Types of Industrial Automation

There are three main types of industrial automation: fixed automation, programmable automation, and flexible automation. Additional types of automation with industrial applications include robotic process automation, integrated automation, process automation, and totally integrated automation.

Are you trying to learn more about industrial automation? Perhaps you’re trying to figure out how to upgrade an existing automated process, or you’re trying to expand your business by implementing new automated processes.

Keep reading to learn the basics of manufacturing and industrial automation types. To find out more about technologies used in automation, continue reading here.

Access Industrial Automation will explain more about each type of automation, its benefits and drawbacks, and some examples of applications.

Manufacturing and Industrial Automation Types

There are different types of automation with manufacturing and industrial applications: fixed (hard) automation, programmable automation, flexible (soft) automation, integrated automation, process automation, totally integrated automation (TIA), and robotic process automation (RBA).

We’ll explore each type of automation and the pros and cons of each type. We’ll also list possible applications, including manufacturing and industrial.

Fixed (Hard) Automation

Fixed automation is an automation configuration that is set up to do a single, or fixed purpose. Hard Automation is another name for fixed automation. Making changes to a fixed manufacturing process to accommodate different product designs is difficult.

Pros of Fixed Automation

Each unit produced has a low cost.
Less maintenance of the automation is required.
Fixed automation produces a lot of a specific product quickly.
Consistency

Cons of Fixed Automation

The installation costs for fixed automation are high, especially considering how difficult it is to reconfigure fixed automation set-ups.
Making changes, even small ones, is difficult with fixed automation.
Fixed automation is becoming more obsolete as more flexible systems become available.

Fixed Automation Examples

Generic production needs with a high demand
Products that require no changes between batches
Automated material handling
Continuous production models
Mechanized assembly

Programmable Automation

Programmable automation is when a program and/or robotic equipment controls the manufacturing process. This type of automation can be reprogrammed between batches to accommodate variations in products that can be created using the same equipment with a different configuration.

Pros of Programmable Automation

Programmable automation is great for products made in batches.
Programmable automation is flexible enough to handle design variations.
Programming is easier than some other automation types.

Cons of Programmable Automation

Equipment for programmable automation is expensive.
Changing functions or products is time-consuming and creates downtime.
Programmable automation produces fewer units in each production cycle compared to fixed automation.

Programmable Automation Examples

Programmable Logic Controllers (PLCs)
Intelligent robotic machines
Computer numerical controlled (CNC) tools/ Numerical control (NC) tools
Industrial robots
Logistical programming
Paper and steel mills
Thermostats
Traditional cruise control

Flexible (Soft) Automation

Flexible automation uses robotic equipment and a central computer to allow smooth transitions between processed and/or products. Computer codes are used to trigger changes in the process. Human operators are responsible for giving the codes or instructions.

Pros of Flexible Automation

More flexible than fixed or programmable automation
Handles in-demand production
Product flexibility
Various product types can be produced in sequence

Cons of Flexible Automation

Cost of custom machinery and programming
Each unit produced costs more

Flexible Automation Examples

Adaptive cruise control
Multipurpose computer numerical controlled (CNC) machines
Warehouse automation
Industrial robots
Self-learning thermostats
Robotic arms that are programmed to do multiple automated tasks

Integrated Automation

Integrated automation simultaneously controls multiple processes to automate all of the processes involved in manufacturing completely. Communication is streamlined between automated processes to reduce the complexity of coordinating independent processes.

Pros of Integrated Automation

Unification of multiple automation systems
Can be used with continuous-process and batch manufacturing

Cons of Integrated Automation

Expensive installation and maintenance
Needs to be monitored by skilled labor

Examples of Integrated Automation

Flexible machining systems
Computer-aided design (CAD)
Warehouse setup and operations
Robotic manufacturing
Automated handling of material
Computer-aided manufacturing

Totally Integrated Automation (TIA)

Totally Integrated Automation (TIA) is a philosophy of automation and manufacturing. The core components are a common software environment, a common communication method, and a common data management system. TIA is pioneered by Siemens Automation and Drives.

Pros of Totally Integrated Automation (TIA)

Less complexity
High productivity
Lower cost per unit
Faster time-to-market

Cons of Totally Integrated Automation (TIA)

This is a philosophy more than a tangible system. TIA is more like a set of ideas that can be incorporated into existing automation.

Possible Totally Integrated Automation (TIA) Examples

Packaging industry
Plastics processing
Automotive
Special-purpose machine manufacturing
General machine construction
Food & beverage industry

Robotic Process Automation

Robotic Process Automation (RPA) uses rule-based logic and structured inputs to automate tasks frequently performed by humans. This technology is not artificial intelligence (AI), even though some people mistakenly believe RBA is AI.

Pros of Robotic Process Automation

Less human labor required
Employees are more engaged and satisfied
Increased productivity
Prevents human errors

Cons of Robotic Process Automation

Regular monitoring is required
Even robotic process automation requires human input
Teaching new employees
Difficulty of scheduling systems
Very expensive implementation

Examples of Robotic Process Automation

Retail
Healthcare
Manufacturing
Warehousing

Process Automation

Process Automation combines flexible and integrated automation systems into one system. This system is designed in a way that fixes bottlenecks in process and/or production performance. This type is used more for data mining than physical manufacturing.

Pros of Process Automation

Streamlines communication across departments & platforms
Increased processing speed
Reduced errors and less data loss

Cons of Process Automation

Expensive installation
Skilled labor needed for implementation
Maintenance can be expensive

Process Automation Examples

Condition monitoring and I/O
Managing data
Gathering data
Automating repetitive tasks
Integrating data sources and services

Access Industrial Automation Services in California

Access Industrial Automation in central California offers automation support services. Whether you need a new system designed and built or updates to an existing system, you can find the service you need. AI Automation is located in Ceres, CA, and serves the surrounding area.

Contact Access Industrial online or by phone by calling 209-577-1491.