The Future of Manufacturing Automation in 2024

When the term “manufacturing automation” comes to mind, many people immediately envision conveyor belts, precise robotic arms handling products, and concerns about workforce reductions.

That’s an overall image of automation in manufacturing that people are aware of. Although it’s true to some extent, there’s so much to automation – thanks to the industrial robotics boom.

As assumed before, automation is not a threat to workers. But in fact, it’s a tool that can help and make tasks easier when utilised properly.

An automated manufacturing system is not just limited to the production line, you can use it for automating inventory, purchasing, order completion, and even marketing. In short, you can pretty much automate every manufacturing business process for better productivity.

The global market is projected to be worth $200 billion when it comes to industrial automation. And one of the major areas that will be benefited is the manufacturing industry. It is mainly as manufacturers will gain more control of the operations and increase production capacity or reduce costs through automating the manufacturing processes.

Industry automation has come a long way since the revolution. Now, we have intelligent systems, advanced robots, and connected devices that perform complex business for us while optimising the manufacturing process.

Yet, there is a lot to come. The future of manufacturing automation is exciting with emerging technologies and trends that promise to revolutionise the industry. And that’s exactly what we are going to explore in this blog – the trends and future of automation in 2024.

But before that… let’s look at what exactly we mean by manufacturing automation.

What is Manufacturing Automation?

In the context of manufacturing, automation means using technology and equipment to automate the production process without the need for human intervention.

The goal of manufacturing automation is to increase accuracy, efficiency, and productivity in the production process. It also plays an important role in minimizing human error as well as reducing manual labour. When we talk about automation, it includes everything from electromechanical systems that are programmed to perform several tasks to manufacturing business management.

Although the traces of automation are found from the pre-historic era, the industrial boom has given it a major uplift. According to the International Federation of Robotics, around 3.5 million industrial robots are in operation around the world. The study suggests a steady growth rate of 30% each year with a massive push post-pandemic.

Automation may not be the right choice for every manufacturer out there, but most companies can find benefits from implementing one of the different types of automation.

Types of Automation in Manufacturing

There are numerous ways to automate your manual production and business processes. Here are the basic five types of automation in manufacturing.

CIM (Computer-Integrated Manufacturing)

When the entire manufacturing process is run by automated programs, it falls under the bracket of CIM. It includes several types of automation systems including enterprise management, computer-aided engineering, robots, and automated integrations.

If you implement CIM, the product is often prototyped and then manufactured through a series of automated robotic line production. In this case, even the quality control, data management, storage, and distribution are automated.

IIoT (Industrial Internet of Things)

This automation type includes various devices and machines using AI (artificial intelligence) for connecting via sensors. This helps in enabling data and information to be shared in real-time which improves the output of the product. This process also includes machine-learning algorithms that in return help in improving the precision of the final product.

Fixed automation or Hard Automation

This automation mainly defines the process that includes repetitive actions in a production line. All the machines here are pre-programmed for performing a certain set of tasks with precision and consistency.

Robotic automation is one such type that includes a similar method where robots carry out tasks such as packaging and painting.

Associated with single-part production in large volumes, a very fitting example of fixed automation is a machine that dedicatedly produces a single type of gear automatically.

Programmable Automation

It refers to using higher-level programmable systems like PLCs (Programmable Logic Controllers) for controlling machines and devices to complete tasks and operations.

This type of automation majorly comes in handy while manufacturing products in batches that range anywhere from a few to thousands at a single time. Once a batch is done, the equipment needs to be reprogrammed again to adapt for the next product in line.

Associated with batch production, a very fitting example of programmable automation is a machine that automatically produces different types of gear with a changeover that causes downtime.

Flexible Automation

As the name suggests, this automation in manufacturing process type allows to change the demands for refined results. This method uses computer-controlled machines that can also be operated manually to make the changes at any time.

Associated with on-demand or real-time production, a very fitting example of flexible automation is a machine that automatically produces different types of gear without a need for manual changeovers or shutdowns.

Benefits of Automation in Manufacturing Industry

Reduction in Production Time

The topmost benefit of switching to the automated manufacturing process is the increase in production speed you get that helps with the growing competitive market.

We already know that machines can produce more in less time with fewer errors. And when you pair this with advanced sensors and robotics, you can achieve complete validation of the production as well as inspection process. This helps in maintaining the overall quality while maintaining the production rate.

Less Human Error

Reducing human error not only helps with better product quality but also acts as a way to achieve higher safety. This in return decreases any repairs, recalls of products, or any serious injuries to workers. This also allows you to use human resources for better purposes like the research and development part of the project.

No Shortage of Labour

If you think of it in a way, machines are very less likely to be in short supply. The technology of automation manufacturing can minimise the skill gap that we face as well as the shortage of the labour force. This in turn will show in the profit and overall livelihood of the manufacturing company.

Improved Tracking and Analytics

Automation uses sensors, advanced machines, and robotics to track inventory, maintenance, and finish products. This helps in easily dispersing data through the supply chain. The more optimised planning and scheduling of the business process help in better decision-making and ROI.

Big Trends For Manufacturing Automation in 2024

Automation in manufacturing is set to expand in 2024 staying in line with the steady growth since COVID. According to the speculations, the industry’s strength will continue to grow with technology, the use of AI, and the inclusion of smart tools.

Here are some of the top manufacturing automation trends most likely to rise in 2024 –

Increased Use Of AI

Artificial intelligence is already changing the face of factory automation and it will have a huge role to play in the coming year. According to a survey, it is estimated that around 93% of companies will include AI for growth and innovation.

Right now, AI is majorly used for machine learning like analysing data, optimising processes, and predicting equipment failures. However, in the future, it is expected to become more sophisticated and can learn from the experience and make decisions.

AI-powered systems can optimize production processes, predict equipment maintenance needs, and enhance quality control.

Integration of the Internet of Things (IoT)

The rise of the Industrial Internet of Things is expected to be a huge trend in the upcoming year. This type of automation increases productivity by severalfold as it connects smart devices via advanced sensors and automates manufacturing processes.

Although it is already used in several manufacturing processes, you can still expect greater integration in the future with more devices connected via the cloud. This connectivity can lead to better data collection, analysis, and optimization of manufacturing processes.

In short, it will allow you to collect and analyse data in real-time to make more effective and efficient decisions.

Expansion of CoBots

Collaborative robotics (CoBots) are robots that work alongside humans in industrial settings for manufacturing and other tasks. Unlike the bulky, huge traditional ones, these are more flexible, smaller, and can work safely along with human workers.

Next year, we can expect to see a rise in cobots given their affordability and ease of programming for smaller tasks. This improves the chance to automate tasks while maintaining the human touch.

The use of robots and collaborative robots will continue to expand, especially in tasks that are repetitive, dangerous, or require precision.

Growing Prominence of Cybersecurity

As manufacturing automation becomes more data-driven and connected, cybersecurity will become an important concern over time. You will need to take certain steps to protect the systems and data from cyberattacks as this could lead to downtime and physical damage to equipment.

In the future, we can surely expect to see robust cybersecurity measures implemented across the manufacturing industry. Some of them will likely include intrusion detection systems, advanced encryption algorithms, blockchain technology, and other security measures.

Increased Connectivity

With the arrival of 5G, you can expect an increase in connectivity, greater reach, and download speeds. A report suggests that 5G will enable the factories to improve productivity by 30%, assemble 50% faster, and 90% improvement in error detection.

So, automation of manufacturing is likely to increase demand for more 5G smart devices and machines.

Demand for New Skills

The rapid rise in technology and automation means that you will need upskilled labour who knows how to handle automation tools.

So, the new market will need manual labour specialised in areas like Augmented Reality (AR), Virtual Reality (VR), and other AI technologies.

The ability to understand, build, and utilise Digital Twins will also be in demand. Digital twin technology allows manufacturers to create virtual replicas of physical systems or products. This technology can be used for design validation, performance monitoring, and predictive maintenance.

Sustainability and Green Manufacturing

This era is all about sustainability and a green world. It creates a brand image and appeals to people when companies make efforts to keep our planet safe.

So, it is a no-brainer that manufacturers will increasingly adopt automation and robotics to reduce energy consumption and waste, aligning with sustainability goals and environmental regulations.

What are the Main Drivers to Understand the Future of Manufacturing Automation?

Understanding the future of manufacturing automation requires consideration of several key drivers and factors that are shaping the industry. These drivers are influencing the direction in which manufacturing automation is evolving.

Here are some of the main drivers to consider:

Technological Advancements

Rapid advancements in technology, such as robotics, artificial intelligence (AI), the Internet of Things (IoT), and machine learning, are driving automation in manufacturing. These technologies are becoming more accessible and cost-effective, enabling manufacturers to automate various processes.

Cost Reduction

The pursuit of cost reduction remains a significant driver for manufacturing automation. By automating repetitive and labour-intensive tasks, manufacturers can lower labour costs, minimize errors, and increase production efficiency.

Quality Improvement

Automation can enhance product quality by reducing human error and variability in manufacturing processes. Consistent, high-quality products are essential for meeting customer demands and maintaining a competitive edge.

Increased Productivity

Automation can significantly increase productivity by enabling continuous production and reducing downtime. Machines can work around the clock without fatigue or breaks, leading to higher output levels.

Supply Chain Resilience

Recent disruptions to global supply chains, such as the COVID-19 pandemic, have highlighted the need for resilient and flexible manufacturing processes. Automation can help manufacturers adapt quickly to changing market conditions and supply chain disruptions.

Customization and Personalization

 Consumer demand for customized and personalized products is increasing. Automation, especially through flexible manufacturing systems and 3D printing, allows manufacturers to efficiently produce customized goods.

Environmental Sustainability

Sustainability is a growing concern in manufacturing. Automation can help reduce waste, energy consumption, and environmental impact by optimizing resource utilization and minimizing material wastage.

Workforce Dynamics

The availability and cost of labour are changing in many regions. Automation can help address labour shortages, particularly in industries with difficult working conditions or a need for specialized skills.

Data and Analytics

 Automation generates vast amounts of data, which can be leveraged for predictive maintenance, process optimization, and informed decision-making. Data analytics and AI play a crucial role in manufacturing automation.

Regulatory and Safety Compliance

Compliance with safety regulations and quality standards is essential in manufacturing. Automation can help ensure consistent adherence to these requirements, reducing the risk of errors and accidents.

Global Competition

 In an increasingly competitive global marketplace, manufacturers are looking for ways to gain a competitive edge. Automation can lead to lower production costs and improved product quality, making companies more competitive.

Collaborative Robots (Cobots)

 The rise of collaborative robots, or Cobots, is making automation more accessible to smaller manufacturers. Cobots can work alongside human workers, enhancing productivity and safety.

Reskilling and Workforce Development

As automation becomes more prevalent, reskilling the workforce to operate and maintain automated systems is crucial. Investment in workforce development and training is a significant driver for the future of automation.

Cybersecurity

As manufacturing systems become more connected, the need for robust cybersecurity measures to protect against cyber threats becomes critical.

Government Policies and Incentives

Government policies and incentives, such as tax credits for automation investments or regulations promoting sustainability, can influence the adoption of automation technologies.

Is the future of automation in the manufacturing sector already here?

While the manufacturing sector has witnessed remarkable advancements in automation, it would be very early to declare that the future of automation has fully arrived.

Instead, we find ourselves in a dynamic period of transition where cutting-edge technologies like advanced robotics, artificial intelligence, the Internet of Things, and additive manufacturing are reshaping the industry’s future.

These innovations have certainly begun to revolutionize manufacturing processes, enhancing efficiency, quality, and sustainability. However, the true potential of automation in manufacturing is far from being realized completely.

Future developments and adoption rates will vary across industries and regions, as companies continue to adapt to changing market dynamics, workforce needs, and technological capabilities. As manufacturing automation evolves, it will be crucial for businesses to remain agile, stay informed about emerging technologies, and invest in workforce training to harness the full benefits of automation.

In essence, the future of automation in the manufacturing sector is an ongoing journey marked by continuous innovation and adaptation. It is a future filled with possibilities, and while significant strides have been made, there is still much ground to cover. The industry continuously pushes the boundaries of what automation can achieve in the pursuit of greater productivity, sustainability, and competitiveness.

As we approach 2024, the future of manufacturing automation is teeming with potential, promising further advancements and transformative possibilities. To stay at the forefront of this evolving landscape, businesses must remain vigilant, embrace innovation, and adapt to the changing tide of automation technologies.

Stay tuned for more updates and insights on the exciting developments in the world of automation. And if you need any help with understanding automation for your business, feel free to shoot a message.