Automation in Manufacturing: Balancing Technology and the Human Touch
For manufacturing facilities and their staff, the word “automation” evokes a mix of excitement and apprehension. Every plant worker, engineer and manager has seen a project fail due to a mismatch of expectations and communications (look up the cartoon about the engineer’s tire swing) – other failures like technical resources and budgets domming a project from the start – but many projects fail because they didn’t consider the human element during the design phase.
It’s not just about considering the cost of maintenance and who will do it, where parts will come from and who will buy them, and how often things will need maintenance – the human impact of an automation project has to consider how humans interact with the systems and hardware, how they feel about its deployment, and how it improves their lives as well as the productivity of their day and the facility as a whole.
Getting Automation Right
Many automation projects begin at the upper levels of a manufacturer, with a scope defined by individuals who may not be the ones using or troubleshooting the system daily. By the time the system is installed, operators can feel frustrated rather than empowered, and the system may never fulfill its initial promise and ignores the concerns of maintenance staff and daily operators who never asked for their input.
Another common issue is “over-automation,” where projects try to include more functionality than needed. These systems can feel cumbersome, slow, and difficult to maintain because nobody at the plant understands how they work and what makes them stop working as desired. Sometimes, facilities are not given a plan to maintain or update the system, leaving operators without backup copies of programs, training, necessary software, or the cables and tools needed for adjustments.
The key goal of an automation project should be simplicity: a system that meets the manufacturer’s needs without excessive alarms, complicated displays, or unnecessary inputs. It should be “right-sized” for the process, the operators, and the facility – and include a plan for long-term maintenance and support.
Why Human Involvement Matters
Automation is increasingly viewed as a way to compete globally, especially in regions with lower labor costs. While automation is essential for the future of manufacturing, human intervention remains irreplaceable – even in the climate of AI.
Humans continue to excel in manufacturing in ways engineers fail to predict. Operators can notice patterns, connect factors, and take initiative in ways automated systems cannot. Sure, modern AI-powered vision systems can analyze thousands of parts per minute, but their cost to procure, deploy, train and evaluate is incredible compared to the average operator who can combine visual and tactile feedback. For simpler systems, AI works great – but as complexity or the number of variables increase, humans are still the better choice.
We worry about peak performance of equipment, and OSHA mandates that we worry about human ergonomics and safety – but how rarely do we consider how automation systems generate (or reduce) operator fatigue?
ISA101, for example, has great input on screen design to make response times faster, reduce fatigue and information overload. ISA18 has guidance on alarm methodology, driving away nuisance alarms which result in operator apathy to real issues or drown them out entirely.
By respecting our plant staff (be they managers, engineers, technicians, operators and the tradesman that keep the plant running) manufacturers achieve safer, more efficient, and more satisfying work environments. This approach ensures operational resilience while keeping the workforce engaged and empowered.
Automation Services We Provide
Encorus Group offers comprehensive engineering, design, and field support to help manufacturers implement effective automation systems:
- Control System Specifications and Evaluations (Hardwired, PLC, HMI)
- Certified Allen Bradley System Integration
- Instrumentation Specifications
- Risk, Reliability and Process Safety Review – PHA/HAZOP, PFMEA, SIF/SIL
- Machine and Equipment Design
- Instrumentation and Equipment Tagging
- PLC/HMI/SCADA Programming (Ladder Logic, Graphics Design, PID Loop Logic, Object-Oriented Programming)
- Outage/Turnaround/Commissioning Support and Training
- Control Panel Design, Construction, and FAT
- Database Design (SQL, Access, etc.)
- Power system evaluation and design
- Power distribution system evaluation and design
- Motor and equipment controls, Starters and Variable Frequency Drives.
If you have questions about automating your process, facility, or building, contact Geoff Chadwick (716) 592-3980 ext. 173 or gchadwick@encorus.com.
