Automation in manufacturing: the impact on safety and efficiency

A skills shortage stemming from the pandemic and Brexit immigration changes continues to plague the UK. Many sectors have been affected, and manufacturing is one of the hardest hit, experiencing the largest skills gap in the industry since 1989.

Many plants are consequently struggling to maintain productivity and meet customer demand, which is still higher than pre-pandemic levels for some.

Due to the growing labour gap and the need to generate increased output levels, manufacturers have had to turn to automation. Automated equipment reduces the staff requirement, leaving factories with fewer vacancies to fill without harming productivity.

However, there are still fears around automation, especially for those who have not used it before. The most pressing concern is the impact on staff safety and overall performance.

We explore the impact of automation on safety and efficiency to help you determine if it is suitable for your plant.

• Why has there been a move to automation?
• The impact on safety and workers
• The impact on efficiency
• What else do I need to know about implementing automation in my plant?

Why has there been a move to automation?

Automation has been a staple in the car industry for years, with automated equipment fulfilling vital roles within factories. However, the trend has started to spill into other manufacturing sectors, including food. It’s a critical factor of the fourth industrial revolution.

One of the reasons for the shift is the impact on efficiency. Automated machines and robots are often seen as more reliable as they are connected to one another and consistently complete tasks with minimal room for user error. They speed up processes, allowing manufacturers to generate greater output levels.

They also help to reduce waste and to do more with less through higher accuracy rates.

The most significant driver of the move towards automation is the labour gap UK manufacturing is facing. Plants are finding it challenging to recruit the needed skills, leading to staff shortages that harm their ability to run lines and complete tasks.

Automation is a solution to the issue, with one system potentially filling the role of several workers. It allows factories to overcome skills gaps without compromising productivity or quality.

Due to the lack of available workers, many recruiters have increased salaries to attract candidates, creating another obstacle for manufacturers. In the face of a cost-of-living crisis, factories will do everything they can to minimise costs.

Labour costs are a considerable part of expenditure. A study by Deloitte found that robotic process automation has the potential to save 40-75% in labour hours – amounting to improved profit margins.

With the challenging climate plants currently face, automation will help to ease all manner of evils.

The impact on safety and workers

For plants new to automated processes, there may be concerns about the impact on staff safety.

Automation is positive for worker safety. By using machines to perform potentially unsafe tasks (including those that require physical exertion or could cause repetitive strain injuries), your employees are better protected.

It’s also possible to utilise automated systems in hazardous environments, such as when working with high or low temperatures or toxic materials. This again reduces the danger to staff health.

Machines have greater capabilities than humans. They can lift heavier loads or process the tiniest parts. It eases the pressure on your workers, allowing a robot to do a job that may take them hours to do while minimising the risk of injury and other ramifications.

While automation is safe, you must train your staff properly when introducing new processes for maximum risk avoidance. It’s especially integral if you are utilising semi-automation or manual intervention is still required from workers.

With training, you will empower your staff to understand the machinery and use it correctly to prevent any incidents. You should make sure your processes and policies comply with safety at work standards – which we may see address automation more as it grows in popularity.

Investing in reliable machinery and ensuring it is regularly maintained is crucial to prevent harm and keep everything in good working order.

Outside of safety concerns, there is controversy around automation and job reduction. However, automating your factory doesn’t mean removing staff. Instead, the focus should be on reducing the need for humans to conduct the more mundane tasks and use their skills in areas where they are better utilised.

By placing human workers and automated processes together – as many manufacturers are starting to do – you access faster turnaround times and improved efficiencies that benefit everyone, from employees to customers. 

The impact on efficiency

One of the significant advantages of automation is improved efficiency, provided you utilise intelligent machinery and adequate processes.

When programmed correctly, automated systems will fulfil tasks consistently, in keeping with your parameters and faster than manual processes. It removes the risk of human error creating inconsistencies, delays or flaws, so you generate better results in a shorter timeframe.

It’s possible to embed quality control into automated processes. Any product that does not meet the specifications will be removed from the line or production halted until the issue is resolved. In some cases, these are issues that a human would struggle to detect.

This element of quality control reduces the chance of flaws in output, as issues such as contamination or poor-quality materials are removed from the line. It will also prevent problems such as failure to meet weight limits or poor packaging. As a result, you will consistently satisfy customers and reduce the risk of complaints.

Most automated systems have data collection built in. They use this data to respond to other machinery and your output, enabling them to perform the right action at the right time.

The data collected can also be analysed to understand production line performance. This allows you to refine your processes and improve efficiency even further for greater rewards. 

What else do I need to know about implementing automation in my plant?

Committing to automation is a big step if your plant does not already utilise it. However, it’s easier than you think to introduce it into your plant. Moreover, it’s likely to become a necessity.

Here is what else you need to bear in mind about automation. 

1. You don’t need to jump all in

Very few factories are entirely run by robots. Automation is commonly used for specific elements of production. You might want to introduce only partial automation if you’re new to it.

Examples include utilising semi-automatic machinery that still requires some labour (though on a reduced scale) or adding one piece of automated equipment rather than a full line. This will enable you to benefit from automation without having to go all in straight away.

2. Remember, it’s an investment

Automated machinery may carry a high price tag. It may be off-putting for some manufacturers, particularly with the given current cost pressures, but you are able to finance it over 5 years through leasing and hire-purchase solutions.

It’s crucial to see it as an investment with a short payback period. Automation reduces labour costs, meaning you can quickly access a return on your investment. It also enhances productivity and performance, bringing further financial rewards.

3. Choose fit-for-purpose machinery

Whether automated or not, any machinery you install into your production lines must be fit for purpose. It should be compatible with your product types and plant conditions and able to fulfil all the tasks you need to.

When purchasing an automated solution, consider whether it addresses your requirements. This will enable it to meet your specifications and generate consistent results. 

In summary

Automation is increasingly commonplace in UK factories. As the skills shortage lingers and manufacturers endeavour to maximise efficiency and reduce costs, the trend shows no signs of slowing.

Although it is becoming necessary for many plants, some concerns may be associated with automation. Fortunately, it has proven benefits for worker safety, efficiency and performance.

Finding reliable and compatible solutions is crucial if you are looking to introduce automation into your plant.

Yamato offers a wide range of machinery with various levels of automation, suiting every set of needs.

Examples include our semi-automatic weighers, automated multihead weighers and production inspection equipment. Each is designed to drive productivity and improve results.

To learn more about how automation can help you or our solutions, speak to a Yamato expert today.