What is Fixed Automation?

Get to know industrial automation, an important part of modern manufacturing, focusing on fixed automation systems. This article will help you understand the benefits and drawbacks of this system, which are great for consistency and high-volume production but can be rigid and expensive to set up.

In-Depth Understanding of Fixed Automation

Industrial automation plays a pivotal role in modern manufacturing, offering a diverse range of systems tailored to specific production needs. Among these, fixed automation, also known as hard automation, stands out as a consistent performer. According to a report by McKinsey, automation will account for 25 percent of industrial companies’ capital spending over the next five years. Characterized by its unyielding workflow, high-volume production capabilities, and inflexible structure, fixed automation is designed for repetitive tasks with minimal variation.

In fact, the world can save 749 billion working hours by automating 64 percent of manufacturing tasks according to Windward Studios. While it excels in maintaining consistent quality and automating material handling, it poses challenges when it comes to accommodating changes and incurring high initial installation costs.

What are the Pros and Cons of Fixed Automation?

Fixed automation systems are often used where the manufacturing process remains unchanged over time. They shine in environments where high-volume production of identical units is required and where tasks are consistently repeated. These systems rely on programmed commands and computer control for a smooth and predictable production process.

Advantages of Fixed Automation

• High Production Levels: One of the key advantages of fixed automation is its ability to generate large quantities of products efficiently. This leads to a lower cost per unit produced, making fixed automation a cost-effective solution for businesses with high production needs.
• Consistent Quality: With an automated process following a set procedure, there’s less room for error, leading to better output quality. The production procedure is also easy to trace, allowing for quick identification and resolution of any issues.
• Reduced Maintenance: Fixed automation systems are designed for durability and rarely fail, resulting in decreased downtime. This reliability means they require less maintenance compared to other types of automation systems, improving workplace safety.

Limitations of Fixed Automation

• Rigidity: Fixed automation systems can be less suitable for businesses with fluctuating production requirements or short product life cycles due to their inflexible structure. They struggle to adapt to new products or process alterations.
• High Initial Cost: While more economical in the long run due to lower per-unit costs and reduced maintenance expenses, the upfront investment required to set up these systems can be substantial.

6 Fixed Automation System Examples

Fixed automation is primarily used in manufacturing settings where high-volume, repetitive tasks are performed with minimal variation. Here are a few key uses of fixed automation:

1. Automated Assembly Machines

Automated assembly machines are used in industries such as automotive, electronics, and appliance manufacturing. They perform tasks such as placing parts into a product, securing parts together, and performing quality checks. With high precision and speed, these machines can produce a large volume of products in a short time, reducing cost per unit and enhancing productivity.

2. Chemical Manufacturing Processes

Fixed automation systems are extensively used in chemical manufacturing processes. These include automated batch processing systems that control the sequence of operations, continuous process automation systems that manage ongoing production processes, and hybrid systems that combine elements of both. Such systems ensure precise control over variables like temperature, pressure, and flow rate, leading to consistent product quality.

3. Material Handling Conveyer Systems

In industries such as food and beverage, warehousing, and logistics, material handling conveyor systems move products from one stage of the production process to another. They are designed for efficiency and reliability, reducing manual labor and minimizing product damage.

4. Machining Transfer Lines

Machining transfer lines are common in the automotive industry where different machining operations are performed in a sequence. Each station performs a specific task, and the workpiece is transferred automatically from one station to the next, ensuring high-speed production and consistency.

5. Paint and Coating Automation Processes

Paint and coating automation processes involve the use of robotic arms and automated spray systems to apply paint or coating to products. These systems ensure uniform application, reduce waste, and protect workers from harmful fumes.

6. Web Handling and Converting Systems

Web handling and converting systems are used in industries like paper, film, and foil manufacturing. These systems manage the unwinding, processing, and rewinding of materials in a continuous manner, ensuring high-speed production and consistent quality.

While fixed automation provides numerous benefits such as high-speed production, consistent quality, and efficient material handling, it is less flexible when it comes to accommodating changes in the production process. Therefore, it is most suitable for industries that require high-volume, repetitive production with minimal variations.

Smart Factory Suites and Fixed Automation

Smart Factory Suite, offered by Shoplogix, is a comprehensive platform that can be integrated into fixed automation systems to further enhance their capabilities. Here’s how:

1. Real-Time Data Collection and Analysis: The suite can connect to any machine, old or new, to collect, calculate, and analyze key efficiency metrics across the organization. This real-time data collection can provide valuable insights into the performance of fixed automation systems, enabling manufacturers to identify and rectify inefficiencies.
2. Improved Operational Efficiency: By utilizing the suite’s advanced analytics and manufacturing intelligence, manufacturers can make data-driven decisions that improve operational efficiency. This is particularly beneficial for high-volume production environments where fixed automation systems are commonly used.
3. Rapid Deployment and Scalability: The suite can be fully deployed in weeks and collect data in days using configurable preset templates based on client best practices. This rapid deployment and scalability make it an ideal solution for industries using fixed automation systems that require minimal downtime.
4. Enhanced Quality Control: The suite includes modules for quality control, which can complement the consistent quality output delivered by fixed automation systems.
5. Efficient Energy Management: The suite also offers energy management features that can help manufacturers using fixed automation systems to monitor and reduce their energy consumption.

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Final Thoughts

Fixed automation serves as a cornerstone in industrial manufacturing, particularly for high-volume, repetitive tasks. While it presents challenges in terms of adaptability and initial costs, its ability to ensure consistent quality and streamline material handling makes it a valuable asset in the right production environment. By understanding the unique characteristics and trade-offs of fixed automation, businesses can make informed decisions regarding its implementation, ensuring that it aligns with their specific production requirements and long-term goals.