Factory automation means doing production work with machines, robots and software while reducing human intervention. But automation is not a system you install in one go; it is a journey taken step by step. In this article we explain the layers of automation, where to start and the most common mistakes.
The layers of automation
| Layer | What it does | Example |
|---|---|---|
| Field | Measures and moves. | Sensors, load cells, motors, valves, robots. |
| Control | Runs the machine. | PLC, robot controller. |
| Supervision | Sees, records and alarms on the plant. | HMI, SCADA, operator software. |
| Production management | Work orders, efficiency, traceability. | MES software. |
| Business | Orders, stock, accounting. | ERP software. |
If the lower layers are not solid, the upper ones are useless: you cannot get a correct report from a sensor that measures wrong. For the difference between PLC, HMI and SCADA see PLC, HMI and SCADA explained.
Where to start?
- Find the bottleneck: Which station slows production most, produces the most defects or depends most on people? Starting there gives the fastest return.
- Measure first: If you do not know how much you produce, how much you scrap and how long machines stand still, collect data first. Often simply making things visible pays off.
- Pick repetitive, heavy and dangerous work: Welding, handling, stacking and weighing are the best candidates.
- Start with a small pilot: Try it at one station, see the results, then roll it out.
- Evaluate existing machines: You do not always need a new machine. Renewing the software and control of a sound machine can be much cheaper. See automation retrofit.
Common mistakes
- Automating a bad process: A complicated, messy process is not fixed by automation, only sped up. Simplify the process first.
- Leaving operators out: If the people who will use the system are not involved in its design, it will not be used.
- Depending on one person: If only one person knows the program and settings, production stops when they are away. Documentation and a simple interface are essential.
- Closed systems: Systems that cannot talk to other devices or share their data block growth later. Prefer open protocols such as Modbus TCP and OPC UA.
- Ignoring maintenance: A system without spare parts and service support becomes expensive at the first failure.
How to calculate the return
Simple calculation: divide the total investment by the net monthly saving from the automation. The saving comes from fewer labour hours, less scrap, faster production and less downtime. You can find a worked example for welding robots in welding robot payback period and one for concrete plants in our waste calculator.
What DKT does
- Control and monitoring software: PLC-connected operator screens, record and report software; CPlants and APlants for concrete and asphalt plants.
- Robotics: Welding robots with machine vision and industrial robot arms.
- Design: Mechanical design and kinematic analysis of custom machines and automation systems.
Summary
- Factory automation has field, control, supervision, production management and business layers.
- Start from the bottleneck and from measurement, and try a small pilot first.
- Automate a simplified process, not a bad one.
- Open protocols, documentation and service support pay off in the long run.
Let’s find where to start your automation
Tell us about your production and the station that troubles you most; we will define the first step together.
For working with us from abroad see automation company in Turkey.