The Five Benefits of Modular Automation for Manufacturers

In the modern-day manufacturing industry, companies must be able to respond instantly to the ever-changing business landscape. Manufacturers meet various challenges, such as global trade disruption, labor shortages, and increasing operating costs.  

Many manufacturing businesses have implemented modular automation technology to mitigate daily challenges, such as workplace safety in hazardous areas, transportation, low-efficiency levels, etc. The concept of modularization allows manufacturers to reconfigure the production line to meet their specific requirements.  

Companies harness the power of modularization to separate production and equipment lines and create two layout-free automated lines that operate individually. Since the new era of industrialization is moving fast toward full factory automation, let’s delve deeper into the advantages of module automation for manufacturers.

1. Real-time response to increased demand 

Modularization refers to the process of arranging smaller parts of the production line in a different order. Manufacturers can apply it to a manufacturing plant to separate the same production line into mobile modules that can operate individually.  

Since each module is reconfigurable, an operator can program mobile modules to fulfill different purposes. Each module is highly compatible and integrable with other modules. This enables the same production lines to meet different goals, allowing the manufacturer to adapt to increased demand in real-time.  

This high-end adaptability makes a manufacturing line highly flexible and scalable, allowing a company to repurpose the same production line for specific scenarios to save labor, space, and time while improving productivity.  

Manufacturers can leverage such operational flexibility and efficiency to ensure less downtime, faster time-to-market, and cost-efficiency. All these benefits are why so many manufacturing businesses opt for cooperating with leading global modularization providers, such as Robotunits, and investing in modular automation systems for production equipment.

2. Increased scalability of operation 

Every business owner of a manufacturing operation is looking for the most effective automation solutions to help them meet customer demand and ensure business growth. However, automating traditional workflows requires resources that most companies can’t afford due to many unexpected expenses, such as replacing obsolete systems, kinematics, and equipment.  

Thankfully, modular automation is an affordable investment that can ensure numerous advantages for a manufacturer. Increased scalability is the best example. Since modularization allows you to reconfigure the production line, you can use interchangeable modules to build a dynamic system and scale up your manufacturing capabilities.  

Moreover, you can quickly adapt to an ever-increasing demand and scale up your operation to meet the production goals of your target market and provide greater value to your consumers.

3. Reduced downtime 

Labor shortages are the leading cause of downtime in the manufacturing industry. A company with manpower shortages can’t cope with the ever-changing production tasks and will face downtime that can cost it a lot of money.  

Manufacturers can mitigate these costs by investing in modular automation to reduce the risk of labor shortages, improve efficiency, and increase productivity.  

Automation can do wonders for productivity by bringing the following advantages: 

• Guaranteed machine efficiency 

• Increased operational affordability 
• Lowered life cycle management and maintenance costs 
• Less capital expenditure. 

Increased production flexibility allows for faster time to market while guaranteeing maximum uptime.

4. Cost-efficient production 

Most manufacturers avoid investing in automation technology due to high investment requirements. The cost of automating traditional production workflows typically exceeds the manufacturer’s investment capabilities.  

In addition, newly automated production systems require advanced operational skills and highly trained staff to manage and maintain modularization systems. Most manufacturers still cling to large outdated production systems and rigid on-site solutions that need lots of manpower, maintenance, and floor space.  

The problem with this obsolete equipment is that it takes forever to ensure a return on investment. Since modular solutions are more affordable, easy to maintain, and scale up according to specific production needs, they allow for a more cost-efficient production approach that ensures better ROI while increasing productivity and effectiveness.

5. Process standardization 

Automated modules are compatible with more than just the production line. This flexible reconfiguration allows for integration with various machinery, making manufacturers highly adaptable to rapid production demands and product changes.  

It also ensures the additional benefit of saving time, effort, and resources on hiring additional manpower in-between procedural shifts. In other words, manufacturers can minimize initial investments while ensuring maximum uptime, expedited product change, increased plant efficiency, and enhanced productivity.  

Conclusion 

Modular automation is the solution to many arising problems associated with large-scale automation systems. Since these processes are at the core of every production line, manufacturers must work around the clock to ensure maximum production uptime and meet the ever-changing consumer demands. However, the automation of traditional production systems is expensive for many manufacturers. Instead of replacing entire systems, manufacturing businesses can harness the power of modular automation to integrate interchangeable modules into the existing systems and reconfigure their production lines according to their specific needs.  

This modularization is a newly-developed industrial approach to mitigating operational costs and risks while achieving benefits such as better safety, higher productivity, increased efficiency, and affordability.