Automation justification

Automation ROI: For maximum return on investment (ROI) when deciding to automate, ensure systems can scale with an operation, evolve, and be redeployed for maximum return on investment. For a productivity boost, follow 6 key steps for determining when and where to apply or upgrade automation. Don’t automatically think commercial-off-the-shelf technologies are better than a lean customized solution. Finally, economical controllers and universal programming software can ease the point of entry.

By Mark T. Hoske September 9, 2013
For maximum return on investment (ROI) when deciding to automate, ensure systems can scale with an operation, evolve, and be redeployed for maximum return on investment. For a productivity boost, follow 6 key steps for determining when and where to apply or upgrade automation. Don’t automatically think commercial-off-the-shelf technologies are better than a lean customized solution. Finally, economical controllers and universal programming software can ease the point of entry. See more description of each article and links to each at the bottom.
For modular conventional, robotic, or hybrid motion control applications, ensure that systems can scale with an operation, handle evolving packaging styles, and be redeployed to alternate production lines for maximum flexibility and return on investment.
Automation can boost productivity when correctly applied. Here are 6 steps for determining when and where to apply or upgrade automation.
How to automate is as important as when. Custom is not a four-letter word. Weigh the benefits of commercial-off-the-shelf (COTS) and a custom solution, rather than restricting an automation project view to a COTS or custom solution. Customers may steer away from anything custom for a variety of reasons—many of which are unfounded.
With automation becoming more flexible, smaller lot sizes can make it practical to profitably automate what previously was considered only for hand assembly. Modular, flexible embedded PCs, programmable with one software platform, can lower the entry point for when to automate. Here are considerations when looking at what and when to automate.
– Edited by Mark T. Hoske, CFE Media, Control Engineering, mhoske@cfemedia.com 
Online extras
Also see the “Real World Engineering Blog” July 16 post, “If it ain’t broke, don’t automate it?” Maybe it is broke, and you just don’t recognize it. Sometimes problems and inefficiencies in plants persist simply because nobody wants to take responsibility for finding a solution. Effective automation might be the key.

Also, link to the following: 10 steps to a smoother automation system upgrade — When migrating or upgrading your automation system, don’t forget to examine this group of areas outside of the HMI, controllers, and I/O. These suggestions will help you identify and deal with lurking problems early in the process.


Author Bio: Mark Hoske has been Control Engineering editor/content manager since 1994 and in a leadership role since 1999, covering all major areas: control systems, networking and information systems, control equipment and energy, and system integration, everything that comprises or facilitates the control loop. He has been writing about technology since 1987, writing professionally since 1982, and has a Bachelor of Science in Journalism degree from UW-Madison.