How can you use automation to reduce labor costs in your plant?

1 What is automation?

Automation is the process of using machines, robots, sensors, computers, and software to control, monitor, and execute tasks that are usually done by humans. Automation can range from simple devices like timers and switches to complex systems like artificial intelligence and machine learning. Automation can be applied to various aspects of plant operations, such as production, maintenance, quality control, inventory management, logistics, and safety.

2 Why use automation?

The main reason to use automation is to reduce labor costs, which can account for up to 70% of the total operating costs of a plant. By automating tasks that are repetitive, tedious, hazardous, or require high precision, you can save time, money, and resources, while increasing your productivity, quality, and reliability. Automation can also help you reduce human errors, waste, downtime, accidents, and turnover, as well as comply with regulations and standards.

3 How to use automation?

The first step to use automation is to identify the areas of your plant that can benefit from it. You can start by analyzing your current processes, workflows, and performance indicators, and look for opportunities to improve efficiency, quality, or safety. You can also consult your employees, customers, suppliers, and stakeholders to get their feedback and suggestions. Then, you can prioritize the tasks that are most suitable for automation, based on factors such as feasibility, cost-effectiveness, return on investment, and impact.

The next step is to choose the right automation tools and solutions for your plant. There are many types of automation technologies available in the market, such as industrial robots, programmable logic controllers, computer-aided design and manufacturing, enterprise resource planning, and internet of things. You need to evaluate the features, functions, compatibility, and scalability of each option, and compare them with your needs, goals, and budget. You also need to consider the integration, installation, training, and maintenance requirements of each solution.

The final step is to implement and monitor the automation process. You need to plan and execute the automation project carefully, with clear objectives, timelines, and responsibilities. You also need to communicate and collaborate with your employees, customers, suppliers, and stakeholders throughout the process, and address any issues or concerns that may arise. You need to measure and evaluate the results and outcomes of the automation process, and make adjustments or improvements as needed. You also need to provide ongoing support and training to your employees, and ensure that they are comfortable and competent with the automation tools and solutions.

5 What are the challenges of automation?

Automation can present some challenges to your plant operation, such as high initial costs that can affect cash flow, profitability, and return on investment. Technical issues like malfunctions, breakdowns, or cyberattacks can disrupt operations and compromise data. Automation can also affect the roles, skills, and attitudes of employees and create resistance or fear. Moreover, ethical and social questions may arise regarding the impact of technology on human dignity. All of these issues can affect performance, quality, security, culture, communication, collaboration, reputation, trust, and responsibility and require careful planning, budgeting, maintenance, backup change management training and ethical and legal compliance.

6 How to optimize automation?

In order to maximize the advantages and minimize the difficulties associated with automation, you must take a strategic and balanced approach that encompasses alignment, adaptation, collaboration, and evaluation. This means aligning your automation strategy with your business strategy, as well as adapting it to changing market conditions. Additionally, you need to collaborate with employees, customers, suppliers, and stakeholders throughout the automation process. Finally, you must evaluate your automation strategy regularly to ensure it is delivering the desired results and outcomes. By taking this approach, you can ensure that your automation tools and solutions fit your needs, are flexible and scalable, and perform according to specifications. Most importantly, this approach will ensure that all stakeholders are involved, informed, engaged, satisfied, loyal, and respectful.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?