Since the Industrial Revolution, manufacturing has been constantly looking for ways to make processes more efficient and cheaper. With the rise of robotics and complex machines, manufacturing has never been more successful.
Depending on your business, you’ll want to explore the processes that would pay off tenfold if automated. In electronics, the creation of printed circuit boards, transformers, cables, and other products can be much more precise.
This article explores the role of automation in streamlining electronics manufacturing, as well as some of the key benefits that it brings to this industry.
Automation is a concept that refers to the use of technology, whether hardware or software, in order to perform tasks with 0 or minimal human intervention.
In electronics manufacturing, automation could be robotic assembly lines, automated inspection systems, and software tools for testing. The goal of automation is to make the process as streamlined as possible.
For example, an engineer can use Eagle PCB design software to design printed circuit boards (PCBs). Then, an integrated automated manufacturing system will be able to produce PCBs with a click of a button.
Of course, the process will take a bit more time and effort than the single click of the button, but you get the point. Automation also ensures that manufacturing processes are consistent.
Imagine if you totally rely on human workers. There could be days when some of them are stressed, sick, or tired and can’t deliver the results that are usually expected. Instead, the automated system will work always as intended unless there’s a malfunction.
Benefits of automation
There are numerous benefits that automation can offer for your business. While the list is basically endless, will explore some of the key advantages that this concept will offer you.
If you’re having problems with one of the aspects that these benefits could solve, you should definitely explore the potential of automation.
Streamlined processes
By automating processes, you’re eliminating inefficiencies in production by handling repetitive and time-consuming tasks. When manufacturing complex products such as electronic devices or circuits, the whole process consists of multiple stages.
Automation allows for a smooth transition from one page to another. Pair this with good project management software, and you’ll be able to understand the bottlenecks in each stage.
Some examples of what automated systems can do include:
Soldering,
Assembly,
Component testing
The whole process will be faster and more accurate than if everything were done manually.
Consistent results
When you’re producing electronic devices, a small problem with soldering or assembly can make the product useless. A small percentage of faulty products is normal in many industries, yet businesses should always try to make this number 0.
With manual labor, there are many ways in which the process can go wrong. Whether there are new employees who don’t yet grasp the production process, or they are less focused at one point, manual processes can’t guarantee consistency the way automated ones can.
Automation ensures uniformity across production batches and allows you to always expect the same product quality. For example, I’ve worked on assembling junction boxes, one of the employees had a bad day, and the cables inside them looked totally untidy.
At the same time, a senior employee made a junction box that looked perfect. The client would receive two junction boxes that significantly vary in quality. This is where automation would step in and ensure less variability.
Increased product quality
With the help of automation and robotics, electronics companies can achieve higher precision and product quality. Part of this is because the chances of human error will be minimized. On the other hand, the effectiveness that automated systems offer is unmatched compared to manual workers.
Automated systems can also recognize problems early in production, allowing the whole process to be more efficient and accurate. With automation in all stages of the manufacturing process, the products will be inspected by software or systems that will ensure high quality.
Employee engagement
In the past, employees had to manually complete the whole manufacturing process. While humans still need to be present in the manufacturing process, they won’t have to do everything manually.
Most importantly, workers won’t have to do repetitive or time-consuming tasks over and over. Instead, they’ll participate in the process through managing the software, inspecting quality, and doing other more rewarding work.
Higher employee engagement means that they’ll be more motivated to work, and you’ll be able to retain more of the workers. Furthermore, by automating processes that are physically exhausting, you’ll protect your employees.
More safety
With more automated processes, employees will participate in less tedious activities. By automating the labor-intensive stages of electronics manufacturing, your employees will protect their help.
Furthermore, certain processes, especially in electronics, can be dangerous. If a machine or a robot completes them, you’ll protect the safety of your employees. A safer workplace will help you attract new employees to your company.
Similarly, your current employees will feel more safe, which can lead to them feeling more motivated and engaged.
Challenges of automation
There are numerous benefits to automation, especially in electronics manufacturing. However, it’s also important to consider some important aspects of automation. Firstly, you’ll be met with high initial costs if you don’t have capacities at this moment.
For example, you’ll have to introduce new assembly lines or robotic components, all of which are expensive. Some of these costs can be alleviated if there’s a possibility for integration with your current systems.
On the other hand, you’ll also have to find the personnel who are capable of handling these new systems. You’ll need engineers who will be able to establish automated systems and integrate them with your software and other aspects of your business.
Then, you’ll need managers who are knowledgeable in writing the code for your automated systems or spend money on pre-built software. Similarly, the employees that will work at your company will need to upskill themselves in order to properly work at their new workstations.
This can be a piece of cake if your employees are already knowledgeable or if the new system is easy to use. On the other hand, you’ll either have to:
Wait sometime before they get used to the new system,
Fire underperforming employees
Create courses and training programs for your employees
Each of these three scenarios has lesser or greater downsides, and it’s important that you choose the option that minimizes the negative impact.
Impact of AI on automation
Artificial intelligence is becoming more important for various industries. Automation is often synonymous with it. AI enhances automation by enabling predictive maintenance and adaptive learning.
For example, an AI-powered robot can visually recognize the parts of the product that are unfitting or “rough.” This way, your testing capabilities are enhanced, and you’ll be able to deliver consistent results and products with increased quality.
AI algorithms can also help with gathering other valuable data. You can implement AI software that will gather results on the performance of each employee, which can help you understand their skills over time.
This way, you’ll be able to understand the ups and downs of the manufacturing process and understand if there are bottlenecks.
However, AI is still a relatively new technology, and many people refrain from using it. The presence of AI in electronics manufacturing is also limited, as we’re yet to see industry-wide implementations of AI.
The implementation of AI can be a double-edged sword. For example, you can use AI-powered software that will skyrocket your company’s performance, or it can turn out that the software isn’t yet capable of providing the necessary results. This makes AI implementation still risky.
The role of automation in electronics manufacturing is essential
Without automating at least some processes, your competitors will get ahead of you. Of course, you shouldn’t jump in and automatize processes using the latest, untested principles, but you should do thorough research and understand how to adequately implement automation.
While you might have some initial costs associated with new equipment and personnel, you’ll significantly improve the chances of your company’s success in the long run. For example, you’ll reduce waste and make the workday of the employees more engaging.
On the other hand, you’ll be able to scale your business in the long run. As manufacturing technology continues to advance, the integration of automation will drive the industry toward a more efficient and sustainable future.
Last Updated 20 hours ago
