Throughout our decades of experience engineering automation technologies for manufacturers, one question we hear most often is, “How can investing in today’s automation technology help my company in the long run?”

It’s a wise question. Automation is indeed a serious investment, and you need proof that such an expense will boost your company for years to come, not lock you in with technology that will quickly become obsolete.

That’s where flexible automation comes in. A flexible automation solution can quickly adapt to new products and new throughputs, giving you peace of mind that this technology can change with the times.

The “locked in” automation technologies are called fixed automation – a form of automation that is no longer a top choice in most applications due to its rigid and highly specialized nature. As a champion of flexible automation, we’ll explain how each approach works, how it can impact your business, and why flexible automation is the winning choice for forward-thinking manufacturers.

Initial Investment

Fixed automation is generally a lower up-front cost than flexible automation. That’s because fixed automation equipment is built for one specific product or use, whereas flexible automation equipment delivers more sophisticated controls, reprogrammable components, and a modular design that can be readjusted. Flexible automation offers a multi-product capacity; fixed automation is tied to its single use. In the long run – about 5-10 years post-integration – flexible automation provides a lower cost per product type than fixed automation.

Product Variety

Fixed automation handles one product, or one specific product range. This is all that their tooling, fixtures, and mechanical configurations allow them to do. Flexible automation, on the other hand, enables you to generate multiple different products using the same manufacturing automation equipment. Flexible automation systems incorporate programmable parameters and interchangeable components that allow you to switch between different product types without the need for extensive, time-consuming reconfiguration.

Reconfiguration Time

Fixed automation equipment is built with hardwired, mechanical controls and highly specialized, permanent tooling. Reconfiguring or updating fixed systems is a lengthy and arduous process. Flexible systems are designed with modularity in mind, incorporating programmable logic controllers (PLCs) and standardized, reusable tool interfaces that you can use for multiple different purposes like inspection devices or welding heads.

Production Volume

To maximize the utility of a single-use technology, fixed automation systems are best suited for high-volume products. Because flexible automation is adaptable to so many uses, it meets an acceptable unit cost at a lower product volume than fixed automation. We recommend flexible automation for medium to high volume demands. Flexible automation solutions are also a great tool for manufacturers in niche markets.

Market Readiness

Because fixed automation cannot readily adapt to product changes or new product introductions, they cannot easily meet market fluctuations. Flexible automation technology can adjust product mix in real time and change production times based on the demand of each particular day. This responsiveness better prepares your business for market changes in the long term and better serves your customers through shorter lead times.

Space Utilization

Fixed automation requires a dedicated assembly line for each product. If your facility makes four products, you would need to install four different production lines. Alternatively, one flexible automation system can handle all four products in one unified production line. Flexible systems let you maximize your floor space and grant you the opportunity to grow without adding additional space.