From automation to autonomous: The future of industrial operations

Across the globe, manufacturers are moving towards autonomous operations. With rapid advancements in artificial intelligence (AI), robotics, and the Internet of Things (IoT), autonomous manufacturing provides businesses with increased efficiencies, enabling them to be more resilient and adaptable as they operate in more complex environments. 

Remembering that autonomous manufacturing isn't a new and far-removed concept is essential. It is simply a progression of what already exists. 

At our recent Automation Fair 2024, Rockwell Automation's chief executive officer, Blake Moret, highlighted that autonomous manufacturing " adds additional elements of autonomy" into existing workflows. It's about implementing systems that can learn and use AI to add value by being part of existing workflows. 

For instance, inline quality control systems can detect and address issues during production, avoiding costly batch rework. AI engines also optimize real-time processes to reduce downtime and ensure seamless operations, often without manual intervention.

Echoing his sentiments, chief technology officer Cyril Perducat described the convergence of AI with integrated robotics and software-defined automation as a "unique inflection point for the industry," and rightly so. By equipping physical machines on the factory floor with AI capabilities and tapping on the agility and flexibility of software to run automated tasks and make changes in real time, workers can be freed to take on more of a supervisory role and explore other new opportunities to drive productivity.

Autonomous manufacturing is about how people can work differently as they learn how to use AI and automation to elevate the work they do. The ability to analyze data, predict outcomes, and quickly adapt to changing environments will give businesses that have made the pivot an edge. These capabilities will enable manufacturers to improve processes and operational efficiency while addressing the challenge of finding and retaining a skilled workforce.  

Stepping into a new era of manufacturing

In our latest State of Smart Manufacturing Report, almost all the manufacturers surveyed said they use innovative manufacturing technology like collaborative robots (cobots), autonomous mobile robots (AMRs), and autonomous guided vehicles (AGVs) to augment their workforce. Emerging technologies such as AI and wearable technology also ranked highly on the list of investment areas. 

Based on these results, it's clear that manufacturers are keen to explore these solutions. Recent advancements have made integrating these technologies into workflows easier, acting as enablers to drive greater efficiencies and positive impact. 

A principal area of focus for Rockwell Automation over the next few years will be in production design, control, and logistics. Our autonomous material handling solution, OTTO, has transformed production logistics with flexible and nimble autonomous operations. Using two OTTO AMRs, global packaging leader Mauser improved throughput by 600% and reallocated three workers to higher value-added roles. We're also planning to strengthen our edge and cloud technologies, whereby Edge can serve as the data broker for information in the cloud to enable a more resilient bridge between the two.

In the area of design, digital twin software like Emulate3D is helping manufacturers build and simulate full-scale operations before actual implementation. This allows teams to identify any roadblocks or defects for troubleshooting ahead of time, saving valuable time and resources. Kenmec Mechanical, for example, identified potential issues in its production lines and machine designs with Emulate3D. As a result, the team could confidently implement real-life solutions, improving efficiency and overall precision. Meanwhile, ECM Technologies cut its commissioning time by 50% through virtual commissioning, throughput simulation, and industrial demonstration.

Software like FactoryTalk DataMosaix helps collect siloed data to decipher and make sense of it for root-cause analysis or predictive analytics. Companies like InControl Systems, which deliver process automation systems, have been able to tap on FactoryTalk DataMosaix to accelerate the delivery of digital solutions for clients and provide new capabilities. 

Together with FactoryTalk Analytics VisionAI, manufacturers can run advanced defect detection with trained specialized AI models so that even the subtlest and rarest possibilities for anomalies are identified. One of the key parts is its implementation, as it uses a no-code approach, making it a user-friendly tool for those with little to no coding experience. 

These are just a few ways we are already moving towards industry autonomy and software-defined operations. 

Autonomous manufacturing goes beyond just efficiency and business bottom lines. It's about creating more resilient, agile, and sustainable workplaces using technology to support humans with refined intelligence.