Practical Ways to Implement Automation Into Your Manufacturing Processes

Summary

Integrating automation into manufacturing processes has become a strategic imperative and a fundamental necessity for facilities seeking to enhance efficiency, increase throughput and remain competitive in a dynamic market. Businesses have taken note of its advantages, as a recent McKinsey & Company report said that over the next five years, automation is set to account for 25% of industrial companies’ capital spending. This includes AGVs/AMRs, radio remote controls, monorail systems, safeguard sensors and more.
 
Automation on its own is such a broad group of technologies. By analyzing your current manufacturing processes, you can gain a better sense of the specific types of automation that might seamlessly fit within your operations and where they can be adopted successfully. For moving products through production steps, you might consider a monorail system, a cost-efficient way of directing materials through a process line. Within your overhead crane systems, look at implementing radio remote controls that allow for tandem lifts, greater operator flexibility and visibility, and increased throughput.
 
There are various ways that facility managers and OEMs can implement automation within manufacturing processes to boost productivity and subsequently increase profitability throughout the year–let’s take a look at a few.

How to source and invest in the right equipment

The foundation of a successful automation strategy lies in the selection of and investment in the right equipment. There are countless solutions, technologies and equipment that can improve efficiency, boost safety and enhance productivity in the manufacturing space. To select the best solutions for your business and ensure a seamless integration, facility managers must source equipment that aligns with their specific production needs and long-term goals.

1. Locate existing pain points: Before investing in automation for your facility, start by conducting a thorough analysis of your current processes. Identify bottlenecks, areas of inefficiency and tasks that can benefit from automation–like repetitive, mundane, or dangerous tasks people currently manage. By understanding the unique requirements of your manufacturing processes, you can narrow down what type of automation is right for your facility and what equipment is necessary.

2. Engage with reliable vendors: Partnering with a reliable and comprehensive vendor is key to capitalizing on the power of automation. Identify partners with an extensive portfolio of products that can guide you to the best solution for your operations instead of a single product partner who may guide you toward their desired product. Partnering with someone to deploy your automated equipment or solutions can also help ensure your staff gets properly trained on the operations.

3. Implement scalable solutions for future growth: Look beyond immediate needs and invest in scalable automation solutions that can grow with your business. Future-proofing your automation strategy ensures adaptability to evolving market demands and technological advancements. To help offset the cost of new equipment or technologies, think through how it will benefit your business in the long run, not just immediately.

4. Invest in training programs: Equip your workforce with the skills needed to operate and maintain the newly acquired equipment. Investing in training programs ensures that employees are not only comfortable with the technology but also capable of maximizing its potential. On the flip side, automated systems tend to make it easier to learn and train new employees, cutting down on onboarding times and ensuring your facility is running as efficiently as possible.

Examining new automation priorities

With advanced technology and processes come increased safety procedures and protocols to keep workers out of harm’s way while also increasing equipment longevity. Today’s automation solutions significantly contribute to worker safety by cutting down on manual processes, increasing worker flexibility and visibility, and modernizing outdated equipment.
 
For example, within crane operations, we’re seeing greater adoption of modern safety features, including sensor-based systems that include load moment indicators, anti-collision systems and zone monitoring to minimize the likelihood of operator injury. Facilities are also adopting mobile robot technology like AGVs and AMRs within operations to reduce repetitive tasks for workers while also increasing safety and compliance by providing real-time insights, enabling predictive maintenance and improving decision-making.
 
In an automated manufacturing ecosystem, the efficient transmission of data and seamless communication between various components are critical to keep things moving and ensure worker safety. Facility managers need to establish a secure, direct and reliable communication network through power and control systems to efficiently direct loads with varying sizes and weights through the production line without interruption.
 
In traditional manufacturing settings, automation and digital transformation have been strongly associated with WiFi infrastructure. However, this can lead to potential drawbacks like outages, cybersecurity risks, inconsistent coverage and limited range. To avoid costly disruptions and unplanned downtime, consider infrastructure beyond WiFi–such as a hardwired PLi-Fi (Power Line-Fidelity) connection. A solution like this can be easily retrofitted, has nearly no maintenance, and works across usage types and existing footprints. The result is enhanced security, reliability and visibility for your employees and facility.
 
Ultimately, automation is not just a choice but a necessity for thriving in a competitive market. Automation can be used as a strategic tool to propel your facility into a new era of efficiency, safety and productivity, but it’s important to pinpoint exactly where your processes can benefit from these solutions the most before expanding to the rest of your facility.