Industrial Automation is transforming manufacturing units in innumerable ways. It provides a conducive environment for machines and humans to work together in harmony for generating desired outcome. From improved operational efficiency, enhanced product quality, to trouble-free management of production processes, industrial automation has remarkably benefitted the manufacturing industry.

Automation in Manufacturing Industry

Automation in manufacturing refers to the use of modern technologies such as robots, computer software, PLCs, HMI systems, SCADA, etc. to manage equipment and processes within a factory. A logic controller is employed to manage the sequence of production, provide instructions, and handle the overall processes. Manufacturing operations such as production, material movements, administration of shop floor, assembly of products, packaging, etc. can be automated. It reduces human intervention and results in increased output, productivity, and accuracy.

How is Automation Transforming Manufacturing Operations?

With the advent of automation tools and technology, manufacturing industries have seen revolutionary changes. Plant equipment and system automation has minimized the need for manual operations and maximized performance. Further, it has improved the utilization of existing resources and enabled the ability to integrate innovative solutions for increasing manufacturing efficiency. Many industries have recognized and taken advantage of the potential benefits that industrial automation offers. All the processes right from planning, to execution, to delivery, each step can now be automated easily.

Let’s have a look at some prominent applications of automation in manufacturing operations and how businesses can leverage them to their advantage-

Automated Production Line:

An automated production line comprises a series of workstations linked by a conveyor system and an electrical control system. Each station executes a specific operation, and the product moves along the entire production line in a defined sequence.

How automated production line benefit manufacturers?

Automated Production Lines directly translate to less human intervention; hence the following benefits can be derived from it.

1. Increased accuracy and quality of products.
2. Increased efficiency of overall production unit.
3. Swift and consistent production flow.
4. Reduced production cycle time.
5. Increased focus on system enhancement, planning, and supervision while machines do the job!

Various factories have leveraged the benefits of automated production lines and have achieved generated highest ROI. For instance: The production of a car in the automotive industry involves more than a hundred interconnected workstations where several parts are welded together, painted, assembled, checked for quality, and finally transform into a finished product. By deploying end-to-end automated lines dependency on human capabilities reduce, and factories can run 24×7 without interference of operators or shop-floor managers.

Use of Industrial Robots:

A wide array of applications ranging from pick and place, material handling, painting, mechanical cutting, plasma and gluing, assembly, inspection, machine tending, etc. can be performed using industrial robots. Almost any manufacturing operation can be performed with help of robots within a few minutes which might consume loads of time when performed manually.

How does the use of industrial robots benefit manufacturers?

Process automation with the use of industrial robots can ensure that production goals are met with minimum wasted efforts or expenses. Following are some of the most rewarding benefits of employing industrial robots-

1. Robots help decrease cycle-time and cost-per-piece with enhanced operational efficiency.
2. Robots can perform repetitive tasks persistently while maintaining precision levels of the products.
3. Robots are designed to be hard-wearing and can operate in hazardous environments. Leading to improved safety of working professionals.
4. Better floor space utilization can be achieved using robots.
5. Increased production output.

Industrial robots have proved extremely advantageous for industries as they outperform human capabilities in terms of working efficiency. Humans have certain limitations and cannot work for longer hours, on the contrary robots can work non-stop for days or weeks. For instance: Robotic arc welding is one of the crucial processes for manufacturing ecosystems. The use of Robotic arc welders can improve the safety of workers by preventing inhalation of hazardous fumes and arc burns that might occur during the process. Moreover, it can perform high-quality welds in a limited cycle-time with exactness and closeness.

Predictive Maintenance:

Industrial systems and devices can develop failures at any point of time, and in turn, it may impact the production schedules. But, with industrial automation, manufacturers can now predict such failures in advance and prevent such occurrences that lead to downtime. Predictive maintenance uses real-time conditioning monitoring and analysis, to predict when and which equipment needs maintenance. It is more targeted and addresses a definite issue, unlike preventative maintenance that happens on scheduled cycles or after equipment breakdown.

How predictive maintenance can benefit manufacturers?

1. Reduced cost of replacement since the issue is detected beforehand and necessary steps are taken before the damage occurs.
2. Reduced machine-downtime.
3. Enhanced equipment lifespan and efficiency.
4. Improved production planning and scheduling, as operators are already aware of the maintenance hours.

Considering the above benefits, predictive maintenance will aid in operational efficiency and help save costs involved in maintenance.

Mobile Control of Automation Processes:

The use of Wi-Fi-connected tablets, smartphones, and mobile devices has enabled the ease of managing operations with no restrictions of presence. Integration of such devices supports shop floor managers and operators to remotely detect errors, control, and monitor production processes.

How mobile control of automation processes can benefit manufacturers?

1. Enhanced supervision and monitoring of the overall process.
2. Reduced labor costs as less manpower will be required to handle the process.
3. Round-the-clock production with no need for the operator to be physically present.
4. Easy access to information anytime and anywhere.

The importance of controlling automation processes remotely can be understood from the recent scenario of the pandemic. While the movement of people to the workplace was restricted and many industries were running at minimum efficiency, the use of remote access and monitoring of the production process has turned out to be convenient and extremely useful. It can empower industries to run at maximum efficiency even in the toughest times and under most challenging circumstances.

Challenges in Adoption of Automation

While automation has gained enormous traction, challenges in adoption persist for many industries. The biggest challenges that limit industries to fully embrace industrial automation include, resistance to process transformation, lack of expertise for strategic implementation and planning, training of shop floor operators, and inability to align goals with automation needs. Industries lack expert support who can understand the nature of their manufacturing processes and provide innovative automation solutions aligned to their requirements.

Solutions Provided by ENWPS

ENWPS is a group of highly skilled professionals who specialize in supply, installation, supervision, commissioning, and training services for industrial automation. We provide innovative automation solutions and strategies for process design and development, integration of automation systems, improvisation, and enhancement of existing processes, etc. to help industries stay competent in the global environment. For availing reliable and quality automation solutions, contact us at: rfq@enwps.com. And one of our team members will connect with you shortly!

Industrial automation tools are highly configured technical equipment that can control and supervise the entire industrial process. These tools are the building blocks of the industrial automation system as they manage all interconnected devices and systems in the industry. Every industrial automation system is unique and needs a peculiar set of automation tools to integrate with the facility’s infrastructure and production process. These tools make mechanical and repetitive processes extremely easy. And enables the operation of each process with precision and accuracy.

Some key industrial automation tools are listed below, to help understand how industrial automation systems work.

PLC- Programmable Logic Controller

A Programmable Logic Controller works as the digital industrial computer control system that carries out various electro-mechanical processes in an automation environment. PLC continuously monitors data from input devices, processes the information, and concludes manufacturing operations based on it through a pre-programmed set of instructions. It is designed to withstand the harsh working environment and is capable of internal diagnostics.

The scope of industrial applications that can be achieved with PLC is vast. It can even work efficiently as a standalone unit in the industry. From welding, transporting, material handling, painting, purging, packaging and labeling, liquid filling systems, to any manufacturing operation. All the industrial processes can be automated and conducted efficiently with PLCs.

SCADA- Supervisory Control and Data Acquisition

SCADA systems are responsible for controlling, acquiring, and managing real-time data through direct interaction with HMI, sensors, PLCs, and other interconnected devices. SCADA systems continuously record data and events in a log file. This data helps diagnose and fix any issues in the process, mitigates risks of machine downtime, and later the data can be analyzed and optimized for increasing manufacturing efficiency. SCADA systems serve as the backbone of industrial automation and can be utilized in various industries like steel, food, and beverage, manufacturing, power, recycling, etc.

HMI- Human Machine Interface

HMI in industrial automation process plays a vital role in overall management of operations. As the name suggests, HMI or Human-Machine interface is a software application that allows human operators, processes, and machines to interact and work collaboratively in an automation surrounding. HMI converts complex data into a systematic format for strategically controlling the production process.

ANN- Artificial Neural Network

ANN works similarly to the human brain within an industry. It analyzes sophisticated data and factors affecting the manufacturing processes to enable better decision-making.

DCS- Distributed Control System

A distributed control system is a central monitoring network that interconnects different systems and devices within the industrial automation system. These systems are installed when advanced process control is required, and the facility is spread in a wide geographical area with thousands of input-output stations. Complex production processes such as oil refining, chemical processing, water treatment, pharmaceuticals manufacturing, etc. can be handled with DCS.

Robotics

The role of robotics in industrial automation involves a wide array of operations on the production line across various industrial sectors. Arc welding, painting, plasma and gluing, hammering, material handling, palletizing, laser cutting, etc. from simple to critical operations, automation of all the processes is possible. The ability to complete repetitive tasks with accuracy and maintain the highest quality standards is what makes robots viable for industries. Robots are designed to work in hazardous and most challenging environments that go beyond human capabilities. Employing robotics solutions can increase production efficiency drastically.

Optimize your Facility with ENWPS

A custom combination of these automation tools allows automating the industrial process that matches specific requirements. Machines, systems, devices, all work in synchronization to manage the processes and detect errors before it hampers the entire industrial process. Moreover, industrial automation yields safety, reliability, scalability, profitability, provides liberty to operate 24×7 and makes it possible to harness the resources and infrastructure to the fullest. Many enterprises are already leveraging the power of automation, and its high time that your business incorporates it too. At ENWPS we help industries upgrade and achieve their objectives successfully.

ENWPS is a turnkey industrial automation solutions company. Our service areas include-

1. Professional design and engineering services to fulfill the automation needs of a shop floor or assembly lines
2. Supply, Installation, and Commissioning
3. PLC, HMI, and SCADA Programming
4. Robot Programming
5. Data Analytics
6. IoT Implementation
7. Allied Services

With over two decades of expertise in the field, we have successfully provided reliable and hassle-free services for our prestigious customers.

Prepare your Company for Future

Gone was the time when these automation tools were considered a novelty and not everybody could access them. But with changing times, automation has become the standard practice in heavy, medium, as well as small industries. Connect with us at: rfq@enwps.com, +91 2066420320, and we shall be happy to assist you with automating your industrial processes.

With the emergence of modern industrial automation technologies, the way industries used to operate has drastically transformed over recent years. Whether it’s a small unit or a large enterprise, industrial automation has become more of a necessity than choice, and its scope is only increasing. According to Statista, the industrial automation market is projected to grow at a CAGR of around 8% from 183 billion dollars in 2020 to approximately 300 billion dollars in 2026. Apart from this, the disruption in operations due to Covid-19 led industries to rethink use of automation systems for enhancing the scalability and flexibility of operations. Industries looked up to automation and robotics solutions for achieving greater resilience to unprecedented circumstances and maintaining production efficiency.

To help businesses understand, evaluate, and implement industrial automation systems for transforming their facility into smart manufacturing units, we have compiled everything that businesses need to know!

What is Industrial Automation

Industrial automation comprises control systems and smart devices like computers, robots, etc., along with information technologies and computer software to automate industrial processes, eliminating the need for human intervention. For automating the industrial processes, a wide range of industrial communication, control, and networking devices are used, like PLCs, PACs, SCADA, DCS, Supervisory Control PCs, HMI devices, etc. Automating industrial processes helps achieve operational accuracy, financial benefits, enhance production capabilities, eliminate labor costs, etc.

Hierarchy of Industrial Automation Systems

The industrial automation systems are complex and include a plethora of high-tech devices that work in synchronization to achieve the desired result. Hence, for successful implementation of industrial automation in a business model, it’s inevitable to understand the hierarchical structure. For the convenience of understanding, the structure is presented in four levels consisting of devices, systems, and software used at each level.

Fig. Hierarchy of Industrial Automation System (Source)

1. Field level: This is the bottom level from where all the required data for further manufacturing processes are transferred to the control level by use of sensors and actuators. Sensors transform real-time parameters like flow, pressure, temperature, etc. into electrical signals for controllers to interpret and carry out the further process. Similarly, actuators convert electrical signals to form mechanical movements for the processes.

2. Control level: This is the automation execution level where process parameters received from sensors are acquired by automation devices like PLCs and CNC machines. The obtained information is then directed to actuators for programming specific operations.

3. Supervisor and monitoring level: At this level, supervisory and monitoring devices like HMI, DCS, and SCADA controls the overall automation process. From setting machine start to shutdown time, specifying product targets, historical archiving, controlling product parameters etc. is facilitated at this level.

4. Managerial or information level: This is the topmost level which deals with the entire automation system. It includes fewer technical aspects and focuses more on commercial requirements like production planning, market analysis, order tracking, sales, etc. Various communication networks like ethernet, field buses, serial communication systems, etc. are installed for the transfer and exchange of data throughout the hierarchical structure. Gathering data and deriving valuable insights from it is the most crucial step for the management of enterprise and making informed decisions.

Types of Industrial Automation

Industrial automation systems do not follow a one-size-fits-all approach, they defer according to the requirements of manufacturing processes. Therefore, it’s important to know various types of automation systems, to identify the most suitable type for your enterprise. On basis of integration level, and operational flexibility, following are the four main types of industrial automation.

1. Fixed (hard) automation
2. Programmable automation
3. Flexible (soft) automation
4. Integrated automation

For instance, an automotive industry will require flexible automation that can be easily integrated with infrastructure whenever introducing new models. Similarly, each type will cater to the diverse and unique requirements of various industrial units.

Industrial Automation Tools

For efficient management and control of industrial processes, an extensive range of automation tools is incorporated into the system. Industrial automation tools combine process, people, and technology to obtain desired results. Following are some of the key industrial automation tools used,

– Programmable Logic Controller (PLC)
– Supervisory Control and Data Acquisition (SCADA)
– Human Machine Interface (HMI)
– Artificial Neural Network (ANN)
– Distributed Control System (DCS)
– Robotics

Industrial Applications

Manufacturing, automobile, steel, shipbuilding, pharma, oil and gas, paper mills, packaging, etc. various industries can be benefitted from automation systems. With help of automation tools and employing reliable strategies various industrial processes like, packaging, material handling, welding, painting, metal fabrication, quality control, and inspection, inventory management, production planning, etc. can be automated.

Benefits of Industrial Automation

The advantages of industrial automation are not only restricted to businesses but also benefit customers, employees, and everyone involved with the business. From improved safety, reliability, better productivity, enhanced quality, lower operational costs, to reduction in machine downtime, etc. industrial automation has plenty of benefits.

1. Higher return on investment:

If implemented strategically automation systems can remarkably increase the profitability of businesses. Once past the initial implementation stage, automation provides innumerable benefits in terms of costs, ease of operation, etc. But it can only be achieved if the automation system installed is in sync with your process requirements. We at ENWPS, strategically design and implement automation strategies catering to diverse requirements of various industrial sectors. Check out our website for more information.

2. Elimination of error:

Since the entire process is automated, there are minimum possibilities for error as automation systems can detect errors at an initial level of production. Automated systems are also capable of self-diagnostics and quality control checks.

How Sensors and Actuators Drive Accuracy in Automation

Automation components such as sensors and actuators are the backbone of accuracy in industrial systems. Proximity sensors, for instance, detect the exact position of machine parts or materials without physical contact, ensuring precise alignment during assembly. Temperature and pressure sensors continuously monitor process conditions, feeding real-time data into control systems. On the other side, actuators like pneumatic cylinders deliver rapid linear motion, while servo motors provide high-precision rotational control for tasks such as robotic arms or CNC machines. By combining these components, automation systems maintain tight tolerances, reduce human error, and achieve consistent quality in production.

Be Future-Ready with our End-to-End Industrial Automation Solutions

Industrial automation has become an invaluable asset for companies around the world. With ever-growing significance and its potential to cater to custom consumer demands, the scope of automation is only going to fuel over time. It would be wise for businesses to rethink, renovate, and plan industrial automation implementation strategies for their facilities to stay relevant and competitive in the market.

ENWPS is an industrial automation solutions company located in Pune, Maharashtra (India). Our team designs, tests, validates, plans, implements, and takes care of all the operations involved for the successful installation of automation systems. Our team directly coordinates with industry personnel and provides necessary industrial automation training alongside installation and commissioning.

For more information, contact us at: rfq@enwps.com. We look forward to helping your business achieve its organizational goals.

Among applications that would benefit from early adoption of industrial 5G are obviously related to implementation of Industry 4.0 in manufacturing.

By now everyone is familiar with the term 5G from the mobile users’ perspective – an upgrade over 4G that will offer better cell phone services and browsing experience. But when it comes to Industrial 5G, it more than a generational shift, since 5G has a very strong focus on the industrial requirements of machine-to-machine communication and the Industrial Internet of Things (IIoT). Industrial 5G will revolutionise the IIoT experience with higher bandwidth and the kind of reliability never experienced before. It also provides a much higher device density and ultra-low latencies. So far, this kind of bandwidth and reliability came only with cable connections. With 5G, it becomes wireless, making it easy to connect the numerous devices without cables, ideal for the smart factory ecosystem. In short, industrial 5G will unleash the true potential of IIoT with a bandwidth to support massive data transfers required for artificial intelligence and machine learning applications in the journey of digital transformation.

Benefits of Industrial 5G

So far much of the talk about the smart factory was in the realm of theory, though the equipment as well as support systems – machines, robots, autonomous guided vehicles (AGVs), AR/VR/XR – were available. However the key element was missing – high speed data transmission in real time that makes the hardware operate to the full potential. With industrial 5G roll out within a striking distance, the fourth industrial revolution is now ready to take off. Consider these facts:

• At 20 Gbps, the peak data transfer rate of 5G is 20 times faster than 4G. 5G also has extremely low latency, which makes it as good as using cables for data transfer; and a high reliability of up to 99.99 per cent.
• There is no limit on the number of devices connected with 5G. If 4G can connect a maximum of 2000 devices in a given area, 5G can support up to 1 million devices in the same area, making it ideal for a smart factory where everything is connected.
• Of the smart factory, it is said only the structure of the plant – walls, floor and ceiling – is fixed and everything else could be moveable or reconfigurable for flexible production. Only 5G can support this kind of flexibility.
• Tailor made local networks under 5G communication standards can easily assure of data safety and security, with controlled access to authorised persons only.

Industrial 5G Roll Out

According to a study published recently by GSMA Intelligence, as of March 2021, 157 mobile operators have launched commercial 5G services in 62 countries. 5G is available in some locations in USA and Canada for about two years now with ATT and Verizon as service providers. So is the case in Germany, with Deutsche Telekom providing 5G services in cities like Berlin, Darmstadt, Munich, Bonn and Cologne by late 2019. Even UK and France have rolled out services in select cities from 2019 and 2020 respectively. In China, 5G services were rolled out at a few locations in 2019 by China Unicom.

After many missed deadlines and much delay, 5G trials have begun in India with the Department of Telecommunications granting permission to Bharti Airtel, Reliance Jio and Vodafone, as well as MTNL to conduct 5G technology trials recently. With that the trials have begun, the validity period being 6 months. The spectrum allocation will be done in days to come.

Major automation companies like Siemens, Bosch and ABB, among others have already commenced their own trials and have the hardware ready for the eventual roll out.

Applications to Benefit with Early Adoption

Among applications that would benefit from early adoption of industrial 5G are obviously related to implementation of Industry 4.0 in manufacturing, for more and more autonomous systems in factories. Other major application areas include the various services for smart cities including HD cameras to monitor safety; smart energy, such as smart grid control; smart buildings and connected offices, including sensor-based building management; and healthcare services including emergency services

In India, Capgemini in collaboration with Ericsson has set up a 5G Lab in Mumbai to accelerate the deployment of 5G solutions for industry to enable innovation, experimentation and deployment of 5G and Edge technologies for clients across industries. This is expected to bring a step-change in connectivity, services automation, autonomous devices and various applications. However, early adoption in India is expected to be in segments like energy and utilities, manufacturing and health care.

How ENWPS Can Help?

With over two decades of experience in executing several automation and robotics projects and providing various services, ENWPS is eminently qualified to handle industrial 5G projects. As of now 5G technology is still not widely implemented in industry and is a work in progress. But the need for such high reliability and low latency wireless services has long been felt. The technology is expensive and not every project needs it at the moment. The experts at ENWPS understand the nuances and can prioritize projects for implementation based on global use cases.

Talk to us today! Reach us on rfq@enwps.com

The modern PLC can be used to put in place a robust preventive maintenance programme.

What is a PLC?

A Programmable Logic Controller (PLC) is a type of computer used for machine control and is like the brain of a machine and holds the key for troubleshooting in case of any problem. PLC programming is done for specific tasks, so reviewing the steps in the program can lead to fault diagnoses and rectification. The PLC receives inputs from various sensors, switches, barcodes and other data fed by the operator, and gives output in the form of signals for the operation of motors, solenoids, indicators and alarms, etc., in a given sequence. Any change in the operation is effected through a PLC. Similarly any malfunction can be detected by reviewing the PLC actions. Now this is typical reactive maintenance once a fault occurs. Contemporary technologies go beyond that and in conjunction with IIoT devices and data analysis, a PLC can be used for predictive maintenance by anticipating faults and problem before they occur, analysing data patterns for anomalies and oddities.

How Data Acquisition Works in PLCs

For predictive maintenance, the PLC needs to use data, which is collected in course of the plant operation – data of parameters like vibration, temperature, electrical current, voltage, sound frequencies, pressure, etc., is collected by various sensors and dated, labelled and stored appropriately. While this data is good enough for regular troubleshooting, it is not enough for applications like preventive maintenance or other IIoT projects. The PLCs normally are programmed to measure parameters to indicate OK or Not OK, but not to monitor variations within those limits. This is because the primary role of a PLC is to control the machine operations and not data collection which is incidental. If any change has to be made in PLC operation, it needs a skilled programmer who may not be available and any attempt to do so without the expertise could actually have negative consequences. There are other methods of data acquisition but even those are not perfect.

So how can the data requirements for predictive maintenance be adequately addressed when it comes to PLCs? The answer here is provided by advances in technology, especially the IoT and Edge Computing devices that are now available for use with modern PLCs. These facilitate data collection from all the equipment (OT data) besides having the capability to process it further to provide structured data for storage in the cloud, also matching it with the requirements of the IT systems, offering transparency as well as greater control with better security through IT and OT collaboration. Modern PLCs also work with cloud platforms like Microsoft Azure or Amazon Web Services that make data collection and storage easier and provide tools to customise predictive maintenance operations as required.

Role of PLCs in Process Control & Monitoring

Plants exist to manufacture products, but the primary purpose of a plant is to make profit, which can be done only if the plant operates with optimum efficiency and minimum or no downtime. Any disruption in plant operation results in losses so process control and monitoring is extremely important, which brings the ball back to the PLC court. PLC, as mentioned earlier, is the brain of the machines and equipment, and is programmed to automatically control the operating conditions of the plant in which products are manufactured. Any deviation from process, in the absence of effective control, is likely to cause stoppage or worse, damage. Given the fact that most manufacturing processes are operating in harsh and hazardous environments, especially the chemicals or petrochemicals sectors, the smallest errors in reading of can cause significant safety problems and may even result in extensive damage to equipment or even loss of life. The role of a PLC in process control is thus central to safe plant operation with a predictive maintenance schedule in place.

Conclusion – How PLCs Ensure Smooth Plant Operation

A PLC is programmed to operate in a sequence and repeat the same in cycles. It can detect the status of each equipment operated with the output, and also monitor all input devices like sensors and switches in real time. It applies the user-created logic, and then executes it based on the input status, thereby controlling the devices like motors and valves, either turning them on or off. During these steps, the PLC also does a safety check by communicating with internal diagnostics and programming terminals, to ensure that everything is within normal operating conditions. Equipped with IIoT enabled data acquisition and analytics, the PLC acts quickly when a discrepancy occurs by alerting the operator, based on the built-in troubleshooting tools, initiating remedial measures. The modern PLC can be used to put in place a robust preventive maintenance program, avoiding costly downtime due to equipment failure.

ENWPS has been in business for 20 years and we specialize in Automation and Robotics. We provide innovative automated systems coupled with technology expertise. Our team of engineers, technicians and programmers design and develop customized solutions for a variety of end-user industries, including: Petrochemical, Manufacturing, Food and Beverage, and Pharmaceutical. Talk to us today! Reach us on rfq@enwps.com.