For many manufacturers, the prospect of an automated, human-free factory feels light years away. Will Industry 4.0 and IIoT be effective in changing the way we work, and can automation address worker and skills shortages?
In a recent blog, Omron Automation looked at the realities of full and semi-automated manufacturing, the role of robots and why humans remain almost irreplaceable.
Some goods are not suited to an automated line, and some processes are impossible without human intervention or co-operation. Yet mass production aims to deliver ideal efficiency and cost-effectiveness, with the greatest profit and return on investment.
Digitalisation is not binary
Certain products demand a hands-off approach like semiconductor fabrication where contamination risks are high. But what about those manufacturers producing low-volume, high-mix products to maximise customer choice? Is their route to automation blocked by their need to differentiate?
Digitalisation is not binary, at least not in the sense that it is all or nothing. Every manufacturer can make at least some use of automation technology. How much though, depends on a range of factors. For example, how much of the production process requires complex decision-making and improvisation: areas suited to humans.
Worker and skills shortages
Today there is a move to production lines where the skill of the operator is most valued, such as in supervisory roles. Also, by aligning the attributes of humans with the tireless efficiency and accuracy of automated collaborative robots (cobots).
But how do manufacturers establish where and how to automate their lines? How can they see where to realise cost savings, or what the end results will be, before investing in what might feel like a disruptive change? This is the realm of the system integrator, and the technology vendor. The partners to industry who can show traditional manufacturers how their operations can benefit by starting a move into digitalisation.
Proof of concept
From system analysis to full on proof of concept, covering separate line applications to entire facilities. In this role, trusted integrators are the first point of contact for manufacturers seeking improvement. OMRON also offers its services in this process, and its proof-of-concept laboratory and high-tech facilities where prototype systems show exactly how manufacturers can benefit from automation. So, what can manufacturers expect?
A digital look ahead
Machine vision is a growing field of automation, with advanced 3D vision systems that address complex pick & place operations. Until recently, cameras were only able to process products in fixed positions on the line. Today, high-resolution cameras coupled with machine-learning algorithms can identify objects randomly positioned in transport bins. This increases the viability of camera systems for varying products, running at faster speeds on automated lines.
Advances in robotics
There is one area where the modern factory is most aided by automation and that is in robot technology. From intra-logistics moving materials and sub-assemblies through the production line to fixed-line robots, to collaborative units. It is here that producers can realise real savings. Introducing the right robots in the right place helps realise savings in time, energy, safety, and cost.
The range of robots that are available for everyday tasks both working alone or alongside a human operator comes as a surprise to many businesses. For example, cobots are simple to program, and easy to re-deploy for different tasks. They combine mobility, dexterity, and accuracy, enabling the automation of ever more complex tasks. A good way to overcome worker and skills shortages.
