Modern manufacturers are increasingly reliant on automation, with benefits including improved productivity and the satisfaction of varied customer demands.

Indeed, the global industrial automation market is projected to reach a value of approximately £240 billion by 2030, up from roughly £120 billion in 2023.

Realising the importance of automation in the competitive manufacturing sector, companies may either opt for a fixed or flexible approach. 

Read on as we highlight the differences, helping you to make a well-informed decision. 

Learn about Automate UK’s role in providing guidance and support specific to automation adoption.

Understanding Fixed Automation

Fixed automation (also referred to as hard automation) involves the integration of equipment that’s designed to perform a specific task or process. 

As an example, you might have a conveyor system exclusively for the purpose of moving vehicle components between production stages.

Such automation has traditionally been the first choice for warehouses, with fixed systems enabling the mass production of identical products at high speed.

They can be programmed with specific instructions for the performance of set tasks in stages.

Other examples of fixed automation include:

• Equipment for the mass assembly of car engine parts and electronic devices

• Machining transfer lines for the performance of sequential tasks, such as drilling and milling

• Web handling and converting systems for the production and processing of paper and foil packaging.

Understanding Flexible Automation

Flexibile automation systems differ in allowing rapid adaptation to manufacturing demands. 

Such technologies are designed for easy reprogramming and reconfiguration, with the capacity to take on different types of processes and tasks. 

This kind of flexibility can make the difference, as manufacturers seek success across fast-moving markets.

As an example, manufacturers are making increasing use of robots for such tasks as heavy lifting and precision component installation. 

These robots can be relied on to work safely alongside human factory staff, moving freely and adapting to new tasks as needed.

Other examples of flexible automation include:

• CNC machines, which can be reprogrammed for the production of parts with various specifications

• Adaptive assembly lines, with integrated AI, sensors, and robotics enabling product variations across the same production line

• AI-driven workstations for the inspection and testing of various product types

Such flexible automation systems are ideal for low to medium-volume production, with the capacity for frequent product variation and customisation. 

They are also an excellent choice in environments where quick changeovers are required.

Benefits & Drawbacks of Fixed Automation

As mentioned, there’s a range of benefits associated with fixed automation. 

Designed to perform repeat processes at high speeds, such systems can greatly enhance throughput and productivity. 

The limited range of functions also means that fixed equipment is relatively unlikely to break down, with maintenance being typically quick and easy.

Used for the performance of tasks in the dull, dirty, and dangerous categories, fixed automation systems can reduce the strain on human workers. 

Such machines can be left to run continuously, with little need for monitoring and adjustment. 

This can make for a return on investment in as little as 1 to 3 years, with manufacturers able to rely on high-level precision and repeatable product quality.

Despite such benefits, the rigid and inflexible nature of fixed automation means that it can’t be wholly relied on in the fast-moving manufacturing sector. 

Such machines often come at a high initial cost, limiting the prospect of SME adoption. 

Modification can also be expensive, given that fixed machines are commonly designed for a single purpose. 

This makes it difficult to fulfil changes in demand, also limiting the potential for innovation and growth.

Benefits & Drawbacks of Flexible Automation

Prioritising adaptability and responsiveness, flexible automation promises to solve many of the problems associated with the fixed approach.

It enables organisations to make adjustments as needed for greater resilience and a competitive edge.

As mentioned, flexible automation systems can be easily reprogrammed for the efficient performance of various tasks and handling of different product types. 

Like fixed technologies, the flexible alternatives can also lessen the demand on human workers, in turn boosting productivity and accuracy.

With the capacity to take on various production tasks, flexible systems reduce the need for capital and operational expenditure. 

Such systems are designed for easy reconfiguration, enabling production based on market demands. 

Often integrated with advanced sensors and machine learning technologies, they can be relied on for the automatic identification of product issues and improvements in quality.

Requiring a lower level of capital expenditure, fixed technologies are ideal for smaller businesses with limited budgets. 

They can be implemented over time, with automation scaled according to market demand. 

Controlled and monitored via user-friendly programmes, flexible systems also make for a quick return on investment.

Of course, there are some downsides, with flexible systems often being relatively complex and requiring advanced programming to suit different production environments. 

This makes for a greater risk of system errors and downtime, calling for more dedicated monitoring and maintenance. 

There may be a sacrifice of speed and efficiency in the switch between fixed and flexible systems, with potentially higher production costs. 

It can also take time for staff members to adapt, with training needed to ensure the best possible use of flexible technologies.

Choosing the Right Automation for Your Manufacturing Needs

There are a range of factors to consider in deciding on the suitability of fixed and flexible automation. 

As mentioned, fixed automation is the best choice for the repeat manufacturing of standardised products in large volumes. 

However, flexible systems can take on a much wider range of applications, being scaled to suit the levels of demand. 

The best choice may also come down to your long-term business goals and expected market trends.

As the leading trade association for manufacturing sector suppliers and end users, Automate UK can help you in making the best possible automation choice.

We promise guidance in making the most-informed technology decisions through access to the latest insights and knowledge sharing opportunities. 

Join Automate UK as we empower the automation industry together.