How can automation ensure quality, consistency, and future-proofing?

By OEM Update Editorial April 8, 2024 6:58 pm IST

Industrial automation is a force driving efficiency and quality in the manufacturing sector. Sameer Mudhalwadkar, Sales Director APAC at Red Lion Controls, outlines automation’s transformative power while emphasising its role in data-driven operations, adaptability to future demands, and contributions to sustainability efforts.

Automation is crucial in enhancing product quality and consistency within manufacturing plants, with “data” encapsulating its essence. Automated systems efficiently monitor and record pertinent data points, offering transparent displays and maintaining historical records for analysis. In urgent scenarios, these systems promptly alert users via text or email when alarms are triggered, enabling swift response and resolution. They can autonomously adjust real-time processes to address deviations, ensuring sustained high levels of quality and consistency. The Factory Automation sector is experiencing rapid digital evolution, driven by smart sensors, digital control devices, and advanced drives and controls, which continuously generate production and performance data.

Remote system monitoring, easy data access, and robust data visualisation options are key advantages of implementing automation in a manufacturing plant. Automated systems often facilitate secure remote access and interaction with the system from anywhere worldwide, enabling quick and seamless access to data generated by the automated system. This data is precious, as it can be analysed for process improvements or factored into real-time calculations while also being visualised on a touchscreen interface for effortless monitoring and interaction. Overall, automation enables an enhanced level of access and control that can result in increased uptime, efficiency gains, and quality improvements.

One way to describe the ability to be adaptable and flexible to changing production demands is “future-proofing”. When it comes to ensuring that automated systems are as future-proof as possible, several factors need consideration, such as compatibility with multiple communication protocols and devices, the ability to expand the communication capabilities of the system rapidly, and the ease of extending the input/output (I/O) capabilities of the system. By selecting the right hardware with this level of flexibility, users can ensure that their system will be adaptable and ready for many years of changing production demands.

When choosing automation technologies for a particular manufacturing process, there are several crucial factors to consider, some of which may vary depending on the process itself. Some general considerations include ensuring compatibility with existing devices/processes, being adaptable and prepared for future modifications or additions, and selecting durable hardware that is simple to configure. Regarding the challenge of adaptability and readiness for future changes, one solution is modular hardware, which allows users to easily enhance the communication or input/output (I/O) capabilities of a device on-site with minimal disruption to production.

Users should anticipate several challenges when incorporating automation into an established manufacturing process. For instance, manufacturing facilities typically possess multiple pieces of outdated hardware that may need to be compatible with modern protocols used by newer automation hardware. In such instances, users can employ a suitable protocol converter to surmount communication obstacles and attain extensive connectivity. Another noteworthy challenge pertains to operator training. Whenever modifications are introduced within a manufacturing setting, users should anticipate encountering a learning curve in operations and be prepared to tackle any unforeseen issues that may arise.

Recognising that automation technologies can support sustainability and environmental efforts within manufacturing plants is pertinent. One of the most impactful ways is through potential efficiency improvements. Automation typically involves collecting and analysing historical data, which can inform various system enhancements and enable real-time adjustments to enhance efficiency. These efficiency enhancements can manifest in ways such as reducing scrap rates and minimising the amount of raw materials required for a process, thereby making the entire process more sustainable and decreasing waste. As users increasingly adopt advanced automation technologies and leverage their data, these efficiency improvements are expected to persist.