When you think of industrial automation, the first thing that often comes to mind is increased production speed. While automation certainly drives efficiency, it offers a host of other benefits that are crucial for a company’s long-term success. These advantages, often overlooked, include improved safety, enhanced quality control, and reduced waste.

A Safer and More Productive Workforce

Despite the popular mindset, industrial automation isn’t about replacing people; it’s about empowering them to do their jobs better. By automating tasks that are repetitive or could cause injury, companies can improve ergonomics and reduce the potential for on-the-job injuries, creating a safer work environment and helping to prevent employee downtime. Automation also frees up workers to focus on more complex, higher-level tasks, leading to more engaging and fulfilling jobs. As a result, employees can develop new skills and become more valuable to the company.

There are different types and variations of automation available. At QSI Automation, we design and build custom automation systems, which can be categorized into three main types:

  • Fully Automated Systems: These systems are ideal for processes where all parts of a finished product can be automatically introduced using equipment like vibratory feeders or robotic vision picks.
  • Semi-Auto Assisted Assembly Cells: These cells are used when an operator needs to introduce some components. This is often necessary when parts are difficult to automatically orient, have delicate surfaces that could be scratched, or are large and bulky.
  • Insert Molding Automation: This specialized process involves loading a preformed part (usually metal) into an injection mold where it is over-molded with a thermoplastic resin to create a finished part. These systems frequently include part feeding equipment and post-mold inspections to ensure quality.

Consistency and Quality Control

Automation ensures that processes are reliable and repeatable, which holds a team to a higher standard. Unlike humans, who can get fatigued or distracted, automated systems execute the same task the same way every single time. This minimizes the natural variations that can occur from one human worker to another and ensures that every product coming off the line is identical in dimensions, assembly, and quality. This consistency is essential for creating reliable, standardized products that customers can trust.

In addition to consistency, automated systems generate a continuous stream of data on product quality. This data can be analyzed to identify trends, predict potential equipment failures before they happen, and pinpoint inefficiencies in the production process, allowing manufacturers to make data-driven decisions to optimize their operations and prevent future quality issues.

Because automated systems can continuously work 24/7, production operates at a consistent pace, leading to a higher throughput and allowing for 100% inspection of products, a task that would be impractical and expensive with human workers. By catching defects early in the production process, automation also helps reduce costly rework and material waste.

A Plan for Growth

The manufacturing industry is at an important crossroad. To be competitive, companies need to drive continuous improvement in efficiency and lead time. Automation is quickly becoming a key tool in achieving best-in-class manufacturing. For companies who have not already started integrating automation into their facilities, the key is to start small and have a roadmap for the future. The worst thing you can do is run out and buy a bunch of robots without having a well-thought-out plan. Instead, you should reach out to experts to get different perspectives and identify opportunities for collaboration. Starting with what you know, such as automating a hand assembly process, is a good first step because it allows you to get comfortable with the technology and build upon it over time.

With a partner you trust, the process of implementing automation can be less daunting. And while the initial investment can be scary, the return on investment (ROI) can be quick, with some projects seeing payback in as little as 2 to 6 months, depending on a variety of factors.

 

Securing the Future

According to the Association for Advancing Automation (A3), robot orders in North America were valued at $580.7 million in Q1 2025, a 15% increase in order value compared to Q1 2024 (source: BusinessWire). This shows the ongoing demand for and investment in higher-value automation systems.

Companies need to invest in automation to show customers they are committed to meeting their needs and to remain competitive in a challenging job market. By driving efficiency and quality, automation can help keep manufacturing in the U.S. and allow companies to be consistent in meeting customer demand, while having the flexibility to quickly respond and adapt to market changes.

Article authored by Ryan Berkes, automation and feeder bowl manager at QSI Automation.

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