation was to increase productivity (since automated systems can work 24 hours a day) and to reduce the cost associated with human operators (i.e. wages & benefits). However, today, the focus of automation has shifted to increasing quality and flexibility in the manufacturing process. In the automobile industry, the installation of pistons into the engine used to be performed manually with an error rate of 1-1.5%. Presently, this task is performed using automated machinery with an error rate of 0.00001%.
Advantages of Industrial Automation
Lower operating cost: Industrial automation eliminates healthcare costs and paid leave and holidays associated with a human operator. Further, industrial automation does not require other employee benefits such as bonuses, pension coverage, etc. Above all, although it is associated with a high initial cost it saves the monthly wages of the workers which leads to substantial cost savings for the company. The maintenance cost associated with machinery used for industrial automation is less because it does not often fail. If it fails, only computer and maintenance engineers are required to repair it.
High Productivity
Although many companies hire hundreds of production workers for up to three shifts to run the plant for the maximum number of hours, the plant still needs to be closed for maintenance and holidays. Industrial automation fulfills the aim of the company by allowing the company to run a manufacturing plant for 24 hours a day 7 days a week and 365 days a year. This leads to a significant improvement in the productivity of the company.
High Quality
Automation alleviates the error associated with a human being. Further, unlike human beings, robots do not involve any fatigue, which results in products with uniform quality manufactured at different times.
High Flexibility
Adding a new task in the assembly line requires training with a human operator, however, robots can be programmed to do any task. This makes the manufacturing process more flexible.
High Information Accuracy
Adding automated data collection can allow you to collect key production information, improve data accuracy, and reduce your data collection costs. This provides you with the facts to make the right decisions when it comes to reducing waste and improving your processes.
High Safety
Industrial automation can make the production line safe for employees by deploying robots to handle hazardous conditions.