What are the risks of relying too heavily on automation in industrial engineering?

Yes. "Automation suggested and implemented by industrial engineers offers many benefits such as increased productivity, efficiency, quality, and safety. However, relying too heavily on automation can also pose some risks." Industrial engineers need to be aware of and mitigate these risks. They need to put in place mechanisms for skills preservation in case of emergencies. Emphasis on education and training in the operation and maintaining the automated equipment has to be given to more people instead of developing numbers strictly needed to operate. Development of knowledge to develop and improve the equipment further internally also needs to be emphasized.

Relying too heavily on automation can create an environment where manufacturing personnel lose process knowledge and have difficulty owning the process due to having minimal interaction with the process on a daily basis. This issue becomes apparent when there is a failure in the process and manufacturing personnel do not know how to react. Also in the case of an equipment failure not having manual procedures as back up can cause the process to be stopped for an extended period of time resulting in loss time and potentially product.

Effectivement, il s'agit de trouver un juste équilibre entre le confort et la fiabilité d'une conduite des procédés industriels intelligemment automatisée et une implication participative et active des équipes pilotant les installations. La tout ou trop automatisation peut avoir un impact sur la vigilance humaine qui reste, à mon sens, la meilleure méthode d'anticipation de situations qui ne peuvent être toujours prévues. Certes, la sécurité mise en place et les actions qui en découlent peuvent permettre via l'automatisation de palier à des situations process dangereuses ou critiques mais l'oeil humain avisé et connaisseur de son process, permettra lui, d'anticiper et d'agir si besoin avant d'arriver à cette situation critique.

Multifaceted risks exist when relying too heavily on automation. There could be a loss of knowledge transfer, job displacements and overreliance on technology. There are numerous benefits when things are automated but it cannot be customized to a level that a human can achieve. An automated machine may increase productivity but it cannot customized and hence the suppresses creative thinking and innovation.

I hold a different perspective. While automation may indeed pose risks if implemented without a thorough understanding, I argue that investing in building internal capabilities alongside technological advancements is crucial. With a knowledgeable team, the potential downsides of automation can be effectively managed and minimized.

Automation engineering is a complex and demanding field, requiring a deep understanding of mechanical, electrical, and software systems. But In my opinion, automation engineers must be masters of Communication. The success of automation projects depends on the close cooperation of a team of engineers, installers, and other specialists. From the initial design phase to the final installation and commissioning, a clear communication is essential to ensure that everyone is on the same page, working towards the same goal. This is especially true when it comes to the installation of automation modules. These modules are designed to work in a specific way. Any deviation from the prescribed installation procedures can lead to problems.

Automation changes your cost base from variable to fixed. This then shifts your bottle neck from sales to manufacturing. It creates a fundamental structural change in your business and significantly reduces your flexibility and ability to deal with market dynamics. Embarking on automation requires your industry to be stable and well established.

Melhorar os processos através de maquinas modernas e softwares modernos requer m?o de obra técnica habilitada para atender as necessidades desse universo. O prinicipal ponto além de investir em moderniza??o e investimentos de ativos, é de extrema importancia que a forma??o de m?o de obra compatível com a nova necessidade também seja considerada.

It has been my experience over decades that automation systems are the most stable part of a work cell if maintained properly. Variation in parts and materials is the biggest culprit followed by modifications to the automation to “make bad parts work”, thus destroying its stability.

While industrial automation really helps improve efficiency and output from manufacturing plants and processes, Industrial automation can be very expensive. Aside from the high cost of components/devices that make industrial automation possible, almost or more is sometimes spent on bringing the technical know-how to install/configure these components. In very severe situations, this may lead to downtime on operation

As the aim of any plant automation is to: 1. Increase productivity 2.Reduce costs solutions (especially for human-based labour) 3. Improve quality. 4. Use resources efficiently. 5. Generate greater profit. All above will add pressure on the Human resources side by displacing low skilled workers from industrial plant, requiring developing new skills to support the automation platform. There always will be the ethical side related to human resources which are not able to change and adjust to the new automated environment with all implications to individuals and society.

Automation is typically implemented as a ROI case. Reducing costs and also improving safety, consitancy and accountability of production inputs and outputs. This can negate and ethically trump labour and social implications. Society will shift to design, construction, operating maintaining these systems while I believe we will also see a shift in competition via the use of human contributions the the creative side of businesses.

The outcomes of the automated process in heavily automatized industries may be attributed to the machines rather humans, however, this notion is only believed to prevail in case that human forgets its role in creation of the automated entity. This will inevitably contributes to have major impacts on the human being and its life. The impact of machine control over the human life may be considered the final consequence of this tactless and probably mismanaged situation aroused by the human being. Still, human shall be designated to remain the final decision maker in the final result of the machine, through minimal approval procedures, otherwise, the devastating machine governance over non-artificial entities will be huge risk.

En la mayoría de los casos de automatización no solo beneficia al propietario, sino también a la población en general, porque gracias a bajar costos y tiempo de producción de diferentes artículos, el cliente paga menos dinero por ello Hay que fluir con la evolución.

Automation is used in systems to minimize the human activity in controlling a system. The more automated the system, the more is the need for sensors detectors and actuators. But the increase in these also makes the system more prone to failure, as well. For that reason there needs to strike a balance between how much automation should be considered in a process. There's no one size fits all scenario, as each process has its own control philosophy. However it is crucial to study the impact of automation on a particular process. It is the responsibility which should be shared by design experts, and stakeholders like operations and maintenance professionals to ensure the system is safely operable.

In considering the risks of over-relying on automation within industrial engineering, it's essential to recognize the potential for economic loss due to rapid obsolescence, decreased system flexibility, increased cybersecurity threats, and over-dependency on specific suppliers. Automation may also inhibit innovation, introduce complex integration challenges, and necessitate continuous regulatory compliance updates. The reduced redundancy of human skills can pose significant risks during system failures, and cultural shifts within organizations may lead to resistance among employees. Moreover, the environmental impact of disposing of outdated automated systems needs careful consideration to ensure sustainability.

You need to understand if your process is in a state that is ready for automation. This includes making sure operations is onboard and supportive, you understand how they are actually performing the process on the floor vs. what is in a SOP. You need to optimize the process in it's current state before adding in automation. When you automate an inefficient process it does nothing but magnifies those inefficiencies. Also, automation is not a magic wand, it has its short comings, you need to discern what the solution can actually do and not what you hope it will do.

Automation also reduces innovations, Employees only reply on what the machine is doing as opposed of thinking about the best alternative which are cheaper and better

A few thoughts: - Maintenance cost will be much higher than manual production, consider it when planning ROI and power your calculation by 3 - If you need very high uptime, a lot of your money will end up in your spare part storage. - You can send away people, you cannot send away the machines if your demand is dropping. Especially hard if your machines are custom built. - Depending on region, getting proper professionals can be challenging.