There are four types of automated machines – fixed, programmable, integrated, and flexible manufacturing systems (FMS). In this blog, we’ll analyze the benefits of each model and guide manufacturers in selecting the most suitable option for their automation goals based on their specific needs.
The Four Types of Automated Machines
1. Fixed Automated Machines
Special Purpose Machines for Material Handling
Fixed assembly machines are designed for specific tasks within a manufacturing process. Often referred to as special purpose machines, these devices are optimized for material handling and repetitive tasks, such as sorting, assembling, or packaging. By focusing on a limited range of functions, fixed assembly machines can achieve high levels of efficiency and speed.
Here is a breakdown of their key aspects:
Functions:
- Repetitive Tasks: These machines are used for recurrent tasks and require high precision.
- High Volume Production: They are ideal for mass-scale production where the same operations need to be performed repeatedly.
Components:
- Mechanical Systems: This includes conveyors, robotic arms, and other mechanical parts.
- Control Systems: This typically involves programmable logic controllers (PLCs) or other control systems that manage the machine’s operation.
- Sensors and Actuators: These components help in monitoring and controlling the process by providing feedback.
Advantage:
- Cost-Effectiveness: For high-volume production, these machines can be more cost-effective compared to manual labor.
For example, SDC designed and built an automated machine for the fragrance consumer products industry that was focused on automatically adding a wick into a plastic holder. Because this system was streamlined to complete a special purpose, and only ran one product line, we were able to achieve a cycle time of 140 parts per minute – achieving our customers’ desire for high-volume production. Learn more about SDC’s system here.
2. Programmable Automated Machines (PAS)
Batch Production with Custom Machines
Programmable assembly machines are systems that use automated controls and programming to change machine tooling and operational sequences and produce products in batches. These machines are typically programmed to accommodate many different product configurations, enabling them to perform a wide range of tasks with high precision.
Here is a breakdown of their key aspects:
Functions:
- Batch Production: PAS are ideal for batch production where different product variants or short production runs are needed. The system can be quickly reprogrammed to switch between a variety of product configurations.
- Quality Control: PAS can be programmed to perform complex inspections, testing procedures, and ensure product quality and consistency.
Components:
- Control Units: These include Programmable Logic Controllers (PLCs) or Industrial PCs that execute the control programs and manage the operation of the machinery.
- Input/Output Devices: Sensors, actuators, and other devices provide data to the control system and carry out the physical tasks.
- User Interfaces: Interfaces such as touchscreens, keypads, or software applications that allow operators to easily input commands, modify programs, and monitor performance.
Advantage:
- Adaptability: Skillfully reprogrammed to handle different tasks or products, making it suitable for environments with frequent changes in production requirements.
SDC designed and built a single drill bit sorting and packaging machine, programmed to effectively handle and drill bits of various sizes with automatic and seamless change over from one batch of products to another. The machine could move parts at a rate of 3.5 parts per second. To learn more about SDC’s expertise and technology click here.
3. Integrated Automated Machines
Lights-Out Manufacturing with Robotics
Integrated assembly machines represent the cutting edge of automation, featuring systems that enable lights-out manufacturing. In this setup, robots handle every aspect of production, from material handling to assembly, without the need for human intervention. This machine can operate continuously and independently, thereby maximizing efficiency and reducing labor costs. Integrated systems are ideal for high-volume production environments where consistency and reliability are paramount. By utilizing advanced sensors and artificial intelligence (AI), these machines can also adapt to changes in production requirements spontaneously.
Here is a breakdown of their key aspects:
Functions:
- Manufacturing: Integrated automated machines are widely used in manufacturing for tasks like assembly, packaging, and quality control.
- Logistics: Automated material handling systems, including robotic picking and sorting systems, streamline warehousing and distribution operations.
Components:
- Robotics: Industrial robots or robotic arms can be integrated into machines to perform tasks like assembly, welding, or material handling.
- Sensors: Various sensors (such as vision systems, proximity sensors, and temperature sensors) are used to monitor and control processes, ensuring accuracy and quality.
- Control Systems: Programmable Logic Controllers (PLCs) or Industrial PCs manage and coordinate the different components of the machine, executing control programs and responding to sensor inputs.
- Actuators: These components perform physical actions based on control signals, such as moving parts, opening or closing valves, or adjusting positions.
- User Interfaces: Interfaces like touchscreens or software applications allow operators to control, program, and monitor the machine.
Advantage:
- Improved Data Collection: Integrated systems often include data collection and analysis capabilities, allowing for real-time monitoring and performance optimization.
The SDC team designed and built a continuous-motion powder-coating and packing machine for a client that needed rolls of tape powder-coated, assembled, packaged, and sealed autonomously. The machine could process rolls at a rate of 150 parts per minute or 2.5 parts per second. Click here to learn more about this machine.
4. Flexible Manufacturing Systems (FMS)
Versatility for Multiple Jobs
Flexible Manufacturing Systems (FMS) offer manufacturers the ability to produce a variety of products using a single machine or a network of machines. FMS are designed to adapt quickly to different production requirements, allowing manufacturers to switch between various jobs without momentous downtime.
This flexibility is particularly beneficial in industries where product demand is unpredictable or where customization is increasingly required. FMS can be programmed to handle multiple tasks, such as milling, drilling, or assembling, making them a valuable investment for manufacturers looking to increase their dexterity and observance to market changes.
Here is a breakdown of their key aspects:
Functions:
- Electronics Manufacturing: Handles the production of various electronic components and devices, often with frequent design changes and updates.
- Aerospace: Manages the production of complex and varied aerospace components, where precision and flexibility are critical.
Components:
- Material Handling Systems: Automated systems, such as conveyors, Automated Guided Vehicles (AGVs), or robots, that move materials and products between workstations.
- Central Control System: Manages the operation of the entire FMS including scheduling tasks, coordinating workstations, and optimizing workflows. Typically involves a Manufacturing Execution System (MES) or other advanced control software.
- Computer Numerical Control (CNC) Machines: Programmable machines that can be reconfigured for different machining operations and product specifications.
Advantage:
- Reduced Setup Times: Quick changeovers and reconfigurations allow for shorter setup times between different production runs.
As an example, SDC created a custom robotic end-of-arm tooling machine to be able to perform various tasks by one machine alone. This technology will enable a company to allocate resources more efficiently for other expenses and significantly shorten the time needed to finish projects. The assembly machine was capable of handling parts ranging in size from 6” to 54” long. Learn more about this assembly process.
How Will These Shape the Future of Manufacturing?
The assortment of assembly machines is diverse, with each type offering unique advantages tailored to specific manufacturing needs. Fixed machines provide efficiency for specialized tasks, while programmable machines offer versatility for batch production. Integrated systems push the boundaries of automation with lights-out manufacturing, and flexible manufacturing systems enable manufacturers to adapt to varying demands.
As technology continues to evolve, these assembly machines will play an even more integral role in shaping the future of manufacturing, driving efficiency, and advancing innovation across various industries.
How SDC Is Involved
At Steven Douglas Corp., we recognize the critical role of assembly machines in optimizing production processes. Our team of experts is dedicated to helping you identify the ideal solution tailored to your unique manufacturing requirements. With over 25 years of experience in designing and building custom assembly machines, we can significantly enhance your efficiency and productivity.
When you partner with SDC, you can expect exceptional service from beginning to end. We collaborate closely with each client to ensure that all needs are met, and expectations are surpassed. Our commitment to quality craftsmanship and cutting-edge technology distinguishes us as a trusted partner in the industry. Click here to begin the conversation.
