{"id":30820,"date":"2025-07-04T13:57:59","date_gmt":"2025-07-04T11:57:59","guid":{"rendered":"https:\/\/i-mas.com\/what-types-of-industrial-automation-are-there-and-what-advantages-do-they-offer\/"},"modified":"2025-07-04T13:57:59","modified_gmt":"2025-07-04T11:57:59","slug":"what-types-of-industrial-automation-are-there-and-what-advantages-do-they-offer","status":"publish","type":"post","link":"https:\/\/i-mas.com\/en\/what-types-of-industrial-automation-are-there-and-what-advantages-do-they-offer\/","title":{"rendered":"What types of industrial automation are there and what advantages do they offer?"},"content":{"rendered":"\n<p>In<a href=\"https:\/\/i-mas.com\/en\/integrated-industrial-automation-solutions-from-idea-to-implementation\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong> industrial automation<\/strong><\/a>, the terms \u201cfixed,\u201d \u2018programmable\u2019 or \u201cflexible\u201d describe much more than the technology next to the line. They define the factory&#8217;s ability to adapt to market, <strong>product design<\/strong> and talent challenges. Knowing the differences-and combining them with <strong>machine vision<\/strong> and <strong>robotics systems<\/strong>-is crucial to designing <strong>process automation<\/strong> projects that are scalable and cost-effective.   <\/p>\n\n<p>The advent of compact servomotors, the falling cost of sensors and the standardization of protocols such as OPC-UA have democratized these technologies even for SMEs, which no longer need to invest millions to benefit from <strong>automation<\/strong>. <\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Fixed automation: maximum productivity, minimum versatility<\/strong> <\/h2>\n\n<p><strong>Hard automation<\/strong> employs machinery dedicated to an invariable sequence of operations. It is the preferred choice when volume is very high and reference changes are infrequent. Its <strong><a href=\"https:\/\/i-mas.com\/en\/integrated-industrial-automation-solutions-from-idea-to-implementation\/\" target=\"_blank\" rel=\"noreferrer noopener\">precision and speed<\/a><\/strong> make it the queen of continuous environments, such as car body welding or beverage bottling.   <\/p>\n\n<h4 class=\"wp-block-heading\"><strong>What are the advantages of fixed automation?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Extremely low cost per piece. <\/li>\n\n\n\n<li>Production rates impossible to match manually. <\/li>\n\n\n\n<li>Almost perfect dimensional repeatability. <\/li>\n<\/ul>\n\n<h4 class=\"wp-block-heading\"><strong>What are the limitations of fixed automation?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>The line must be stopped (or redesigned) at any design change. <\/li>\n\n\n\n<li>High initial investment, amortizable only with large lots. <\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><strong>Programmable automation: the bridge between batches and customization<\/strong> <\/h2>\n\n<p>In <strong>programmable automation<\/strong>, the mechanics remain, but the logic is modified by software. By reprogramming a <strong>PLC <\/strong>or a <strong><a href=\"https:\/\/i-mas.com\/en\/the-integration-of-humanoid-robots-in-industrial-environments-opportunities-and-challenges\/\">ro<\/a><a href=\"https:\/\/i-mas.com\/en\/the-integration-of-humanoid-robots-in-industrial-environments-opportunities-and-challenges\/\" target=\"_blank\" rel=\"noreferrer noopener\">b<\/a><a href=\"https:\/\/i-mas.com\/en\/the-integration-of-humanoid-robots-in-industrial-environments-opportunities-and-challenges\/\">ot<\/a><\/strong>, the plant can move from one series to another without replacing equipment.  <\/p>\n\n<h4 class=\"wp-block-heading\"><strong>When is programmable automation recommended?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Medium batch production with frequent changes. <\/li>\n\n\n\n<li>Pre-series or ramp-up phases where the product is still evolving. <\/li>\n\n\n\n<li>Organizations seeking a balance between variety and unit cost. <\/li>\n<\/ul>\n\n<p>The<strong> SMED <\/strong>facility reduces downtime and allows niche markets to be exploited without dramatic penalties in overall equipment efficiency. <\/p>\n\n<h2 class=\"wp-block-heading\"><strong>Flexible automation: the heart of Industry 4.0<\/strong> <\/h2>\n\n<p><strong>Soft automation <\/strong>takes adaptability to the extreme. It combines<strong> robotic modules, intelligent sensors and cloud-based software<\/strong> to reconfigure operations in minutes &#8211; or seconds &#8211; without stopping the line. It is the natural enabler of <strong>mass customization <\/strong>and on-demand production.   <\/p>\n\n<h4 class=\"wp-block-heading\"><strong>What are the benefits of flexible automation?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Format change \u201con the fly\u201d. <\/li>\n\n\n\n<li>Native integration with <a href=\"https:\/\/i-mas.com\/en\/the-future-of-scada-systems-trends-and-challenges-in-industrial-supervision\/\" target=\"_blank\" rel=\"noreferrer noopener\">MES\/SCADA<\/a> and IoT for data-driven decisions. <\/li>\n\n\n\n<li>Manufacturing unit batches with the efficiency of a massive line. <\/li>\n<\/ul>\n\n<h4 class=\"wp-block-heading\"><strong>What are the challenges of flexible automation and machine vision systems?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Complex initial engineering and higher CAPEX. <\/li>\n\n\n\n<li>Dependence on profiles with digital skills and industrial cybersecurity. <\/li>\n<\/ul>\n\n<h2 class=\"wp-block-heading\"><strong>Machine vision and robotics: value multipliers<\/strong> <\/h2>\n\n<p>Any of the three models increase their performance when<strong> industrial robots <\/strong>and <strong><a href=\"https:\/\/i-mas.com\/en\/machine-vision-and-ai-keys-to-a-more-competitive-industry\/\" target=\"_blank\" rel=\"noreferrer noopener\">machine vision systems<\/a><\/strong> are added. Robots provide <strong>repeatability and ergonomics<\/strong>; vision <strong>detects defects, guides the robot and feeds the quality system in real time<\/strong>.  <\/p>\n\n<h4 class=\"wp-block-heading\"><strong>How do machine vision and robotics combine to optimize industrial automation?<\/strong> <\/h4>\n\n<ul class=\"wp-block-list\">\n<li>Elimination of manual inspections that slow down the flow. <\/li>\n\n\n\n<li>Reduced returns due to early detection of defects. <\/li>\n\n\n\n<li>Comprehensive traceability for zero defect projects and continuous improvement. <\/li>\n<\/ul>\n\n<p>Companies such as <strong>Ford <\/strong>have already demonstrated <strong>increases of up to 15%<\/strong> in assembly speed by <strong>integrating AI <\/strong>into the control of existing line robots. <\/p>\n\n<p>Ultimately, selecting the most appropriate choice between <strong>fixed, programmable or flexible automation<\/strong> requires an assessment of demand volatility, product life cycle and available budget. <\/p>\n\n<p>In the<a href=\"https:\/\/i-mas.com\/en\/engineering\/\" target=\"_blank\" rel=\"noreferrer noopener\"><strong> engineering department of I-MAS <\/strong><\/a>we apply methodologies based on more than 20 years of experience in<strong> industrial automation and machine vision<\/strong>, integrating <strong>Deep Learning<\/strong> models in different <strong>industrial processes<\/strong>. This approach allows transforming advanced technologies into applied solutions, improving productivity, reducing errors and optimizing traceability and plant control.  <\/p>\n\n<p>Want to learn more about our services? <a href=\"https:\/\/i-mas.com\/en\/contact\/\" target=\"_blank\" rel=\"noreferrer noopener\">Contact <\/a>us or visit our <a href=\"https:\/\/i-mas.com\/en\/projects\/\" target=\"_blank\" rel=\"noreferrer noopener\">projects <\/a>section! <\/p>\n","protected":false},"excerpt":{"rendered":"<p>In industrial automation, the terms \u201cfixed,\u201d \u2018programmable\u2019 or \u201cflexible\u201d describe much more than the technology next to the line. They define the factory&#8217;s ability to adapt to market, product design and talent challenges. Knowing the differences-and combining them with machine vision and robotics systems-is crucial to designing process automation projects that are scalable and cost-effective. [&hellip;]<\/p>\n","protected":false},"author":15,"featured_media":30812,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"ocean_post_layout":"full-width","ocean_both_sidebars_style":"","ocean_both_sidebars_content_width":0,"ocean_both_sidebars_sidebars_width":0,"ocean_sidebar":"","ocean_second_sidebar":"","ocean_disable_margins":"enable","ocean_add_body_class":"","ocean_shortcode_before_top_bar":"","ocean_shortcode_after_top_bar":"","ocean_shortcode_before_header":"","ocean_shortcode_after_header":"","ocean_has_shortcode":"","ocean_shortcode_after_title":"","ocean_shortcode_before_footer_widgets":"","ocean_shortcode_after_footer_widgets":"","ocean_shortcode_before_footer_bottom":"","ocean_shortcode_after_footer_bottom":"","ocean_display_top_bar":"default","ocean_display_header":"default","ocean_header_style":"","ocean_center_header_left_menu":"","ocean_custom_header_template":"","ocean_custom_logo":0,"ocean_custom_retina_logo":0,"ocean_custom_logo_max_width":0,"ocean_custom_logo_tablet_max_width":0,"ocean_custom_logo_mobile_max_width":0,"ocean_custom_logo_max_height":0,"ocean_custom_logo_tablet_max_height":0,"ocean_custom_logo_mobile_max_height":0,"ocean_header_custom_menu":"","ocean_menu_typo_font_family":"","ocean_menu_typo_font_subset":"","ocean_menu_typo_font_size":0,"ocean_menu_typo_font_size_tablet":0,"ocean_menu_typo_font_size_mobile":0,"ocean_menu_typo_font_size_unit":"px","ocean_menu_typo_font_weight":"","ocean_menu_typo_font_weight_tablet":"","ocean_menu_typo_font_weight_mobile":"","ocean_menu_typo_transform":"","ocean_menu_typo_transform_tablet":"","ocean_menu_typo_transform_mobile":"","ocean_menu_typo_line_height":0,"ocean_menu_typo_line_height_tablet":0,"ocean_menu_typo_line_height_mobile":0,"ocean_menu_typo_line_height_unit":"","ocean_menu_typo_spacing":0,"ocean_menu_typo_spacing_tablet":0,"ocean_menu_typo_spacing_mobile":0,"ocean_menu_typo_spacing_unit":"","ocean_menu_link_color":"","ocean_menu_link_color_hover":"","ocean_menu_link_color_active":"","ocean_menu_link_background":"","ocean_menu_link_hover_background":"","ocean_menu_link_active_background":"","ocean_menu_social_links_bg":"","ocean_menu_social_hover_links_bg":"","ocean_menu_social_links_color":"","ocean_menu_social_hover_links_color":"","ocean_disable_title":"default","ocean_disable_heading":"default","ocean_post_title":"","ocean_post_subheading":"","ocean_post_title_style":"","ocean_post_title_background_color":"","ocean_post_title_background":0,"ocean_post_title_bg_image_position":"","ocean_post_title_bg_image_attachment":"","ocean_post_title_bg_image_repeat":"","ocean_post_title_bg_image_size":"","ocean_post_title_height":0,"ocean_post_title_bg_overlay":0.5,"ocean_post_title_bg_overlay_color":"","ocean_disable_breadcrumbs":"default","ocean_breadcrumbs_color":"","ocean_breadcrumbs_separator_color":"","ocean_breadcrumbs_links_color":"","ocean_breadcrumbs_links_hover_color":"","ocean_display_footer_widgets":"default","ocean_display_footer_bottom":"default","ocean_custom_footer_template":"","ocean_post_oembed":"","ocean_post_self_hosted_media":"","ocean_post_video_embed":"","ocean_link_format":"","ocean_link_format_target":"self","ocean_quote_format":"","ocean_quote_format_link":"post","ocean_gallery_link_images":"on","ocean_gallery_id":[],"footnotes":""},"categories":[55],"tags":[],"class_list":["post-30820","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-automation","entry","has-media"],"_links":{"self":[{"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/posts\/30820"}],"collection":[{"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/users\/15"}],"replies":[{"embeddable":true,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/comments?post=30820"}],"version-history":[{"count":1,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/posts\/30820\/revisions"}],"predecessor-version":[{"id":30821,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/posts\/30820\/revisions\/30821"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/media\/30812"}],"wp:attachment":[{"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/media?parent=30820"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/categories?post=30820"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/i-mas.com\/en\/wp-json\/wp\/v2\/tags?post=30820"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}