What to watch in 2023
Published On 12.24.22
As technology has advanced, so have manufacturing processes. More efficient ways of doing things emerge as new trends that trick manufacturers to save money while achieving the same results. This is especially true when it comes to automating or computerizing parts of their production lines.
Computer automation has become prevalent in almost every industry. It is used for everything from programming robots to controlling machinery and equipment.
Efficiency is one of the biggest benefits of plant automation. Using computers to control machines and equipment removes the need for human intervention which can cost time and money. Robots are very good at performing repetitive tasks with little input from humans.
Also, engineers use software to design products; therefore, having automated systems means less expensive redesigns due to hardware limitations. Product designers can also create more elaborate designs due to no limits put by physics.
This article will discuss some exciting developments in manufacturing plant automation in the coming year.
The rise of the AI on the plant floor
Artificial intelligence (AI) has become one of the most popular buzzwords in recent years. It is even being referred to as the technology that will completely change how we live our lives.
The reason for this growing interest in AI is because it can perform tasks that require logical reasoning, pattern recognition, and computational knowledge. These are all things that humans are capable of!
In fact, many believe that advanced forms of AI will eventually replace or at least complement human workers in various industries.
This seems like an overly dramatic statement, but some experts are predicting full automation in certain industries within the next decade. This includes factories, warehouses, and other similar facilities where robots can perform repetitive tasks with high accuracy.
These autonomous machines are not only cost effective, but they also reduce employee turnover due to stress-related reasons. Luckily, there are already a number of companies that offer different types of automated machinery.
Future implementation on the plant floor may include not just hardware robotics but also software in the form of Robotic Process Automation (RPA).
Robotic Process Automation
What is robotic process automation? That is, what does the term robotic process automation mean?
Robotic process automation (RPA) is a software technology that makes it easy to build, deploy, and manage software robots that emulate humans actions interacting with digital systems and software. Just like people, software robots can do things like understand what’s on a screen, complete the right keystrokes, navigate systems, identify and extract data, and perform a wide range of defined actions. But software robots can do it faster and more consistently than people, without the need to get up and stretch or take a coffee break.
You may have heard of robots performing human-like activities before. This is what some refer to as AI (artificial intelligence). For example, many companies use chatbots now to help answer customer service questions via smartphone apps.
Chatbot technology has been around for quite some time, but only recently did people begin referring to them as AI. A chatbot can seem almost intelligent at times because it uses algorithms to determine how to respond to certain questions.
The key difference between traditional AI and RPA is that RPA isn’t autonomous. It doesn’t perform these tasks completely by itself like a robot would. Instead, humans must give it input and tell it when to start and stop working.
RPA has already proven itself useful in areas such as ERP, data entry and quality issue identification. Other appropriate tasks include:
- Recording action items and meeting minutes
- Recording attendance
- Responding to FAQ emails
- Scheduling meetings
- Ordering supplies
- Predicting computer problems
- Creating and filing invoices
AI Driven Predictive Maintenance
Recent developments in manufacturing technology have made it possible to automate many of the tasks that need to be done within plants, including inspection, testing, and analysis of products. These advanced systems use artificial intelligence (AI) to analyze performance data and determine when maintenance or repairs are needed to keep production running smoothly.
When an equipment repair is due, the system will alert staff so they can get ready for scheduled downtime or carry out the work immediately
This predictive maintenance uses software and robots instead of human workers and technicians, reducing overhead costs while ensuring efficient operation of machinery.
The next step forward is using computer-controlled machines and robotics to do the actual work. For example, instead of having humans pour molten metal into molds, there are now automated arms doing this job. The same goes for assembling components onto finished goods, etc.
Cloud Based Control Systems
A hosted, cloud-based, SCADA system is provided as a service and can be connected to a variety of processes at virtually any geographical location over a secure, private network. Operators can securely access and interact with their process data, potentially from any device anywhere in the world at any time.
With minimal network infrastructure deployed at the assets, a secure connection can be established with existing control system infrastructure. For organizations who are not yet automated but may be hesitant due to budget constraints, the cost savings of a hosted SCADA system can help by limiting capital investments to only control system hardware such as local operator interfaces, instrumentation, and installation. If assets are already automated via a control system, the move to SCADA in the cloud is simplified even further.
Security, performance, reliability and maintainability are common concerns when deploying onsite servers and network infrastructure. By offloading these functions to a cloud provider, asset owners can focus more on running an efficient and profitable business.
Another benefit inherent to a properly designed cloud-based SCADA solution is scalability. As assets are bought and sold, the system can be ramped up and down in a quick, efficient, and secure manner. Integrated cybersecurity, in combination with the flexibility of user and role-based access control, allows for specificity of access to applications for any combination of view, control, and configuration per asset.
Meeting labor demands through automation
One of the biggest hurdles to efficient manufacturing is staffing. Companies are constantly trying to find ways to reduce overhead, save money, and increase production.
One way many companies have done this in recent years is through automated guided transport (AGT) systems. These work by having robots that travel along rails or tracks next to each other transporting materials from one area to another.
The robot picks up the material and takes it where it needs to go while someone stays back to monitor it. This cuts down on human labor needed to keep things running and organized.
Some even have computer chips built into them so they can detect changes in objects and need not be supervised directly. This gives engineers more flexibility when changing out parts or creating new ones.
These types of robotics come with their own set of challenges such as cost but overall they are a worthwhile investment if you want to remain competitive in the industry.
Aging workforce adapting to new technologies
The manufacturing industry is changing, and rapidly. Technology has improved efficiency of production across the board – from raw material procurement and processing, to product assembly and shipping.
This includes improving productivity through use of automation and robotics. They are used for repetitive tasks that can’t be or aren’t as efficient done manually, like assembling products or packaging materials.
The average cost of an automated robot in the United States is around $50,000-$100,000, which makes them accessible to almost any size business. There are many examples of companies using robots in their plants, even making a profit!
While some workers may feel threatened by changes such as this, it is important to remember that they are not going away anytime soon. Having experience with these new technologies is a valuable asset to most employers.
What people without technology expertise can do is learn how to work effectively within a plant environment that has been modified by tech. This will include things like learning how to communicate efficiently about changes, understanding what roles individuals have in the process, and knowing your job well.