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Unlocking the Potential of Hyperautomation in Manufacturing

December 10,2024

What Is Hyperautomation and How Does It Differ from Traditional Automation?

Traditional automation focuses on optimizing individual tasks, such as deploying robots for repetitive processes like pick-and-place operations. Hyperautomation, on the other hand, takes a holistic approach by optimizing entire production workflows. The goal is not just task-specific improvements but end-to-end efficiency across the manufacturing process.

Introduced as a top strategic trend in 2020, hyperautomation promises to transform operations through advanced technologies like Artificial Intelligence (AI), Machine Learning (ML), and the Industrial Internet of Things (IIoT). However, success depends on aligning business goals — revenue growth, cost reduction, and risk mitigation — with appropriate technologies.


The Business Case for Hyperautomation

To fully realize the benefits of hyperautomation, manufacturers need to evaluate its impact on three core business objectives:

Revenue Growth: By automating repetitive tasks and enhancing customer engagement, businesses can scale output and achieve higher efficiency.

Cost Reduction: Redesigning processes to reduce errors and improve production quality results in lower operational costs.

Risk Mitigation: Addressing inefficiencies and safety hazards, such as manual feeding of machinery, can minimize compliance risks and improve workplace safety.

A structured roadmap that ties these objectives to automation tools is essential for success.


Can Hyperautomation Work with Legacy Equipment?

One challenge manufacturers face is integrating hyperautomation into factories relying on legacy equipment. Machines like Programmable Logic Controllers (PLCs), which can remain operational for decades, often lack the connectivity needed for a hyperautomation strategy.

The good news is that retrofitting older machines with smart sensors can enable them to communicate with IIoT platforms. These sensors collect valuable operational data, which can be used to optimize workflows, reduce costs, and boost productivity.


Ensuring Interoperability in a Hyperautomated Environment

To successfully implement hyperautomation, manufacturers need to ensure that all devices within their ecosystem can communicate effectively. This involves selecting communication protocols compatible with existing machinery. For instance, while Allen Bradley PLCs work seamlessly with ProfiBus, not all protocols are universally compatible.

To minimize integration challenges, businesses should consider adopting open-source architectures like the Robot Operating System (ROS). These platforms promote flexibility and interoperability, reducing friction between diverse systems and devices.


Future-Proofing Your Hyperautomation Strategy

Hyperautomation relies on the latest technologies, which can evolve rapidly. To future-proof their investments, manufacturers should focus on scalable and adaptable solutions. Regularly updating systems, training staff, and staying informed about technological advancements are key to maintaining a competitive edge.


Conclusion

Hyperautomation represents a significant step forward for manufacturing, offering opportunities to optimize processes, reduce costs, and enhance operational efficiency. While challenges like legacy equipment and system compatibility exist, they can be addressed through strategic planning, retrofitting, and open-source solutions.

By aligning hyperautomation with clear business objectives, manufacturers can transform their operations and stay competitive in an increasingly automated world.

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