AI in Industrial Automation: Transforming How Industries Think

For many years, industries have been hugely dependent on automation. From conveyor belts and control systems to robotic arms, every piece of automation has made the execution of industrial operations easier and faster. 

However, industrial automation comes with two limitations: 1) It relies on fixed instructions, and 2) It needs human intervention after execution. This is why implementing AI in industrial automation has become a primary necessity.

Just like traditional automation, AI-powered automation helps in automating repetitive tasks and simplifying complex processes. But instead of depending on pre-set rules, AI automation analyzes the given process, understands it, and performs it with human intelligence, due to which it does not require your oversight. 

That’s why the global AI in industrial automation market size is estimated to reach USD 111.8 billion by the end of 2034 at a CAGR of 18.8%.

Source: insightaceanalytic.com

Today, this blog will provide you with detailed insights into how AI in industrial automation is transforming the way industries think.

Understanding AI in Industrial Automation

Today, artificial intelligence (AI) has become the most common technology that adds the ability to analyze and make informed decisions with precise data analytics. Industrial automation has been utilized for ages, simplifying complex and repetitive industrial processes, such as logistics and manufacturing, through the use of control systems and robotics. 

However, although industrial automation is meant to streamline complex processes, it needs human intervention after each process, which eventually becomes time-consuming. 

But imagine each industrial process being automated smartly without needing any human oversight. This is exactly what happens when AI is implemented in industrial automation. Smart industrial automation brings numerous benefits, such as:

• Minimizing unwanted downtime and material wastage with predictive maintenance and automated quality checks.
• AI-powered machines can take over high-risk tasks, such as handling toxic chemicals, thereby preventing hazardous situations.
• AI-powered analytics tools precisely inspect each product, minimizing the chances of defective products reaching customers.
• By automating repetitive tasks with AI, you can easily boost the overall productivity and efficiency of your industrial processes.

How AI is Transforming Industrial Automation

Traditional automation can simply automate tasks without analysis or critical thinking, which eventually results in errors and inefficiency. But the combination of AI and traditional automation brings impactful success for industries. Here’s how.

1. Maintenance Prediction

Industries involve large-scale operations that require heavy-duty equipment for execution. However, such essential operations can suddenly come to a halt due to the failure of critical machinery. And downtime in industrial processes means long delays and costly penalties. 

This is why timely maintenance of machinery and equipment becomes a prime necessity to ensure smooth operations. However, industries involve an innumerable number of pieces of equipment and machinery, which makes it challenging to inspect each machinery at regular intervals. 

AI automation uses analytics tools that analyze machine vibrations, usage data, and temperature accurately and predict when the subsequent failure can occur. This allows industries to prepare for maintenance and prevent unnecessary downtime.

2. Detailed Inspection of Product Quality

Workers cannot precisely test the quality of each manufactured product, especially when the company produces hundreds or thousands of products daily. But poor quality products, when delivered, can leave a bad impression on customers, attracting them to your competitors. 

That’s why quality assurance of each product is essential before delivery. Smart industrial automation has the power to inspect thousands of products quickly and efficiently in a day. 

While it is easy for humans to miss tiny defects or cracks after hours of work, AI can easily spot them, thus allowing you to deliver quality products every time.

3. Smarter and Efficient Supply Chains

Not just present, but industries need to be prepared for future demand in today’s competitive era. Though predicting future product demand or scarcity is not possible for us (humans). But intelligent automation makes it happen. 

AI, with the help of smart analytics, easily forecasts demand and manages logistics. Moreover, by using AI for business automation, you can track the product inventory regularly in real time. The precise tracking allows you to match customer demand with production and also prevent understock or overstock situations. 

4. Productive Operation Execution

Automation helps in operating and running machines. But AI automation operates machines with human intelligence. Running a machine in any industry does not mean simply switching it ON or OFF. 

It also means implementing different operations, such as adjusting temperature, pressure, and mixing, automatically without needing human oversight. 

Quick execution of operations allows industries to boost productivity. This also allows workers to focus on more crucial processes while resting assured that the production is being executed well.

The Future of AI in Industrial Automation

AI is conquering every industrial landscape; it’s obvious that it is the future of industrial operations. Here’s how.

1. Personalized Production

Usually, in industries, mass production means producing large quantities of identical products. But in today’s digital era, customers prefer to have personalized products, from demanding custom features in cars to tailored packaging. 

Although it may seem challenging for industries today, AI will make it happen in the near future. AI workflow automation will automatically analyze customer needs and adjust the machine settings accordingly. 

And not months or weeks, but AI will be able to execute it in a fraction of the time. This means industries can easily deliver custom goods in bulk, without compromising on quality or efficiency.

2. Automated Self-Adaptability by Factories

Is it possible for a factory to self-monitor itself and quickly adapt to growing needs and demands? It would sound nearly impossible today, but the blend of AI and industrial automation will make it happen in the near future. 

As AI can analyze large chunks of data in no time, smart automation will detect inefficiencies, adjust production speeds, and even assign tasks to workers automatically, even without needing any human instruction or oversight. 

This will help not only in reducing downtime and boosting productivity but will also help businesses in adapting to changing market demands quickly and efficiently.

3. Smarter Decision Making with Digital Twins

Today, testing several products simultaneously and spotting potential defects or risks is challenging for industries. 

But AI will make it possible in the near future through digital twins. A digital twin is a virtual replica of a physical factory, machinery, or any manufacturing process. By combining this virtual simulation with AI, you can analyze the product during its manufacturing and identify potential defects that may be hidden within it. 

For instance, before launching any product, factories can test it in real time with a digital twin and identify all the potential risks, safety issues, and energy waste involved in it. This will eventually help companies ensure efficient production every time.

Final Say

Traditional automation has always been meant to improve efficiency and productivity. But when combined with AI, it not only streamlines processes but also enhances task accomplishment with human intelligence.

Want to streamline your industrial processes with accuracy? Technocrats Horizons becomes your effective partner. Our AI automation agency helps businesses simplify complex processes with efficiency without needing human intervention, so you can easily focus on making important strategies.

Contact us now to streamline your industrial operations quickly and efficiently.