Automation is the most talked-about term of the decade in manufacturing. While it might seem like this means it has been adopted in most manufacturing facilities, that is not the case. There is still some hesitation and misconception around its adaptation. Here are some of the most common reasons why manufacturers dismiss automation.
1. Not affordable:
This is the number one reason. Since automation is a newer technology, people associate this with hefty expenditures. But it’s expensive not to adopt it.
Through automation, processes become faster thereby increasing output. This reduces costs, mainly by eliminating the need for more manual labor, also achieving more in less time through minimum effort. This will improve the ROI justifying the need for automation.
Labor accounts for up to 75 percent of the total cost of a piece of nonautomated capital equipment. With automation, manufacturers can go for more efficient usage of employees while the operations are taken care of.
Automation also saves on energy expenditures as retrofitting or replacing an older machine with automation can reduce energy costs. Automated equipment runs steadily, bringing consistency in energy consumption.
Other minor costs like inspection, tool changes, etc are reduced due to consistent performance.
2. Not easy to use:
Automation technology can be a double-edged sword. Automation helps improve consistency by achieving better fit and form. Through this, final assembly is simpler and easily managed by low-skilled employees. When it comes to automated machines, they are complex, and operating them requires highly skilled employees.
The answer to this problem is in training. When your employees are properly trained, they do not feel threatened by automated technologies and feel confident thereby increasing the quality of work.
3. Not easy to maintain
Most automation systems come with inbuilt diagnostic technology that can help identify issues when they start. Along with the console that provides details of processes, operators can easily find out where the issues are and fix them helping remove most problems at the root. An automated system that has a modern control package design can ease your maintenance efforts.
4. Won’t adapt to new job demands
It is a fact that your work will change in the future. Today, a component shelf life or assembly program in the manufacturing world is much shorter than it was even two years ago. Now programs mostly last only somewhere between two to three years. This confirms the need for new programs.
The misconception is solved when the automated process is well designed for flexibility without complete retooling. This helps match the automation with the changing requirements without much hassle.
5. This is only for big volume manufacturers:
Since automation increases productivity, this means reduced cycle times and reduced scrap. Mainly, automation simplifies operations and where for smaller production setups, labor costs are a concern, this is of even more importance.
Automation ultimately helps you garner faster ROI and no matter the size or volume of production, it will add value to your process massively.
6. It’s a safety hazard
Good education of automation itself can eliminate most of the fear surrounding the safety of automation. Besides, the reality is that automation can enhance safety in the shop.
With proper training and integration of safeguarding machines and their controls, you can decrease the danger to the operators, improve their awareness of danger zones, and create a safe and fruitful operating atmosphere.
This content was originally published on the Ace Micromatic website.
