Undoubtedly, industrial operations have seen increased efficiency by implementing automation in warehouses and factories across the world. The word “automation” was first used in the 1940s, and the first industrial robot was introduced in the 1960s. As operations moved into the twenty-first century, automation is slowly being replaced with autonomous equipment, when possible. Autonomous vehicles are not an entirely modern idea. Leonardo da Vinci drafted a sketch of a concept in the 1400s, but building a piece of equipment that works correctly every single time needs today’s technology. What types of autonomous equipment are available, and how can companies leverage it to move beyond automation?
Defining Automation
Automation refers to the use of technology to perform tasks with minimal human intervention. It typically involves predefined rules, scripts, or systems that execute repetitive or structured processes efficiently and consistently. Automation is designed to increase productivity, reduce errors, and save time by handling routine tasks that would otherwise require manual effort.
Examples of Well-Known Automations
Assembly Line Robots are programmable robotic arms designed to perform repetitive tasks such as welding, painting, and assembling components with high precision and speed. These systems are a cornerstone of modern manufacturing, especially in the automotive industry, where companies like Ford and Toyota rely on them to streamline vehicle production and ensure consistent quality.
CNC (Computer Numerical Control) Machines automate machining processes like cutting, drilling, and milling by following digital design files. These machines eliminate manual tool handling and allow for highly accurate production of complex parts. CNC technology is widely adopted in aerospace, electronics, and metal fabrication, where precision and repeatability are critical.
Packaging Automation refers to systems that automatically sort, label, seal, and palletize products. These solutions enhance speed and consistency in the final stages of production and are essential in industries such as food and beverage, pharmaceuticals, and consumer goods, where high-volume packaging and compliance with safety standards are key.
Conveyor Systems are automated transport mechanisms that move materials or products through various stages of manufacturing. Often integrated with sensors and robotic arms, these systems support sorting, inspection, and quality control. They are commonly used in logistics, automotive, and electronics manufacturing to improve workflow efficiency and reduce manual handling.
Industrial Control Systems (ICS) include technologies like PLCs (Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition) systems, which monitor and control machinery and processes in real time. These systems are vital in chemical processing, energy, and heavy manufacturing, where safety, precision, and uptime are paramount.
3D Printing Automation involves additive manufacturing systems that produce parts layer by layer from digital models. When automated, these systems can operate continuously with minimal human input, making them ideal for prototyping and custom part production in industries like aerospace, medical devices, and automotive.
The Downside of Automation
Any operations manager or automation engineer knows that projects labeled as “automated” often promise efficiency but can deliver complexity, rigidity, and disappointment.
Automation projects often come with challenges like:
- Drastic changes needed from operators while still requiring them to perform many manual tasks.
- Failing to eliminate unnecessary or incorrect steps and instead simply digitizing inefficiency.
- Taking too long to integrate and configure, delaying ROI and frustrating teams.
- Lacking flexibility. Once processes are set, they’re hard to change.
- Inability to scale, adapt, and learn. Automated systems break easily under stress or change.
Defining Autonomous
Autonomy refers to systems or machines that can make decisions and adapt to changing conditions without human intervention. Unlike automation, which follows predefined rules, autonomous systems use sensors, data analysis, and artificial intelligence to interpret their environment, learn from experience, and respond dynamically to new situations.
Examples of Autonomous Systems
Autonomous Mobile Robots (AMRs) are intelligent machines designed to transport materials within warehouses and manufacturing facilities. Unlike traditional Automated Guided Vehicles (AGVs), AMRs use sensors, cameras, and dynamic mapping to navigate complex environments, adjusting routes in real time to avoid obstacles or congestion. These robots are widely used in logistics, e-commerce fulfillment centers, and automotive manufacturing, where flexibility and adaptability are essential.
Smart Quality Inspection Systems leverage artificial intelligence and computer vision to detect defects in products during the manufacturing process. These systems can adjust inspection parameters based on environmental factors like lighting or product positioning, and they improve over time through machine learning. Industries such as electronics, pharmaceuticals, and automotive rely on these systems to ensure consistent quality and reduce waste.
Predictive Maintenance Systems use IoT sensors and AI algorithms to monitor equipment performance and predict failures before they occur. These systems autonomously schedule maintenance or adjust operations to prevent downtime, improving reliability and extending asset life. They are commonly used in heavy manufacturing, energy production, and transportation, where equipment uptime is critical.
Adaptive Manufacturing Cells are robotic workstations capable of reconfiguring themselves based on the product being manufactured. For example, a cell might switch tools or adjust its workflow when a new product type is introduced, without manual reprogramming. These systems are used in automotive, aerospace, and custom fabrication, where product variation and flexibility are key.
Autonomous Process Optimization involves AI-driven systems that analyze production data in real time and autonomously adjust parameters such as temperature, speed, or pressure to optimize output and reduce waste. These systems are increasingly adopted in chemical processing, food production, and advanced materials manufacturing, where precision and efficiency directly impact profitability.
The Downside of Autonomy
Stories of self-driving cars breaking protocol and harming others can make the idea of autonomy seem like a risky choice. In industrial settings, the stakes are just as high, if not higher.
Autonomous projects often come with challenges like:
- System failures and safety risks can occur when a system malfunctions.
- Loss of human oversight means someone is able to quickly intervene when challenges arise.
- High implementation costs, including equipment, training, infrastructure, and workflow changes.
- Job displacements and workforce resistance leading to a culture wary of change.
An Autonomous Machine That Solves the Forklift Power Problem While Avoiding the Downsides of Autonomy
In high-demand manufacturing and distribution environments, keeping forklift fleets powered efficiently is a constant challenge. Concentric developed the PowerHIVE™ system as a breakthrough solution that redefines how facilities manage forklift energy.
PowerHIVE™ is the industry’s first fully autonomous forklift battery management system. While Concentric once referred to it as “automated,” the technology has evolved far beyond simple automation. PowerHIVE doesn’t just follow programmed instructions; it makes intelligent decisions in real time. It replaces manual battery charging and swapping with a robotic, adaptive system that reloads batteries in under 2 minutes. Operators simply park their equipment, step into a safety zone, and press a button. PowerHIVE™ handles the rest.
Investing in Efficiency: The Short-Term and Long-Term Payoffs
PowerHIVE™ addresses many of the challenges of both autonomy and automation. Drastic changes are not necessary for operators or the facility infrastructure. PowerHIVE™ installs in just three days, and operators can be trained in as little as 15 minutes. Floorspace is reclaimed due to the small footprint. One electrical drop and 600ft2 can power up to 100 trucks. The system is universally accepted by teammates across all departments due to its easy-to-use interface and undeniable increase in efficiencies, and we have heard many stories of the culture improving as a result. Operators think of the system as a member of the team, and many facilities choose to name their robot. Data is available for the fleet so customers can see how and when their equipment is being used. Even better, this data is translated into actionable insights. New trucks can be added to the fleet as needed, and different types or brands are no exception. The PowerHIVE™ system grows and scales with the customer’s business. Most importantly, safety risks associated with charging or swapping batteries are eliminated. Operators never need to touch a battery again.
Autonomy is the future. And PowerHIVE™ by Concentric is leading the charge. Contact us to learn more!