Understanding the 3 Types of Manufacturing Automation

Manufacturing automation has come a long way since it was first introduced after World War II. By the 1970s, it had become a common industrial method to improve productivity and efficiency. Today, it plays a crucial role in almost every manufacturing sector.

Automation in manufacturing means using technology to handle various tasks and processes, reducing manual effort and increasing efficiency. It helps businesses produce more in less time, with fewer human errors. Automation also shifts human involvement from repetitive tasks to more skilled roles like designing, operating, directing, installing, and troubleshooting automated systems, robots, software, and machines.

There are three main types of manufacturing automation: Fixed Automation, Programmable Automation, and Flexible Automation. Each of these is designed to meet different production needs.

Let’s understand them in detail.

1. Fixed Automation (Hard Automation)

Fixed automation is also called hard automation because it is designed to produce a single type of product in large quantities. Once the system is set up, the sequence of operations is fixed, meaning you cannot change the product design or process easily. It is best suited for high-volume production where the same product is manufactured repeatedly.

Since fixed automation systems involve specialized machinery, they require a high initial investment. However, this cost is justified by the high production rates and efficiency they offer. The biggest challenge with fixed automation is its inflexibility — changing the product design would require significant modifications, which can be expensive and time-consuming.

Examples of Fixed Automation:

• Automated assembly machines
• Web handling and converting systems
• Chemical manufacturing processes
• Material conveyor systems
• Machining transfer lines
• Paint and coating automation processes

This type of automation is commonly used in industries like automobile manufacturing, where large quantities of the same car model are produced efficiently.

2. Programmable Automation

As the name suggests, programmable automation allows manufacturers to program the machines for different tasks. Unlike fixed automation, where the system is rigid, programmable automation provides flexibility in producing different products, although in batches.

This type of automation is particularly useful when companies need to manufacture products in medium volumes, where each batch may be slightly different from the previous one. The system requires some setup time to change from one product to another, but this is much easier and cost-effective compared to fixed automation.

Key Features of Programmable Automation:

• Machines follow a programmed set of instructions.
• Suitable for batch production (dozens to thousands of units per run).
• Can handle different products, but requires reprogramming.
• High initial investment, but greater flexibility compared to fixed automation.

Examples of Programmable Automation:

• Numerically controlled (NC) machine tools
• Programmable logic controllers (PLCs)
• Industrial robots

Industries like electronics and packaging benefit greatly from programmable automation, as they often produce different variations of a product in small to medium batches.

3. Flexible Automation

Flexible automation takes programmability one step further. It allows manufacturers to switch between different product designs almost instantly without stopping production. This is made possible through advanced computerized control systems.

In a flexible automation system, machines are controlled by computers, and human operators manage the programming through Human-Machine Interfaces (HMIs). The system can produce multiple product types simultaneously with minimal setup time. This is ideal for industries that need to manufacture a variety of products in medium to low quantities.

Key Features of Flexible Automation:

• Highly adaptable to different product designs.
• No downtime between production batches.
• Controlled by a central computer system.
• Ideal for customized or made-to-order products.

Examples of Flexible Automation:

• Robotics
• Assembly systems
• Material handling systems

Flexible automation is commonly used in industries like consumer electronics and medical devices, where product designs change frequently.

Which Type of Automation is Best for You?

Choosing the right type of automation depends on your manufacturing needs:

• If you need to produce the same product in large quantities, fixed automation is the best choice.
• If you manufacture different products in batches, programmable automation is more suitable.
• If you require frequent changes in product design with minimal downtime, flexible automation is ideal.

Investing in automation can significantly improve production efficiency, reduce costs, and enhance product quality. However, it’s essential to evaluate the upfront investment, long-term benefits, and specific production requirements before making a decision.

Final Thoughts

Automation is transforming the manufacturing industry by improving efficiency, reducing costs, and enhancing quality. The choice between fixed, programmable, and flexible automation depends on your production needs. While fixed automation is best for high-volume production, programmable automation allows for batch production, and flexible automation provides the highest level of adaptability.

Investing in automation can give your business a competitive edge, increase productivity, and improve overall operational efficiency. If you are looking for an expert partner in manufacturing automation, PARC Robotics is your go-to solution.

Let’s build the future of manufacturing together!