As 2023 draws to a close, the industrial automation landscape continues to evolve. Artificial Intelligence (AI), Machine Learning (ML), Collaborative Robots (cobots), Internet of Things (IoT), 3-D printing and other technology advances continue to push industrial automation in new directions. Recently, a group of experts shared their insights about industrial automation trends and what 2024 may hold.

The experts:
Jim Beretta, Brand and Marketing Consultant, Customer Attraction Industrial Marketing, moderator for the webinar hosted by the Association for Advancing Automation (A3)
Joe Gemma, Chief Revenue Officer, Wauseon Machine
Jeff Wells, Director, Automation Sales, Ehrhardt Automation Systems
Tom Rozema, Chief Revenue Officer, JR Automation
Joe Wykes, Chief Revenue Officer, Vention

One of the legacies of the global pandemic is a continued global labour shortage. Wells noted that many customers are exploring automation for the first time, either as a way to automate functions to allow them to redeploy existing personnel, or as a way to meet continued labour shortages. This creates unique challenges for robot integrators, as new customers may be unfamiliar with the skillset required to support the automation, and may not have the necessary budget allocation. “The earlier the robot integrator can be involved in the project discussions, the easier it is to ensure that all the customer’s needs are met.”

Wykes noted that as technology becomes more accessible, the “inevitability of automation” has shifted automated solutions from a “nice to have” to “need to have.” In addition, companies need to be able to quickly produce new products in response to customer demand, and automation provides the speed to move from idea to execution. 3-D printing is becoming more mainstream, and with the process cycle improving, many companies are adopting 3-D printing solutions.

Many materials handling and warehousing operations are not only increasing the use of automated transfer vehicles (ATV) and autonomous mobile robots (AMR), they are adding cobots to ATV or AMR to complete additional tasks.

Wykes added digital twin and simulation allows companies to “de-risk” a project with a “like for like experience” to design, experiment and test a solution prior to execution and implementation. Gemma added that vision technology is providing an affordable innovative solution, especially when combined with ML and AI, 4D vision or lighting. Rozema noted they have seen broader use of digital twin applications to gain efficiencies in many industries with multi-sku environments or multiple product lines.

As part of this trend, there has been an increase in projects for low volume, high mix environments that require flexibility and fast or automated changeovers. In addition,many companies are scaling back internal engineering in favour of outsourcing technology or process improvements leveraging expertise readily available. Alternatively, companies are also making a skillset investment in technology-enabled engineers to drive automation in the businesses, or find ways to use automation to deliver more faster.

While many automation companies eat,sleep and breath big data, IoT and Industry 4.0, for customers it is often a case of diametrical opposition. Some customers have fully embraced big data, smart applications and IoT, while others are unfamiliar or have not added smart systems for managing the data, or allowing IoT connectivity. That can be a challenge for automation companies trying to introduce smart automation solutions or update existing infrastructure to include IoT and Industry 4.0 applications. Software, data and applications can provide opportunities for nimble, agile responses for manufacturers, and data management will become more important. AI and ML can provide assistance with adding smart solutions to a manufacturing operation that may have piecemeal automation solution.

Part of the challenge of big data is storage. In the advent of 5G, Cloud-based digital architecture has seen a shift. Improvements in security technology and protocols provide better digital solutions and allow for enhanced global technology connectivity, while adding a layer of protection against cyber attacks.

The labour shortage is not unique to manufacturing; robot OEMs and integrators also have trouble finding and retaining skilled talent. Apprenticeship programs were discontinued, and interest in manufacturing declined. In the advent of the new technology, the industry is partnering with education institutions to shape curriculum to spark interest in cutting edge manufacturing. Involvement in the school system with events like First Robotics generates excitement and interest from an early age. Once employees have been hired and trained, by providing enhancement opportunities, investing in management and providing flexible or hybrid work options companies have a better chance of retaining skilled and valuable personnel.

A legacy of the global pandemic was the resulting supply chain issues due to shutdowns and shipping delays. While there is a great deal of “chatter” about reshoring, in reality it has been more a “nearshoring” situation where companies have moved plants to North America but located them in Mexico rather than the United States. Rather than “reshoring”, companies are “stayshoring”, investing in factories in North America to ensure equipment and technology will be readily available in the future.

Looking forward into 2024, one of the technologies that Rozema thinks will continue to advance is generative AI to leverage technology and historical data to push out responses faster. Wells noted that he expects more consolidation in the automation industry in 2024, while Wykes felt that cobots will continue to provide opportunities for more widespread adoption especially when paired with simulation applications to make adoption easier and faster. He also noted that the trend towards “not if, but when” and “I may not have been first but I shouldn’t be last” will continue to drive innovation and adoption of the technology. Gemma is hoping for a national policy to support automation and development of the technology. The prevailing opinion that technology somehow takes jobs away is changing, and many countries in the world already have a national strategy.

Finally, a number of technology companies caught the attention of the panel in 2023.

Here are the ones to watch (in no particular order):
Apera AI 4D vision
Olis Robotics
Formic
Agility Robotics
Dexterity
Keyence
Flexibowl
Tulip
Universal Robots
Flexbotics

If you have an automation project and would like to learn more about some of the industrial automation trends from one of our automation experts contact us at sales@ehrhardtsolutions.com

Unscheduled downtime wreaks havoc on production schedules and stresses people to make up for lost time while protecting cost objectives.  Strategies for minimizing downtime used to focus on scheduled equipment maintenance and the ability to quickly repair anything that went wrong. Now, with automation, there is software and technology as well as hardware to manage. 

Having good service agreements and skilled repair people are still essential for keeping production running smoothly. However, technology has changed the playing field for preventing downtime by making data more accessible. Knowing exactly what is going on in your production process can completely alter the way problems are managed and mitigated. Data eliminates much of the guesswork about how much maintenance is needed, and what causes downtime. 

A system with built-in intelligence can also start to recognize patterns such as a temperature shift that regularly precedes equipment failure. Knowing the precursors to equipment failure can help preventive maintenance be much more effective. Critical equipment can be set up with monitoring sensors so that you aren’t limited to doing maintenance on a schedule, but rather by what the equipment actually needs.

To minimize downtime, multiple strategies can and should be deployed. We’ll explore some of the most effective strategies in this article. 

Identify root causes

What if downtime isn’t caused by machinery malfunction, but rather by process inefficiency? By monitoring the production line and gathering data, inefficient processes can be identified. For example, does a robotic arm “fail” because there is no part ready for it to pick up? The root cause of that problem lies further downstream, even though it might be the stopped robot that causes a production downtime event.

Streamline setups

Is setup taking much longer than it should? When retooling takes longer than it should, it moves from planned downtime to unplanned. In some cases, downtime costs may outweigh the cost of having extra equipment available to eliminate time lost to setup. It’s a good idea to re-examine setup processes to look for ways to improve efficiency.

Prevent human errors

Humans make errors, but some of them can be prevented. Knowing which errors are made repeatedly can help identify training needs or a procedure that needs optimization to minimize errors. In some cases, a “poka-yoke” may be needed. Poka-yoke is a Japanese term for mistake proofing. An example would be re-designing a component or tray so that it can only be oriented the correct way.  Eliminating the possibility to do things wrong makes training new operators easier, and minimizes mistakes that cause downtime. 

Mitigate supply chain issues

Keeping a minimal inventory works well when you can count on parts arriving just in time. Unfortunately, supply chain issues have compromised inventory predictability. Downtime caused by “waiting for parts” needs to be identified and addressed with procurement personnel. Reliability should be factored in to decisions about sourcing essential parts, and setting minimum inventory levels.

Allow time for equipment care

When setting KPIs, be careful to ensure that machine operators aren’t penalized for taking the time to stop and care for equipment. The old adage “a stitch in time saves nine” applies here. If operators are under pressure to keep production running at maximum speed at all times and not stop except for dire circumstances, they won’t be able to make small adjustments that can prevent a bigger stoppage later. 

Instead, build in time allowances and rewards for operators who do take the time to check, care, and maintain equipment to keep it running optimally even after their shifts are over.

Train operators using digital tools

Having properly trained operators is essential to keep equipment running; however, training people can slow down production. To optimize training, take advantage of simulators and digital options to allow adequate time for explanations and a complete understanding of how all equipment works, without the pressure of training on a running production line.

Multi-faceted strategies, data analysis, and digital tools offer many opportunities to minimize automation downtime.

To learn more about reducing downtime in your next automation project, contact sales@ehrhardtsolutions.com

Chad Ramsey, Director of Automation for Ehrhardt Automation Systems recently participated in The Robot Industry Podcast to share insights about how to reduce risk in automation.

Minimize Automation project risks
Some of the biggest risks in automation include cost, project delays, time to integration, design time and technology challenges. There are a number of things that can be done to minimize these risks during an automation project.

1. Comprehensive Specification Document
   One of the most important aspects of an automation project is the specification document. You need to have a good sense of what the project goals are, what components will be needed, and what you want the results of automation to achieve. Involving an integrator early in the process can ensure that your Request for Quote (RFQ) or Request for Proposal (RFP) is comprehensive and will achieve your desired results.

2. Qualify vendors early
   If you know what type of functions you want to automate, you can qualify 3rd party suppliers early in the process. Automate the functions that make sense in your operation, and are good candidates for automation. One of the biggest risks manufacturers are facing is a labour shortage, and robots can cover some of the shortfalls and labour challenges.

It’s important to remember there is nothing wrong with a manual integration station for components that may not lend themselves easily to automation. Collaborative robots are designed to work in tandem with their human counterparts, and processes can be custom-designed to switch seamlessly from robot to human and back.

3. Design for Assembly or Manufacturability
   Ehrhardt Automation specializes in 100% custom design integrations, and can work in tandem with manufacturing engineers to ensure the final project meets the needs of each client. It is important the integrator look at both the project as a whole and then at each component, including technical expertise at the client’s company, technological readiness-how open and familiar existing staff is with automation, risk analysis, safety concerns and then create an integration project solution to decrease overall manufacturing risk.
4. Staff
   Staff may be hesitant to support automation, seeing it as a way of replacing staff with machines. Ramsey said, “The earlier you can get your staff involved the better, really get their perspective and get their understanding. They may have some skills, feedback or perspective that you are not aware of. Getting overall perspective and understanding of the problems from the point of issue or operation is key.”

While initial training is essential and will provide a level of comfort, it is also important to include training in the budget in subsequent years. There is often a concentration on initial training, but retraining may not occur, and it is important to provide refreshers for ongoing success and to keep certifications active. In addition, ensuring more than one person is fully trained on the operation can both provide opportunities for peer training, and avoid situations where the only person who understands every aspect of the machine leaves the company, leaving no one ready to step in.

Finally, identify facility champions who can become subject matter experts, and become the point people for training and questions. Peer acceptance is the easiest way to widespread acceptance, especially if staff see the new potential and opportunities the automation is providing.

Importance of Specification Document
It bears repeating that a comprehensive specification document is the key to a successful automation project. Partnering with an integrator early in the process can ensure that a company new to automation will have all the important sections covered in the specification document.

The basis of any specification document is a clear understanding of what the automation project hopes to achieve. It can then include different sections, depending on the type and scope of automation.

The vendor document is often a standalone document within the specification document. It will often be a general document and then the specification document is equipment specific, and includes information such as run time, cycle time, piece to piece, including an operator. The more definition is the basis for a strong specification document.

Supplemental documents could include engineering drawings, or a call with an integrator to clarify and define all the specifications and requirements.

Engineering Study
Depending on the type of project, either the integrator, the customer, or both can request an engineering study as part of the proposal. This is often completed on projects that have higher elements of risk.

Engineering studies are intended to ensure that all components will work as intended, following safety protocols and tolerance levels. They ensure that all parties will be satisfied with the final project, and can include a physical design, a build and/or an integrated test with or without the customer present. Ramsey advised an engineering study can involve “10-30% of the project cost and that can be carried into the next stage of the project. Generally components and equipment that is acquisitioned as part of the engineering study can be moved into the main project, assuming the engineering study goes well.”

Common automation projects that would include an engineering study include:

Vision Robot automation vision systems can be impacted by light, the environment, shine or reflection, or even the colour of the part, so it is common to request an engineering study. It’s a relatively cheap and easy study, and 3rd party providers will often partner with the integrator to provide the vision engineering study as a value-add.

Robotics Some of the common engineering studies for a robotics project could include whether the robot can deal with non-standard, malleable or non-rigid parts or if a manual integration station will need to be incorporated.

New Technology Integrations that include new technology, such as 3-D printing or vision or IoT compatibility will request an engineering study to ensure the technology performs the way it needs to.

Deliverables from an engineering study can be as simple as tooling, video, reports or test parts. In complex builds, it could include a live demo with the customer onsite or watching via computer link. Since a successful engineering study will reduce risk and increase the probability of a successful installation, it is worth the cost and time to have an engineering study completed.

Non-Disclosure and Intellectual Property (IP)
One of the most important aspects of the specification document may include who owns any intellectual property that comes out of the engineering study and integration build. It is important for the company to obtain a non-disclosure agreement (NDA) and determine who will own the intellectual property (IP) from any engineering study or integration.

Generally, if the client is paying for the engineering study, it will include any parts or technology that is developed in the course of the study, and therefore it will be the property of the client.

In other instances, the integrator may be interested in some aspect of the design that is being created as part of the engineering study (for example, it is a new part or aspect of a vision system that would be beneficial to other clients) and therefore the integrator or supplier could offer a lower cost in exchange for the intellectual property rights of the component.

Health and Safety Risks
An integration install that is halted because no one thought to involve the health and safety engineer is the stuff of nightmares, so it’s always best to involve them early in the project. There are many safety modifications that can be simply and safely added to a design build, such as light curtains, barriers, sensors or rails, but it is easier to incorporate them into the design, rather than to have to hold up the installation while components are modified or moved to accommodate safety concerns after the fact.

Project Management
The last, and most important aspect of reducing risk in automation is good project management from the first day. Clear, frequent, and transparent communication is essential for a successful automation project, and all stakeholders in both the integrator and client sides should have the same understanding of what was sold and promised, and what the expected results are.

It’s easier to have one point of contact for each side, and protocols in place for design changes, issues that arise during design, installation, training and testing. If there is an issue, the project manager should be made aware of it immediately, as well as possible solutions or work-arounds, or potential delays.

A relatively new and serious risk that has emerged since the COVID-19 pandemic has been global supply chain challenges. Parts and components that pre-pandemic would have been available in 4-6 weeks can now require up to a one year lead-time, and if a supplier or integrator does not have a part on their premises, it could take several months to obtain it. Since many integrators offer replacement parts as part of their services, adding spare parts to an initial order has become more important than in the past.

A good integrator will have a plan, supply alternatives, or suggestions for workarounds. They will also be able to identify to the project manager early on if there will be supply chain issues, and how those issues will impact the timeline for the project. Timely communication and transparency can go a long way to a successful automation project.

Ramsey concluded “You want to partner with an integrator who doesn’t stick their heads in the sand but has a plan and alternatives. Every project is specific and communication is the most important aspect. Reducing net risk will increase the chances of a successful automation project. An integrator who is willing to communicate often and on a deeper level is a partner for success.”

If you want to learn more about how Ehrhardt Automation Systems Inc can assist you with your robotic integration needs, you can contact Chad at info@ehrhardtautomation.com.