Manufacturing Automation: The Future of Robotics in Factories

The complicated current state of the labor market within manufacturing is a key factor driving the implementation of high-tech robotics and automation. While the labor market in this sector has stabilized recently, serious challenges remain with talent recruitment and labor shortages. About one in five manufacturing plants reports that a lack of skilled labor is impacting production — and almost 60 percent state issues in getting and keeping reliable staff. 

It’s no surprise then to see a heightened focus on industrial automation — i.e., the use of control systems such as computers, robots and other technology for tackling numerous procedures and mechanical operations to replace or improve human involvement. Robotic helpers can take on simple and repetitive tasks (thus freeing up staff for more complex doings), can perform without breaks and can boost safety by doing jobs that might be risky for human workers.

Let’s take the example of an automotive factory navigating a shortage of skilled labor. Robotic helpers can help out with such tasks as welding, painting and even parts assembly — with work so precise that product waste and errors are greatly reduced.  

Data from an International Federation of Robotics 2024 report further backs up this trend, revealing that factory robot density (the number of operational industrial robots relative to the amount of human employees) was at 197 units per 10,000 humans in North America, up 4.2 percent over the previous year. Worldwide, that number has doubled in seven years. Needless to say, manufacturing automation continues to grow rapidly. Read on to learn more about the future of automation technology and how robotics are being integrated into manufacturing processes.

Why Robotics Continue to Rise in Manufacturing

Gary Zeppetella, senior offer manager of motion and robotics for Schneider Electric, recently wrote a piece for RS Online that highlighted six catalysts driving robotic trends in manufacturing today. In addition to labor shortages, increased operational efficiency, digital technologies, availability, interoperability and the global pandemic are all reasons for this quick growth in manufacturing automation. 

The COVID pandemic, for instance, helped create an industrial climate with challenges that automated solutions and robotics could overcome. “A global pandemic made manufacturing companies face numerous challenges, including isolation restrictions in the workplace, supply chain disruptions and labor shortages,” stated Zeppetella. “During that time, a focus on operational resilience accelerated the adoption of robotics technologies that support remote management and guidance.”

Benefits of Automation on the Factory Floor

The continued rise of automated systems and robotic integration into production lines has been a boon to the manufacturing industry for a variety of reasons. These include: 

• Increased productivity: This is the result of an automated system’s capacity to operate constantly without breaks, which also leads to higher production rates and, therefore, profitability.
• Better consistency and accuracy: The two happen when using robotics and other automated systems, as machines are more precise and human error has been removed from the process.
• Enhanced quality control: Due to better consistency, product quality also becomes better and can also be automated in many cases.
• Improved workplace safety: Automated processes improve safety in a few ways; a key one is the ability of robotic workers to function in hazardous situations and unhealthy environments without danger. 
• Flexibility and scalability: Since automated systems are typically reprogrammable, businesses can grow and scale more easily.
• Improved data analytics: Automation solutions normally include IoT monitoring tools combined with the use of machine learning algorithms to optimize real-time data collection that can be analyzed for better decision-making.

“The use of robotics in industrial applications can lead to increased sustainability in manufacturing by helping end-users meet their economic, social and environmental goals,” emphasized Zeppetella. “Manufacturers can increase process efficiency with faster cycle times, higher yields and lower costs by modernizing manual labor and small throughput tasks with robotics solutions.”

3 Types of Manufacturing Automation

In an industrial sense, there are essentially three main types of automation to take into consideration. 

• Fixed automation: Sometimes referred to as “hard automation,” fixed automation refers to the creation of systems to perform a specific set of functions continually with little to no variation. This type of automation achieves high production rates and is generally used for mass production of products. These systems aren’t about flexibility or easy reconfiguration but instead aim for precision and consistent high-quality results. Examples might include automated assembly machines and material-handling conveyor systems.
• Programmable automation: This describes a kind of automation system that’s programmed to streamline a variety of jobs or production processes. It’s a popular approach for making smaller- to medium-sized batches of products, where variations in design or manufacturing requirements are fairly regular. This kind of system normally includes reprogrammable equipment and human-machine interfaces in which operators can engage and interact easily with the machinery. Examples include programmable logic controllers (PLC), numerically controlled machine tools and the like. 
• Flexible automation: This references a sophisticated tier of manufacturing automation involving systems that can be quickly realigned to juggle different products, processes and production levels. High adaptability and responsiveness to fluctuating needs are hallmarks of these systems, which are also known for their advanced control systems aided by or integrated with computers — and their ability to integrate smoothly with other systems. Examples range from painting and materials handling to mechanical cutting and assembly.

How Automation Can Enhance Job Opportunities

For those concerned about the impact that robotics may have on job opportunities, automating tasks can actually enhance job prospects as well as work environments. By boosting production and efficiency, automation can help boost a manufacturing company’s bottom line and spur growth that could lead to more fulfilling jobs that require problem-solving and maintenance-related skills. And with robots and automation taking on tasks that are dangerous or physically demanding — or situated in unhealthy environments — workplace safety and job environments are improved. 

Additionally, as robotics and automation continue to flourish, a greater need will arise for workers to oversee automated systems. This grows the evolution of fresh skills and training courses, growing the overall skill level (and potential salaries) of the workforce. As the field evolves, we’ll even witness the birth of jobs that didn’t even exist previously, such as full-time robot programmers, new types of AI specialists and cutting-edge automation engineers. 

How to Implement a Robotics Solution

If you’re interested in implementing a robotics solution at your company, this digital transformation can vary greatly depending on a facility’s needs and the scale of your operation. But here are some basic steps to follow: 

• Application assessment: Determine any production bottlenecks or weak points in which robotics technology could boost efficiency. 
• Engineering and design: Perform risk assessments to ensure automation will not only help with efficiency but also maintain safety.
• Installation: Focus on making sure robots are programmed properly and that a factory acceptance test (FAT) is done. Operator training is also imperative during this phase.

Key Considerations When Implementing Robotics

As with most major technological advancements, there are a few things to consider before moving forward with an automation strategy. These include:

• Production speed: This is a primary factor to ponder when putting the proper robotics system into place. If a fast rate of fabrication is crucial, lean toward robots that provide high-speed functioning without short-changing you on precision. And keep in mind Advanced AI and sensors can boost system efficiency with both speed and accuracy.
• Operating environment: Environmental conditions, including temperature and humidity, are especially important to account for when implementing robotics. Another factor is assessing the existing equipment and processes within a facility and determining which system can boost efficiency while avoiding disruptions.
• Robot size: Consider their overall physical makeup to ensure they not only fit within the available space but can perform the required tasks. Do they have the weight and mass to do the required lifting or other tasks? Do they have the reach to seamlessly conduct their specific tasks?
• Scalability: While your immediate needs are the most pressing, if you think future expansion is on the potential horizon, it’s important to implement a system that can grow with your output. 

Manufacturing Automation Trends Today & Into the Future

So, what does the future of manufacturing look like when it comes to robotics and automation? Based on recent trends, we should expect robotic solutions to take on a more prominent and advanced role — and, in particular, become more independent from the need for human oversight. This rise in autonomy will very likely include:

• A greater use of artificial intelligence, allowing for more real-time detection of product defects and on-the-fly logistical decisions with managerial oversight. 
• An uptick in the area of cobots — collaborative robots that work alongside real people to increase productivity and safety. 
• Dark factories — fully automated production plants that run without any regular human oversight — may also become commonplace. Similarly, smart factories — facilities that allow robotics to become more intertwined with various systems to communicate and collaborate autonomously — are another likely trend.

While the newness and high-tech nature of this rising wave toward robotics may feel daunting to some maintenance and facility managers in the industry, a computerized maintenance management system (CMMS) like Coast can help in numerous ways. Maintaining robotics and implementing an operational strategy around workflow and equipment maintenance are just a few examples of what their cost-effective solutions can bring to the table as manufacturing moves forward into the future.