What is automated manufacturing? The ABCs explained

January 9, 2024
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What is automated manufacturing? The ABCs explained

January 9, 2024
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What is automated manufacturing?

Automated manufacturing, aka automated production, is the use of control systems, such as computers, robots, and information technologies (including artificial intelligence) for handling different processes in the manufacturing of components and products.

Automation allows industries to minimize manual involvement or assistance in production operations. As a result,  this type of manufacturing has exploded in recent years thanks to huge leaps in robotics and AI. Now, multi-joint robots can see, grasp, and manipulate complex objects with extreme precision - and are accessible even for small businesses.

While the concept of automation goes back a ways, it was during the Second Industrial Revolution that it came into its own. 

Henry Ford's moving assembly line and the emergence of vast manufacturing facilities marked a turning point. The term "automation" emerged during the 1940s, coined by D.S. Harder, an engineering manager at Ford.

Today, as manufacturers seek to enhance efficiency and reduce costs, several factors converge to drive the adoption of automated labor.

They are: 

  • The need to optimize production processes, minimize downtime, and improve productivity.
  • Industry 4.0 principles, with its focus on the Internet of Things (IoT), machine learning, and AI.
  • Decreased adoption costs. 
  • Increased overall efficiency and effectiveness.

An Oxford report estimates that by 2030, automation investment will increase by $4.9 trillion/year, with no signs of slowing down.

What does automated manufacturing look like?

Picture an auto assembly line where robot arms assemble parts with precision and speed, or a CNC lathe precisely cutting metal components. 

Automated equipment like conveyor belts, lifts, and automated guided vehicles (AGVs) move materials and parts between workstations. Meanwhile, sensors monitor output quality in real-time and make adjustments as needed. - this is not sci-fi talk, it’s now.

This is not coincidental. The tech enabling automated manufacturing is more accessible and affordable than ever before

Robotics, 3D printing, and AI are allowing even small companies to automate parts of their operations and compete with globalized giants. What’s more, these robot systems are flexible, precise, and can work around the clock with no rest, time off, or risk of injury.

What can you automate?

Automation can handle repetitive, dangerous, and mundane tasks. This frees up humans to pursue higher-level, more involved tasks that AI can’t tackle yet. 

But, where do you start? 

Assembly lines

Assembly lines are candidate #1. Six-Axis robotic arms that can lift, move around, and manipulate parts are perfect for assembling everything from minuscule electronics to the largest of cars.

Product testing

Automated systems can test products accurately and objectively. They measure dimensions, scan for flaws, test functionality, and capture data. 

Packaging

If you have a product to ship, automated packaging systems effortlessly handle sorting, loading, sealing, labeling, and palletizing. Pick and place robots cut human handling to a minimum and skyrocket your loading bay’s efficiency.

Inspection

Advances in automated vision systems, scanners, and sensors can inspect parts for defects during the manufacturing process. They detect imperfections, measure components, read serial numbers, and verify information in ways that the naked eye can’t.

Where is automated manufacturing currently used?

Automated manufacturing is currently very popular across several industries, especially those with high-volume production. 

Some of the most well-known examples are:

Auto manufacturing

For a while now, major companies have invested in automation. Now, these assembly lines are highly automated, using robotic arms to weld, paint, and assemble vehicles. 

Only a few human workers oversee the automated systems. The result is much higher vehicle production - and way more consistent to boot. 

Electronics

The circuit boards and components in electronics like smartphones, laptops, and TVs are too small and intricate for shaky human hands. Automated precision robots solder connections and place tiny chips onto boards at a scale not even the most eagle-eyed human could match.

Food processing

Had a great meal today? Chances are, unless you’re getting your nourishment from a homegrown source, you’re consuming food made or packaged in an automated manufacturing chain. 

These automated systems handle everything from sorting and packaging fresh produce to baking, bottling, and canning goods. 

Warehouse logistics

Major retailers and shipping companies rely on automated systems to keep their warehouses running. Robotic arms lift handle palletizing, automated conveyor belts shift goods back and forth, and AGVs zoom materials between workstations.

Benefits of automated manufacturing for large and small businesses

Automated manufacturing offers huge benefits for both large corporations and small businesses. 

We know how major companies benefit across the board. But what’s becoming increasingly apparent is that SMEs can also surf the automation wave and win big.  

Recent advancements in robotics and artificial intelligence have made automated solutions way more accessible to the average consumer. This can help smaller companies maximize resources. stay competitive, and scale in previously unheard-of ways.

What is automated manufacturing good for? Here you go

Yes, you’ll save money

Automation slashes costs in several ways. 

  • It lowers labor expenses and reduces waste.
  • It minimizes errors that could lead to scrapped materials or products. 
  • Automated systems operate efficiently 24 hours a day, 7 days a week without overtime pay or time off.
  • You pay an upfront cost and comparatively smaller maintenance expenses but save in the long term. 

Productivity inevitably goes up

Robots and automated equipment work at a fast, consistent pace and don’t get absent-minded, tired, or complacent. They can assemble products or move materials nonstop, resulting in higher throughput and greater productivity overall.

Exponentially safer

Automating hazardous tasks improves workplace safety by removing humans from dangerous situations. Robots can handle toxic chemicals, heavy loads, high heat, and other risky jobs with no problem. This creates a safer environment for all workers.

Also, robots don’t get pains, aches, or repetitive strain injuries. Collaborative robots, or Cobots, can generally work hand-in-hand with humans unless they operate at a high speed or with dangerous tools. 

Increased quality standards

Automated systems produce consistent, high-quality results with minimal defects.

They perform the same task over and over with near-zero variation, helping companies achieve as close to perfect standards as (inhumanly) possible. 

To top it off, automated inspection systems also spot defects faster and more accurately than human inspectors.

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Is it affordable or mega-expensive? 

Automated manufacturing used to be prohibitively expensive for most companies, requiring massive capital investments in complex machinery and robotics. 

However, in the last few years, advances in robotics and artificial intelligence have caused costs to plummet. What was inaccessible has become commonplace.

Robotics, only affordable

Robots that can handle repetitive or dangerous tasks are now available at a fraction of the cost. Collaborative robots, or “Cobots,” are designed to work safely alongside humans and range from $2000 to over $100,000, depending on the model and application. 

These robots are easy to program (some don’t even require coding knowledge) and flexible enough to handle a variety of applications.

Software and sensors

Inexpensive sensors and AI-powered programs allow companies to automate processes at reduced costs. 

Here’s how they do it: 

  • Vision systems, proximity sensors, and AI can guide robots or control equipment for precise, automated tasks.
  • Cloud-based software can synchronize data from multiple sensors and systems, opening up more opportunities for connectivity and automation.

Paying for itself

Automated solutions necessitate an upfront investment. But, most manufacturers find that the increased efficiency, quality, and productivity ultimately end up paying for themselves. 

Why? Because, as mentioned above, automated robots work non-stop, take no breaks, and minimize errors. Higher throughput, shorter lead times, and more all affect customer satisfaction - and the bottom line.

Keep in mind, though, that many Automated systems work on a subscription basis and require maintenance. However, these costs are only a fraction of the initial investment and are completely overshadowed by the profits from implementing automation. 

Real-world examples of automated manufacturing facilities

Automated manufacturing is used in many industries today. Let’s look at a few real-world examples of companies using automation:

  • Car manufacturing plants are some of the most automated facilities. Robotic arms with multiple joints assemble entire vehicles. Conveyor belts move parts between workstations. AGVs move materials without needing a driver. Giants like Tesla and Toyota utilize highly automated systems to produce hundreds of thousands of vehicles each year.
  • Warehouse operations are one of the big winners of automation. Robotic pick and place systems retrieve items from shelves; automated sortation systems route and organize inventory; many e-commerce companies and third-party logistics providers use automated warehousing to store products and ship them in a flash.
  • Mom-and-pop SMEs and startups are cashing in on automation. Collaborative robots, or “Cobots,” work in tandem with human workers to assist in tasks like packaging or assembly. 3D printers can quickly produce parts and prototypes. Automated CNC machining tools precisely make parts from blanks. 

What is the right time to implement automated manufacturing?

What is automated manufacturing, if not an opportunity? But, as with all opportunities, you need the right time to seize it.

We’re tech die-hards, so we’re a bit biased, and want to say “The time was yesterday.” But the truth is: that not every business meets the ideal criteria to apply automation. 

Here’s a non-exhaustive list of when you should think about scaling up with a robot-partner: 

  • Labor costs are high. Automation lowers the costs associated with wages, benefits, training, and turnover.
  • Fast-growing product demand. Automation allows you to scale up production to meet increased demand without a proportional increase in costs. You can produce more goods using the same facilities and equipment.
  • You want to free up workers to do more fulfilling jobs. By automating routine, yawn-inducing jobs, you enable human employees to focus on more engaging, value-added work like customer service, innovation, and continuous improvement projects. The net outcome tends to be higher job satisfaction, retention, and happiness. 
  • You’re struggling to hire skilled workers over a period of months. 
  • Quality is a differentiator, and that extra 20% precision will help you stand out in an already overcrowded market. 

Are jobs actually at risk? 

Many people are divided about whether automated manufacturing creates or destroys jobs. While automation will displace some jobs, new opportunities will likely emerge.

Here are some areas where automation will create new job positions:

  • Technology 
  • Data analysis
  • Human-machine interaction. 
  • Developing and maintaining automated systems
  • Coding

Overall, the net effect on employment will depend on a variety of factors, including the pace of technological change, whether the workforce proves adaptable and the government policies in place.

But, as with previous industrial revolutions, some job displacement is inevitable. But displacement doesn’t mean “erasure.” What is abundantly clear is that automation is creating a complete reshuffling of the board, and (positive) change is on the horizon.  

Conclusion

We hope we’ve answered the question “What is automated manufacturing?” conclusively,  including how it's revolutionizing businesses of all sizes. 

Despite doom-and-gloom predictions, robots and machines are taking over. But, they’re taking over repetitive tasks and freeing up humans to pursue goals according to their highest potential. 

With automation, you’ll experience: 

  • Reduced costs.
  • Enormous gains in productivity.
  • The reallocation of human labor to mission-critical tasks.
  • The possibility to scale your company to previously unthought heights.

Next steps

Standard Bots’ RO1 can be effortlessly customized to meet your specific manufacturing needs, ensuring a seamless fit with your unique production processes.

  • Easy to use: Shop-floor operators can quickly automate tasks within minutes using RO1’s no-code UI, minimizing downtime and ramping productivity up.
  • Seamless integration: RO1 integrates flawlessly with a wide range of machinery, eliminating compatibility issues and ensuring smooth operation within your existing setup.
  • Superior performance, affordable price: Despite being half the price of the nearest competitor, RO1 delivers exceptional performance, boasting better speed, payload capacity, and precision to elevate your manufacturing capabilities.

Talk to our team today for a custom-engineered analysis.

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