Electrical manufacturing with automation: Efficiency, quality, and safety

Electrical engineering is a large-scale industry that requires precision and high productivity. To meet these demands, more and more manufacturers are turning to automation and relying more on digital design tools to make that automation possible. This shift to automation is not just a trend but a significant transformation affecting various production aspects.

In general, automation in electrical manufacturing has come a long way, especially with the advent of programmable logic controllers (PLCs) in the 1960s. Recent advances in robotics, artificial intelligence (AI), and the Internet of Things (IoT) have accelerated this evolution, bringing unprecedented opportunities and benefits. HRForecast helps organizations manage this evolution by offering insights and solutions for workforce transformation and skills development.

However, it’s hard to talk about automation without conjuring images of a dystopian future where Terminator-like robots might take over. Remember when Arnold Schwarzenegger said, “I’ll be back?” Let’s hope he’s not talking about your work!

In this blog post, we’ll discuss the various features of automation in power generation with examples, numbers, and real-world applications, as well as how our solutions at HRForecast complement these changes. Understanding historical achievements lays the foundation for studying the current state of automation in electrical manufacturing.

Automation in electrical engineering is the application of automated technologies and systems to improve and optimize the industry’s production processes. It involves the creation of printed circuit boards, transformers, cables, electrical equipment, and other electrical devices and systems. In this industry, automation means combining sophisticated software, robots, and control systems to perform operations that were previously performed manually. Let’s explore how these advancements are currently being implemented in the industry.

Automation technology is causing a significant revolution in the electrical manufacturing sector. This is a summary of the existing circumstances:

• Heightened effectiveness and output. Automation has significantly increased manufacturing efficiency by cutting expenses and production times. It allows businesses to increase output and satisfy growing demand.
• Improvement of quality. Automated systems reduce human error and offer precise control over industrial processes, ensuring consistent and high-quality output. Adopting intelligent automation tools, such as generative AI and process intelligence, helps improve quality control and streamline operations.
• Dynamics of labor. Automated systems decrease the need for physical labor but also increase the need for specialized individuals to operate and maintain them. The workforce is being upskilled to become more tech-savvy.
• Optimization of the supply chain. Automation shortens lead times and boosts overall supply chain efficiency by facilitating real-time tracking and inventory management.
• Energy efficiency and sustainability. Automated systems are made to maximize energy efficiency, minimize waste, and support environmentally friendly production methods. It lowers operating expenses and is in line with global sustainability standards.
• Adoption worldwide. Nations with highly developed manufacturing industries, including the US, Japan, and Germany, are setting the standard for automation adoption. Emerging economies are likewise progressively incorporating automation to stay competitive.

Efficiency is a primary driver for automation in electrical manufacturing. Automated systems can perform repetitive tasks with precision and speed, reducing the time and labor required for production. HRForecast’s data-driven insights and workforce planning tools ensure that organizations can effectively integrate automation into their workflows.

Electronics manufacturing is increasingly becoming complex as the size of components and circuits continues to shrink. High component density, small pitches, multiple layers, and small and delicate parts that require precise placement are just a few of the issues manufacturers encounter when building products.

Such issues are likely to introduce challenges that can slow down product assembly and testing. Also, the delicate nature of the circuits requires extra care, but even with this, errors, wastage, and inefficiencies are likely. As competition increases and demand for new features and products grows, manufacturers should look for innovative and efficient ways to do this.

Generally, automation improves processes and product quality while lowering operational and production costs (it’s expected to reach $395.09 billion (about $1,200 per person in the US) by 2029). When implemented well, this translates to lower production costs, which manufacturers can pass on to their customers.

Robotic automation applies to almost all the stages in the electronics production cycle. Among the major areas are material and component handling, assembly lines, etching, inspections, testing, and more. Since most of these are repetitive tasks, robots can significantly reduce labor costs by reducing the number of employees while increasing production times and reducing errors and wastage. The following examples show how leading companies use automation to achieve these benefits.

A prominent example is the automation of assembly lines. Robots with vision systems can easily assemble electrical components, significantly reducing assembly time. According to a study by the International Federation of Robotics (IFR), automated assembly lines can increase production efficiency by up to 30%.

Siemens’ Amberg plant example

Siemens’ Amberg plant in Germany is a testament to the efficiency gains from automation. The plant, which produces programmable logic controllers, has achieved a remarkable automation rate of 75%. This high level of automation has resulted in a 20-fold increase in production efficiency while maintaining a consistent product quality rate of 99.998%. HRForecast has experience with strategic workforce planning solutions that supported Siemens in identifying and developing the necessary skills to enable proactive data-driven workforce decisions.

Automated inspection systems, utilizing AI and machine vision, can detect defects in electrical components with a precision unattainable by human inspectors. These systems can identify minute flaws, such as micro-cracks or soldering defects, ensuring that only high-quality products reach the market.

General Electric (GE) aviation

GE Aviation has implemented automated inspection systems for its electrical components. The use of AI-driven inspection has reduced the defect rate by 25%, enhancing the overall reliability of their products. This quality improvement has also resulted in a 15% reduction in warranty claims, translating to significant cost savings. HRForecast analyzed the labor market in the aviation industry and shared the most demanded positions, rising star jobs, and the changing skills landscape, including sustainability-related and customer care skills. Using this data, aviation companies can optimize their workforce to manage these inspection systems.

Robots can handle hazardous materials, such as volatile chemicals used in producing electrical components, reducing the risk of accidents. Automated systems can also perform tasks in dangerous environments, such as high-voltage testing, ensuring human workers are not exposed to potential harm. HRForecast can help companies develop safety-oriented skills among their workforce to manage these automated systems.

ABB’s robotics in hazardous environments

ABB, a leader in robotics, has developed automated systems for handling hazardous materials in electrical manufacturing. These systems have significantly reduced workplace accidents, leading to a 40% decrease in injury-related downtime. The enhanced safety measures have also improved employee morale and productivity. With HRForecas solutions, ABB could develop and improve its training so that the workforce can work safely and efficiently with these robotic systems. Automation can improve efficiency in routine tasks by utilizing industrial automation technologies, including robotic mowers and automated irrigation systems.

The future of automation in electrical manufacturing looks promising, with emerging technologies poised to revolutionize the industry further. HRForecast is at the forefront, providing the insights and tools needed to navigate this future.

AI and ML are set to revolutionize predictive maintenance in manufacturing. By analyzing vast amounts of data, these technologies can predict equipment failures before they occur, thus minimizing downtime and enhancing productivity. For instance, AI-powered predictive maintenance can significantly reduce unplanned downtime and decrease maintenance costs by up to 10%.

Cobots are designed to work alongside human workers, combining the precision of robots with the flexibility of human labor. These robots improve efficiency in tasks requiring a delicate touch or intricate assembly without replacing human workers.

IoT devices create a smart manufacturing environment by connecting machines, sensors, and systems. This connectivity allows for real-time monitoring and control of production processes, enhancing efficiency, quality, and safety. IoT-enabled sensors can detect anomalies and trigger automated maintenance routines, significantly reducing equipment failure rates and maintenance costs. HRForecast’s solutions help companies harness IoT’s power by providing the necessary skills and strategic insights for implementation.

Automation in electrical manufacturing is not just a passing trend but a powerful force that will continue to shape the industry’s future. As Arnold Schwarzenegger said in “Hasta la vista,” automation echoes that sentiment, promising to return (until next time) with even more advanced and useful technology.

Despite potential fears of a dystopian machine-dominated future, automation creates new opportunities for skilled labor and spurs economic growth. HRForecast, as your strategic partner, can provide the necessary information and guidance for organizations to develop their skills and adapt to this changing landscape.

To support this journey, we’ve compiled lists of the most demanded jobs and skills in electrical manufacturing automation.