What is industrial automation?

Production automation

It is the introduction of technical and software tools that partially or completely take over the management of the production process and the solution of production problems.

Why automate production

The main goal is to reduce manual labor, especially at stages where human intervention is not required, and to make the process repeatable, manageable and predictable.

Automation can solve the following problems:

Increase productivity

Equipment can work continuously in several shifts and accurately repeat all operations. This is especially important in batch and mass production, where even small deviations in working speed affect the result.

Reduce costs

Automation allows for more accurate dosing of raw materials, prevents energy waste, maintains optimal equipment operating modes, and prevents unplanned repair costs. As a result, production costs are significantly reduced.

Improve product quality

When an operation is performed by a machine, the result does not depend on operator fatigue, attention, or training. This reduces parameter variability and the percentage of defective products.

Ensure safety

Reduced manual labor means fewer risks for personnel. Automated production eliminates worker contact with hot workpieces, heavy equipment components, and toxic substances.

Levels of Production Automation

Individual production sections, entire production lines, or even entire enterprises can be automated. Let's look at the different levels of automation. They reflect the proportion of tasks performed by equipment and the degree of human involvement in the process.

Zero Automation

At this level, all operations are performed manually. The worker feeds the workpiece, selects the mode, starts the equipment, monitors the parameters, and makes process adjustments. The equipment may be mechanized but not have an automatic control system. Zero automation is typical for small-scale manufacturing and repair operations, where most tasks are still performed by humans.

Partial automation

Equipment performs individual functions, such as maintaining a set cutting speed, stabilizing temperatures, or shutting down in the event of overload. However, the main operations (feeding the workpiece, starting the cycle, and changing tools) remain the responsibility of the operator. Partial automation increases productivity and ensures consistent quality, but does not relieve personnel from routine tasks.

Comprehensive automation

Automation covers the entire processing cycle at the department or production line level. The equipment automatically performs all operations sequentially, without human intervention: it supplies workpieces, selects and changes tools, performs machining, and monitors the geometry of the part. The operator only sets the parameters before starting and monitors the operation of the equipment. This level of automation not only speeds up the production of products and helps to minimize defects, but also significantly reduces the dependence of production processes on human error.

Full automation

At this level, a centralized enterprise management system is built: production is integrated with planning, logistics, purchasing and other business processes. The following can be used for full automation: MES (Manufacturing Execution System) is a system that manages production orders, controls machine loading, tracks deviations and collects data on the completion of operations. APS (Advanced Planning and Scheduling) is a planning system that calculates the sequence of tasks, allocates resources and creates a production schedule taking into account all constraints. ERP (Enterprise Resource Planning) is a system that integrates production with other areas of the enterprise: purchasing, logistics, finance and warehouse operations. Full automation of processes allows management decisions to be made based on accurate production indicators obtained in real time.

Process Automation Systems

In industry, automation is most often implemented through automated process control systems (APCS). Let's look at how they work. APCS. How it works APCSs control the process at a specific production site. Their task is to monitor parameters, maintain set conditions, and quickly adjust the operation of equipment. The system performs routine tasks: measuring, comparing, adjusting, switching on and off. Such solutions are implemented in areas with continuous or repetitive cycles: heat treatment furnaces, pumping units, packaging lines, compressor stations, and conveyors. Such processes require constant monitoring and quick response, which technology regulates more reliably than people. Automation systems themselves consist of equipment (sensors, controllers, actuators) and software that processes data and provides control. Equipment APCSs are based on three types of equipment: Sensors measure temperature, pressure, flow rate, liquid level, and other parameters. Controllers process sensor data and issue commands according to a defined logic. Actuators are valves, pumps, motors, and other devices that, at the controller’s command, regulate the operation of equipment: turn units on and off, open and close gas flows, change processing speed, and so on. For example, if the temperature in a furnace exceeds the normal limit, the controller can reduce gas flow or activate cooling using a sensor signal. Software APCS software can vary in complexity. At the basic level, it is limited to the use of an HMI (Human Machine Interface). Controllers transmit signals to an operator panel, which displays current parameters and allows the operator to set desired values. These solutions are suitable for local control where centralized monitoring is not required. More complex systems use SCADA (Supervisory Control and Data Acquisition), a software package for dispatching control and data collection. It integrates data from different areas, visualizes the process and allows you to control the entire production process from a single screen.

Main types and methods of automation

Automation of production processes can be built in different ways, depending on the tasks, types of products and scale of production. Below are the main approaches used in practice. Rigid and flexible automation Automated solutions can differ not only in the level of implementation, but also in how easily they can be reconfigured for a new task. Two approaches are possible here: Rigid automation: The automation system is configured for a specific operation and does not allow for rapid reconfiguration. This approach is used in serial production, when large volumes of identical products are produced, or in areas with repetitive tasks, such as packaging and sorting lines. Flexible automation: Equipment can be quickly reconfigured for a new operation without disrupting the mechanism. This can be done simply by changing the program by defining new parameters, processing routes, or action algorithms. This is suitable for the production of small batches and custom-made products. Stages of implementing automation systems in an enterprise The implementation of automation is not a one-time purchase of equipment, but a consistent process that requires coordination between production, information technology, and economics. Here are the main stages that any enterprise goes through when switching to automated solutions. Audit The first stage involves analyzing the workflow structure. which operations take the most time, where failures occur most frequently, and which areas are unevenly loaded. The goal is to understand which processes should be automated first, what benefits this will bring, and what limitations need to be addressed. Design At this stage, technical specifications are developed, the system architecture is selected, and integration schemes with existing equipment and software are developed. At the same time, equipment, software, and contractors are selected. If the project is large, a phased implementation plan is developed to avoid production interruptions. Installation and commissioning Next, the purchased equipment is delivered to the site, assembled, connected to the network, and the connection between the nodes is configured. After that comes commissioning: checking all functions, testing, and adjusting parameters. At this stage, it is important to ensure the stable operation of the system in real-world conditions. Personnel training The system will not work without trained employees. Employees are trained to use new equipment and interfaces to run processes, monitor parameters, troubleshoot, and make adjustments. Training is provided by equipment suppliers, and sometimes external experts are also involved.

Trends and the Future of Automation

Industrial Internet of Things The Industrial Internet of Things (IIoT) is an approach in which each piece of equipment becomes a telemetry source that collects data on temperature, vibration, load level, operating time, and other parameters. Devices are connected to a network and transmit information to a centralized system, most often via a cloud infrastructure. IIoT makes it possible to: receive data from distributed sites in real time. monitor the technical condition of equipment without manual measurements. detect deviations before emergency shutdown. speed up diagnostics and simplify machine maintenance. Big Data and Artificial Intelligence Modern industry generates huge volumes of data from equipment, sensors, and information systems. To extract value from this data, fast processing and analysis tools are needed. This is achieved through Big Data technologies and machine learning algorithms based on artificial intelligence. They can be used to: identify hidden dependencies between process parameters. predict equipment wear and failure based on data. optimize capacity utilization and energy consumption. Set up adaptive control so that the system automatically selects operating modes based on current conditions. Automation is not just a way to save on employee salaries. Such systems help to make processes more efficient, reduce waste, and ensure consistent product quality, thereby achieving a more stable market position. That is why automation is becoming not an additional component, but the basis of a sustainable modern production model.