FLEXIBLE AUTOMATED SOLUTIONS – DRIVING OPERATIONAL SUCCESS

Flexible Automation: A Complete Guide for Modern Manufacturing

The UK manufacturing sector is undergoing a transformative shift where the demand for adaptable and efficient production systems has never been higher.

Global trade agreements and the recent rise in tariffs imposed by the US have put further pressure on the UK manufacturing sector, for parts, raw materials, or complete goods, and to secure the supply chain. To fully reap the rewards of efficiency and speed to market, offer the agility to up and downscale as well as adjust manufacturing requirements quickly and efficiently in line with changes in both market and consumer demands, flexible automation is a necessity. This is especially critical in the face of labour shortages, where industrial automation solutions such as robotic process automation and automated workstations help to maintain output and optimise the production process.

Our latest guide delves into flexible automation, its applications in manufacturing facilities, the technologies that drive it, its benefits, and the future trajectory of automation in the UK.

What is Flexible Automation?

Flexible automation refers to the use of automated systems that can be easily reprogrammed or reconfigured to handle different tasks or products without the need for complex reprogramming, thereby minimising downtime and enhancing productivity.

Unlike fixed automation, which is typically designed for high-volume production of a single product, flexible automation systems can adapt to changes in product design or production schedules with minimal intervention, achieved through technologies such as robotic automation, computer numerical control (CNC) machines, and Artificial Intelligence (AI). These technologies also help reduce cycle times and improve consistency in mix productions, especially when managing varying production levels.

Fixed Automation vs. Flexible Automation

Understanding the distinction between fixed and flexible automation is key for modern manufacturers when looking at automation technologies to ensure they select the right system for their needs:

Manufacturing based company

Purpose

Fixed Automation: High-volume, repetitive tasks

Flexible Automation: Variable production with frequent changes

Flexibility

Fixed Automation: Very low

Flexible Automation: High

Setup Cost

Fixed Automation: High, but cost-effective long-term for one product

Flexible Automation: Moderate, with faster ROI through versatility

Changeover Time

Fixed Automation: Long and costly

Flexible Automation: Quick and simple

Examples

Fixed Automation: conveyor systems, rotary indexing tables, bottling lines, stamping machines

Flexible Automation: CNC machines, robotic arms, collaborative robots, automated workstations

Applications in UK Manufacturing Facilities

Flexible automation has become increasingly integral to enhancing efficiency and productivity within UK manufacturing facilities, with the adoption of technologies such as industrial robots, collaborative robots (cobots), and artificial intelligence (AI) enabling manufacturers to respond swiftly to market demands and production requirements.

In 2023, the UK witnessed a significant surge in industrial robot installations, predominantly driven by the automotive sector, with the food and metal industries also contributing to this upward trend.

Despite these advancements, the UK sits behind other nations in robot density (and is the lowest of the G7 countries), however, to address this, UK manufacturers are increasingly investing in AI and machine learning (ML) to bolster the deployment and impact of automation. An industry survey indicated that 88% of UK companies have invested or plan to invest in AI and ML within the next 12 months to support robotic process automation and industrial automation capabilities.

With growing support for investment and advanced systems becoming more agile and intelligent, the integration of flexible automation in UK manufacturing facilities is set to further enhance competitiveness, drive innovation, and address productivity challenges in the evolving industrial landscape. These developments represent automation in action, showcasing how the blend of processing machines and smart software delivers real outcomes.

Key Applications in UK Manufacturing

Automated_Warehouse_Solutions

Assembly & Sub-Assembly

Robotic systems can assemble parts quickly, even in mixed-model production, with built-in adaptability to meet varying production levels.

Welding and Fabrication

Automated systems are widely used in automotive and heavy machinery manufacturing enhancing productivity, efficiency, and safety through industrial automation solutions.

Material Handling

Smart conveyors, robotic arms, lift systems and AMRs improve efficiency for material flow around the manufacturing and warehouse areas using material handling systems that reduce human strain and improve throughput.

Inspection and Quality Control

Vision systems and AI detect defects with greater accuracy than humans to improve quality control of manufactured goods and avoid shipment of non-compliant items, streamlining the production process.

Technologies Powering Flexible Automation

Modern flexible automation uses several technologies that can be combined to offer a robust, agile, and efficient solution to today’s manufacturing needs. Some of the key technologies powering flexible automation solutions for UK manufacturers include:

Industrial Robots

These highly versatile programmable robots are capable of performing a wide range of tasks such as assembly, welding, and packaging - key robotic automation tools for boosting performance and reducing cycle times.

Collaborative Robots (Cobots)

Designed to work safely alongside humans, cobots enable human-robot collaboration in flexible assembly environments, supporting a range of manufacturing, packaging, and material handling tasks.

CNC Machines

Controlled by computer programs to perform precise manufacturing tasks, these machines are reprogrammable for different designs or parts, providing a flexible and scalable production environment.

Autonomous Mobile Robots (AMRs)

Used for material handling, AMRs transport components or finished goods across factory floors or between manufacturing and warehouse zones for storage, enhancing efficiency and reducing reliance on manual labour.

Industrial IoT (IIoT) Sensors

These sensors monitor machinery and production lines in real-time using data to enhance predictive maintenance, optimise the use of processing machines, and reduce downtime.

Machine Vision and AI

These technologies offer real-time inspection, measurement, sorting, and quality control, empowering automated workstations to operate with minimal human interaction and faster responses across changing product lines.

Benefits of Flexible Automation

Whether one or a combination of technologies is implemented, the adoption of flexible automation offers numerous advantages for manufacturers, including:

Increased Efficiency

Automation of repetitive tasks accelerates production processes and reduces errors.

Adaptability

Systems can be quickly reconfigured to accommodate new products or changes in production schedules, providing manufacturers with the agility to respond to market demands and adjust within a tight time frame.

Cost-Effectiveness

While the initial investment may be significant, flexible automation reduces long-term operational costs through improved productivity and reduced waste.

Scalability

Manufacturers can scale production levels up or down without extensive retooling, swiftly aligning output with fluctuations in demand.

Higher Productivity

Robots and CNC systems can operate 24/7 with minimal supervision, compensating for labour shortages.

Improved Accuracy & Quality

Precision systems reduce human error and improve consistency, often outperforming manual inspection.

Faster Time-to-Market

Agile systems help manufacturers respond quickly to market demands and custom orders.

The Future of Automation in the UK

The trajectory for automation in the UK manufacturing sector is poised for significant growth as technologies advance and manufacturers increasingly recognise the long-term value of investing in flexible automation solutions and the benefits this brings.

With AI and robotics being two of the leading lights of flexible automation advancement, systems are becoming more intelligent and adept at adjusting swiftly to handle changes in the market, demand for products, and an unpredictable supply chain. The key is knowing how best to utilise the available technology - whether through robotic automation, human-robot collaboration, or other flexible automation examples - to enhance efficiency, scalability, and productivity. Once explored, the UK manufacturing sector is well-positioned to harness the full potential of flexible automation, paving the way for a more resilient and responsive industrial landscape.