What we’re watching next in industrial

A $3.5 million automation overhaul just slashed the cycle time by 40%.

That’s the kind of result that gets attention, particularly in a manufacturing landscape where efficiency is paramount and margins are tight. This transformation—achieved by a mid-sized automotive supplier—wasn't just about flashy technology; it was a strategic integration of new robotics and advanced manufacturing processes that has redefined their production line.

Production data shows that the supplier’s new robotic system increased throughput from 150 units per hour to 210 units, directly contributing to a 14-month payback period that CFOs dream about. The initiative involved deploying two collaborative robots (cobots) alongside human operators, a move that floor supervisors confirm has led to a harmonious blend of automation and human skill.

However, it’s essential to dig deeper into what makes this project successful. While the figures sound impressive, they come with critical caveats worth noting—particularly for stakeholders evaluating similar investments.

Integration teams report that efficient project management and training were paramount. The initial setup required a dedicated week for training operators on the new system, a necessary step that avoided the pitfall of underprepared staff. In an industry where automation often fails due to inadequate training, this supplier's foresight paid off, ensuring that the cobots were not merely installed but effectively utilized.

Yet, not all tasks can be handed over to machines. The supplier still relies on skilled human workers for quality control and complex assembly tasks, emphasizing that while automation can handle repetitive actions, human judgment is irreplaceable for nuanced operations. The supplier's experience highlights a critical insight: understanding the limitations of automation is just as crucial as recognizing its strengths.

What’s more, hidden costs associated with automation often lurk below the surface, and this project was no exception. Although the cobots themselves were relatively affordable, the integration required significant investments in software updates and infrastructure modifications. Power requirements for the new systems added unexpected expenses, as did the need for additional floor space to accommodate the new layout.

What we’re watching next in industrial:

Training protocols: The importance of thorough training for operators to maximize ROI and avoid integration failures.

Task allocation: Identifying which tasks remain best suited for human workers to maintain quality and efficiency.

Hidden costs: Monitoring the often-overlooked expenses related to software and infrastructure changes when implementing automation.

Performance metrics: Keeping an eye on throughput and cycle time improvements as key indicators of automation success.

Workforce dynamics: Evaluating how automation affects workforce roles and responsibilities over time.

As the industry continues to evolve, these insights will be critical for plant managers, automation engineers, and CFOs navigating the complex landscape of capital expenditures and operational improvements.

Sources

Automation World

Control Engineering

Supply Chain Dive