Updated October 2025
Industrial automation is the use of computer-controlled systems such as robots, PLCs, and software to run industrial processes with minimal human involvement. It also uses information technologies to manage various processes and machines in an industry. This technology helps replace human workers.
It is the second step beyond mechanization in the scope of industrialization.
Key Takeaways:
- Industrial automation uses control systems like PLCs, robots, and software to run processes with minimal human input.
- The four main types of automation systems are fixed, programmable, flexible, and integrated.
- Benefits include improved productivity, safety, quality, and flexibility.
- Industrial automation is a key part of Industry 4.0 and the move toward smart factories.
Increase Quality and Flexibility in Your Manufacturing Process
In the past, automation aimed to boost productivity because automated systems could work around the clock. It also aimed to lower costs related to human workers (i.e. wages & benefits). However, today, the focus of automation has shifted to increasing quality and flexibility in the manufacturing process.
In the car industry, workers used to install pistons in engines by hand. This process had an error rate of 1-1.5%. Currently, automated machinery performs this task with an error rate of 0.00001%.
Advantages of Industrial Automation
Lower Operating Cost
Industrial automation eliminates healthcare costs, paid leave, and holidays associated with a human operator. It also does not need other employee benefits like bonuses or pension plans. While it has a high initial cost, it saves on monthly wages, leading to significant cost savings for the company.
The maintenance cost associated with machinery used for industrial automation is less because it does not often fail. If it fails, only computer and maintenance engineers need to repair it.
Increased Productivity
Many companies hire hundreds of production workers for up to three shifts to keep the plant running as much as possible. However, the plant still needs to close for maintenance and holidays.
Industrial automation helps the company achieve its goal. It allows the manufacturing plant to operate 24 hours a day, 7 days a week, all year long. This leads to a significant increase in the company’s productivity.
Improved Quality
Automation alleviates the error associated with a human being. Furthermore, in contrast to humans, robots never fatigue. This implies they can manufacture items of consistent quality at any given moment.
Greater Flexibility
A human operator must provide training to add a new task to the assembly line. However, programmers can program robots to perform any task, making the manufacturing process more flexible.
Accurate Information
Using automated data collection helps you gather important production information. It also improves data accuracy and lowers your data collection costs. This provides you with the facts to make the right decisions for reducing waste and improving your processes.
Enhanced Safety
Industrial automation can make the production line safe for employees by deploying robots to handle hazardous conditions.
Together, these benefits show how the automation of industrial processes transforms productivity and quality in manufacturing.
Industrial automation comes in various forms, each suited to different production needs. When people talk about types of industrial automation systems, they usually mean fixed, programmable, flexible, and integrated automation. Below, we’ll look at each in detail. Each type has its own benefits based on the manufacturing process.
Fixed or Hard Automation
Fixed automation is ideal for high-volume, repetitive production processes. It uses specialized equipment designed for a specific task, such as assembly lines in automotive manufacturing. Once set up, these systems run continuously with minimal adjustments.
Fixed automation works best in places where the production process stays the same. It offers high efficiency, speed, and cost savings for mass production.
Programmable Automation
Programmable automation is suitable for batch production, where the product design may change periodically. This type of automation employs machines that you can reprogram to perform different tasks or produce different products.
For example, electronics manufacturers might use programmable machines to produce different product models in batches. The ability to reprogram these systems offers flexibility while maintaining efficiency, making them ideal for industries with moderate production volume or product variations.
Flexible or Soft Automation
Flexible automation is the most adaptable form, allowing for rapid changes in production without significant downtime. This type of automation can manage different products and production processes. Ideal for industries that need to quickly adapt to market demands or create custom products.
Flexible automation uses robots, sensors, and smart software to make quick adjustments. This provides a high level of flexibility and efficiency. Industries like consumer goods manufacturing or small-batch production often use it where quick changeovers are necessary.
Integrated Automation
Integrated automation brings together multiple machines, processes, and control systems under one coordinated platform. Instead of isolated stations, each part of production communicates and works in sync – from robots on the line to sensors and data systems. This is the foundation of today’s smart factories, where IoT devices and software monitor and adjust production in real time. Integrated automation reduces downtime, improves consistency, and allows operations to scale more efficiently, but it also requires significant upfront investment and expertise to implement successfully.
Each type of automation offers strengths and suits different production environments. By understanding these differences, businesses can choose the most appropriate solution based on their production goals and market demands.
Disadvantages of Industrial Automation
High Initial Cost
The initial investment associated with making the switch from a human production line to an automatic production line is very high. Also, substantial costs are involved in training employees to handle this new sophisticated equipment.
However, these upfront costs yield substantial long-term benefits.
Potential Job Displacement
Industrial automation can lead to job displacement as machines take over tasks once performed by humans. This change may reduce some manual jobs. However, it also creates new opportunities in robotics, data analyzing, and system management.
Cybersecurity Risks
Highly connected automation systems can be vulnerable to cyberattacks if not properly secured.
Maintenance & Training Needs
Advanced systems require ongoing technical support and skilled staff to maintain and operate effectively.
To reduce the impact, reskilling programs are important. They help workers move into new roles and stay valuable in a more automated workforce.
Why Is Industrial Automation Growing?
The industrial automation industry is rapidly expanding because of several key factors. First, growing competition in the global marketplace forces businesses to streamline operations, reduce costs, and boost productivity.
Automation offers a way to stay competitive by enabling 24/7 operations, minimizing errors, and ensuring consistent quality.
Advancements in technology, particularly in robotics, artificial intelligence (AI), and the Internet of Things (IoT), have made automation more accessible and efficient. AI systems can now improve processes in real-time. At the same time, IoT devices gather important data. This data helps with better decision-making and performance monitoring.
Additionally, predictive maintenance technology helps identify issues before they occur, reducing downtime and extending the life of equipment.
As companies focus more on efficiency, sustainability, and growth, industrial automation solutions are becoming an important strategy. It helps them meet these needs and stay ahead in a changing market.
Examples of Industrial Automation
In modern factories, the automation of industrial processes is boosting efficiency across many sectors. Here are a few examples of industrial automation in action:
- Automotive Manufacturing: Modern car factories use robotic arms and automated guided vehicles to assemble products. These robots handle tasks like welding, painting, and installing parts with high precision and speed, greatly reducing human labor and error on the assembly line.
- Food and Beverage Production: Many food processing plants rely on computerized control systems and sensors for tasks like mixing, filling, and packaging. For instance, automated filling machines can fill and cap thousands of bottles or cans consistently, ensuring each unit meets quality standards while minimizing waste.
- Electronics Assembly: Electronics manufacturers use high-speed pick-and-place machines and robotic arms to build circuit boards and devices. These automated systems can mount tiny components onto circuit boards far faster and more accurately than a human, enabling efficient mass production of complex electronics with consistent quality.
- Warehouse and Material Handling: Warehouses and distribution centers employ automation through autonomous mobile robots, conveyors, and smart sorting systems. Such systems automatically move and sort products, often coordinated by an integrated industrial automation system that manages inventory flow with minimal human supervision. This reduces manual lifting, speeds up order processing, and improves safety in logistics operations.
Shaping the Future of Manufacturing
At Sure Controls, we understand the transformative power of industrial automation and why it’s gaining acceptance across so many industries. As manufacturing moves into the era of Industry 4.0, industrial automation is becoming the backbone of smart factories. Connected control systems, AI, and IoT sensors allow businesses to make real-time decisions, reduce downtime, and continuously improve production.
If you’re looking to integrate industrial automation into your manufacturing processes, our team is here to help. With our expertise in automation solutions, we’ll work with you to identify the best technologies and strategies to optimize your operations and achieve your production goals efficiently.
Let us show you how we can make automation work for you.