Industrial automation is a very present topic in our daily lives. But have you ever stopped to reflect on this concept?
When we think about industries, their gains are not limited to the automation of manual labor; they include everything from the integration of software and hardware technologies into equipment to production processes.
Its main purpose is to create processes that aim to provide greater autonomy to production, reducing human intervention within this network.
Today, industrial automation is closely linked to terms such as the Internet of Things (IoT), Cloud Computing, and Smart Factories.
Therefore, understanding the importance of this topic, today we will discuss how industrial automation has impacted the way we produce.
Continue reading this material and check out more details about this highly relevant topic for industries.
To talk about industrial automation, we need to go back a bit in history. The first automation systems date back to the 19th century, when society was experiencing the Industrial Revolution.
This was a major milestone because many tasks underwent changes, as they stopped being performed by humans and started being executed by machines, aiming to increase production. Activities were operated through mechanical parts, which automated the most repetitive stages of routine work.
Later on, these parts gave way to mechanisms that operated through relays and contactors, thus enabling more complex and sophisticated automation on assembly lines.
After the Second World War, innovations became even more significant. The first numerically controlled machines and process control systems were created. In addition, analog integrated circuits emerged, which were precursors to a new generation of automated systems.
With the arrival of the 1970s, the first commercial computers came into play. However, these machines required high maintenance costs and demanded labor-intensive programming. As a result, these machines were replaced by the Programmable Logic Controller (PLC), which was far more advanced and specifically designed for industrial processes.
By the 1990s, technology had become even more advanced, as computers at the time were capable of designing circuits and had high processing capacity.
Thus, automation systems became more efficient, faster, and more reliable, enabling large-scale production with cost reduction, space optimization, and increased reliability and technical safety.
The fact is that all these events were marked by technological leaps. Most manual tasks were replaced by machines until we reached the much-discussed Industry 4.0.
In this new scenario, a service that was previously executed by dozens of people is now performed by a single individual, responsible for maintaining and operating the software that guides the entire production line.
The result of this change brought greater efficiency, cost reduction, and increased production—attributes that would be impossible to achieve using only human effort.
Industry 4.0, or the Fourth Industrial Revolution, is already a reality in major industries worldwide. This term was coined to represent the integration of artificial intelligence, robotics, the Internet of Things, and cloud computing. In this way, it aims to automate industrial activities to improve processes and increase productivity.
In practice, Industry 4.0 uses the most advanced technologies available, such as artificial intelligence, data science, big data, IoT (Internet of Things), and machine learning.
It was a true revolution in industrial operations, elevating automation to a level never seen before!
Knowing the importance of this topic in today’s reality, we also bring some reasons why industries should invest in industrial automation.
As mentioned above, the concept of industrial automation is based on the principle of doing more with less. Therefore, the priority is to make smart trade-offs!
Manual labor generates costs and takes longer to be completed, in addition to involving much higher risks of failure. By automating the production chain, you gain speed, precision, safety, and efficiency.
Automating repetitive activities is one of the most efficient ways to channel effort toward tasks that truly require human work.
Performing repetitive movements over long periods is tedious—we know that. But there is more: these activities put the physical and mental health of your team at risk, as warned by the Ministry of Labor and Employment.
Several studies indicate that these types of functions are agents that cause workplace accidents. Do you know why?
Since these activities are performed automatically, workers may lose focus. In that brief moment of distraction, they may end up getting injured.
Therefore, industrial automation also ensures a much safer work environment.
In addition, automation offers 24/7 monitoring as well as several ways to signal when something is not right in the operation. Whether through visual or sound alerts, sensors warn of any irregularity in the industry.These devices are also capable of detecting and communicating changes such as temperature increases or overloads in equipment and machines in time to prevent tragedies on the factory floor.
Automation systems provide real-time information on production stages and indicators, raw material usage, operational bottlenecks, among other essential data for the proper functioning of the production chain.
In addition, they allow the detection of failures and maintenance urgencies before they cause interruptions or losses.
Many industry managers are already aware of the positive impact brought by industrial automation and, therefore, are already investing in these technologies.
They have realized that, to have a truly competitive business in the market, it is essential not only to invest in machinery itself, but also in training everyone who will work with the technology.
The fact is that industrial automation can be enhanced by other technologies of the 4th revolution, such as Artificial Intelligence, the Internet of Things, and even Big Data.
Therefore, we cannot fail to mention some of its pillars.
It consists of network connectivity between environments, vehicles, machines, or electronic devices. These systems require the use of the internet to operate and allow remote control in industrial environments.
The result is unprecedented levels of connectivity and functionality. There is even talk of the Industrial Internet of Things (IIoT), where the focus is machine-to-machine communication, Big Data, and machine learning.
IIoT includes industrial applications such as robotics, medical devices, and software-defined production processes.
This refers to data structures and involves data capture, management, and analysis. In industrial environments, the following are relevant:
Achieving security is undoubtedly one of the greatest challenges of the 4th Industrial Revolution and aims to create more secure information system environments.
Communication failures between machines exist, but in industries this problem can bring enormous repercussions, affecting the entire production chain — just imagine the losses!
This term refers to system storage through shared servers interconnected via the internet, allowing access from anywhere.
In industries, cloud computing offers the possibility to overcome the limits of company servers and expand system connectivity. The great advantage is that all this happens with significant cost reduction and in a more agile and efficient way than the old model.
Brazil has not been left out of this wave, and today delivers competitive productivity levels and has achieved significant cost reductions.
A study released by ABDI showed that once the new production model is implemented, it is estimated that there will be a reduction of at least R$73 billion per year in industrial costs.
Of this amount, R$34 billion per year will come from efficiency gains, another R$31 billion per year from reductions in machine maintenance costs, and finally, R$7 billion per year from reduced energy consumption.
This savings and efficiency gain in production processes are capable of transforming Brazil’s reality internationally. According to the World Economic Forum report in 2020, Brazil ranked 71st among 141 countries.
Investing in industrial automation should be among the priorities of companies, especially large industries. This investment not only improves internal processes but also helps the business become more competitive and meet market demands.
Regardless of the sector, adopting these practices brings productivity, technology, and increased added value.
It is important to emphasize that there is still much more relevant information about industrial automation. Certainly, each type of industry can achieve specific gains by adopting it in its production processes.
