According to a recent survey of manufacturing companies in Quebec, it is striking to note that a large proportion of manufacturing companies are still managed using manual processes supported in part by office automation tools, whether for logistics, production, or product design. According to the study, approximately three-quarters of manufacturing companies have manual processes or processes supported by non-integrated tools, which means that the level of technological maturity is still low.
However, the same survey shows that while 6 out of 10 companies have appointed an in-house digital manager, only 25% of them have developed a strategic plan for their digital transformation.
It is clear that SMEs are eager to embrace the era of industrial automation, but where should they start, and how should they go about implementing it?
Throughout my career, I have helped numerous companies with their digital transformation processes. In fact, the company I founded specializes in industrial automation and control.
In this article, you’ll learn what industrial automation means for an SME, the simple steps involved, and key tips for getting started with industrial automation for your processes.
What is industrial automation?
First, it is important to clearly define what industrial automation is. According to Wikipedia, “it is the art of using machines to reduce workers’ workload while improving productivity and quality.” In other words, it allows a human to be replaced by equipment (machines, accessories, components, etc.) for repetitive operations or tasks where the operator does not add value.
Often (wrongly) associated with robotization—which the International Organization for Standardization (ISO) defines as “an automatically controlled, multi-purpose, reprogrammable, versatile manipulator system that can be programmed along three or more axes”, automation can take the form of small, low-cost initiatives for SMEs and extend all the way to the integration of custom-built machinery. Automation can be categorized into four main phases;
- Focus on “stiff” repetitive movements
- Focus on “flexible” repetitive movements
- Identify hazardous movements (too fast, too heavy, physically demanding conditions) with a focus on occupational health and safety
- Analyze the data to improve automation
Start with “rigid” repetitive movements that don’t add value
Rigid repetitive movements are defined as the movement of the same object on a repetitive basis. For example: I have a single type of pot that I need to move from point A to point B.
There are many options to consider before you decide to integrate a robot! Sometimes, adding a simple conveyor, a servo motor, or a palletizer would be enough to automate your production—or at least part of it.
Focus on flexible repetitive movements
Following the previous example, flexible repetitive movements could be defined by moving various types of containers of different sizes, shapes, and colors. Some programming is required to instruct the machine on the task it must perform for each container. Without resorting to robotics, you could consider adding a multi-axis gantry-type system.
Identify hazardous movements
Do certain tasks pose a risk to your employees’ health? Whether due to the weight of materials, the pace of work, or challenging physical conditions such as extreme heat?
Take a close look at your workstations, keeping in mind that you should prioritize digitizing those that pose the greatest risk of injury or that could lead to workplace incidents and/or accidents.
Analyze the data to improve automation
The final step is more about continuous improvement. It is not intended for all small and medium-sized businesses. Based on the data you’ve collected, take your thinking a step further: what can you automate to optimize your production?
Add shifts to boost your productivity and maximize the return on your equipment
Some companies are hesitant to invest in equipment for automation because they don’t see the return on investment. When embarking on such a process, it’s important to think big. By maximizing your machinery’s potential—that is, by running it 24 hours a day—you’ll be able to get a return on your investment while significantly increasing your productivity.
Engage and collaborate with your teams
We cannot stress this enough: your team’s involvement at every level is essential to the success of your industrial projects, and Industry 4.0 project management is no exception.
The SME must establish a relatively agile project team that is supported by senior management, guided by management practices (timeline, objectives, validation milestones with senior management, etc.), and led by one or more project managers.
Don’t forget your operators—they’re in the best position to support you in your industrial projects, and they have a thorough understanding of their work environment. If your team isn’t on board, you risk making major mistakes, particularly when assessing needs, and you’ll also face resistance to change during implementation.
Plan your digital transition
The labor shortage is driving small and medium-sized businesses to turn to automation for certain repetitive tasks. I strongly encourage you to begin your initiative with strategic planning to develop a solid, multi-year roadmap. Several grants are currently available for digital transformation, some of which offer reimbursement of up to 50% of project-related expenses. Cyr Automation can assist you with planning, as well as with the design and implementation of your projects.
Currently, the labor shortage is putting significant pressure on small and medium-sized businesses, and this is just the beginning. Do you sense the urgency? As the government is making various efforts to support businesses in their digital transformation initiatives, this is an excellent opportunity for you to explore the issue.
Get your team on board right away, and together, review the four phases listed above to kick off your automation process.
Please know that we are here to support you throughout the process if needed. There are several possible solutions, ranging from technological tools for collecting your data to the design and implementation of new equipment. In fact, we have created a project management guide that you may find useful (link to the guide).
We are experts in industrial project implementation. We handle the mechanical design, manufacturing, and automation of industrial machinery for manufacturers whose growth is being hampered, particularly by labor shortages.