3 Flexible Automation Examples Explained

Last updated on February 7th, 2025 at 07:45 pm

When industries use tools and systems that allow them to switch from one task to another quickly, it’s referred to as flexible automation. Flexible automation examples include robotic arms programmed to perform multiple functions on a production line, such as drilling holes, inserting rivets or screws, sanding, spray-painting, or welding. By engineering robots or automated systems to transition between operations through a simple command change in a controller or a modification of software code, manufacturing facilities can seamlessly adapt to new demands.

This type of custom automation enhances industrial capabilities with intuitive yet sophisticated programming, allowing factories, warehouses, and other automated facilities to teach new skills to their equipment. It is a form of artificial intelligence that can even respond to verbal commands or visual cues. The potential applications of flexible automation for industry are nearly limitless.

Flexible Automation: Engineering Factories for the Future

The theory of flexible manufacturing emerged in the 1960s with the introduction of automated technology to the production line, as computerized numerical control (CNC) machines, programmable controllers and robots began to take over factory floors. Today, it allows industrial equipment to be programmed to do several specific tasks and enables changes to these tasks within a short time frame. This offers factories flexibility in their processes, allowing them to switch production between different types of products quickly.

Typically, flexible automation systems consist of the following:

Part processing machines: CNC machining equipment carries out a portion of these processes, with inspection and other automated workstations combined.
Material-handling system: Conveyancing and other systems move parts from one area along the production line to another, with robots generally used to load and unload the product.
Central computer control system: Communications that come from this central controller provide component routing information and adjust timing within the material-handling system while coordinating these machines’ operational processes.
Human labor: While these systems are based around automation and engineering, this flexibility still requires humans to manage, repair, maintain, and alter procedures when necessary.

Flexible automation systems have highly automated processes that allow them to produce smaller batch sizes as efficiently as bigger production runs. Such fabrication techniques are ideal for on-demand manufacturers, who deal with smaller orders from e-commerce distributors. Though typically, these methods are associated with front-line manufacturing, automation flexibility can be applied to other processes, such as packaging.

Flexible Automation Examples in Manufacturing

Flexible manufacturing techniques allow low-volume and high-mix manufacturers to apply custom automation equipment with negligible cost implications. These techniques and the technology that support them permit manufacturers to react rapidly to design modifications, new orders or even market changes, while also making small batches of product more economical to fabricate. This flexibility is not only used in product manufacturing, automation can be used in the packaging process as well.

Robots are being used with increasing frequency in packaging operations. Robots have been adapted to handle products of various sizes and shapes, including more delicate products. This is especially true of collaborative robots that work alongside human operators. They’re capable of dealing with changing requirements and environments and’re easy to train for new tasks. Such manufacturing automation has become more commonplace within the packaging industry, including automated packaging, source tagging, and automated labeling. Some flexible automation examples include the following:

Automated Packaging

Manufacturing automation for packaging products is as diverse as the products requiring packaging. Packaging ranges from wrapping single pieces of candy that are then bagged for consumers to whole shrink-wrapping pallets of products in preparation for shipping to a distributor. Depending on the product, packaging machine designs must meet a manufacturer’s or distributor’s requirements, and often these systems are highly customized. Packaging automation depends on the type, size, fragility, and other elements of the items being packaged, so the design of packaging systems should provide a wide range of capabilities.

Custom automation in packaging equipment should include the following capabilities:

Easily integrated with other manufacturing automation systems
Feature up-to-data safety technology
Programmable operations that are data-centric
Real-time diagnostics for maintenance and servicing

Automated packaging equipment maximizes efficiency, allowing smaller manufacturers to stay competitive against mass-produced packaged products. Current automation engineering also allows accommodating more types of products with distinct packaging requirements. It helps manufacturers to reduce the time it takes to package a product, thus reducing operating costs.

There are three general types of packaging automation: primary, secondary and tertiary.

Primary Packaging Automation

Whether it’s a head of lettuce or an automotive component, primary packaging is what a consumer sees when buying a product off the shelf in a retail outlet. Regardless of the product, manufacturers need to consider many issues regarding equipment, including floorspace, quality control, throughput and volume. Consideration must also be paid to what’s being packaged, particularly any cleanliness requirements and dimensional issues. How the product is presented also matters, as packaging is a marketing form.

The first stage of automated packaging involves equipment like:

Conveyancing system to infeed or outfeed products.
Hoppers for gathering products from which they’re conveyed in a steady flow.
Linear feeders that both orient and sort the product.
Vibratory bowls that help orient bulk products as they’re fed singly through other machinery.

Packaging systems are designed to classify, orient, allot, position and introduce products quickly, and in a manner that won’t damage the product.

Secondary Packaging Automation

Also known as case packaging automation, it involves packaging single products together in larger cases or other types of containers to protect them when in transit. Custom automation equipment provides more incredible speed, reliability, and accuracy than manual packaging. Flexibility is integral to deal with product changeovers for equipment at this stage. Manual packaging often requires much more space for material storage and workstations, while packaging automation usually reduces the space needed.

There are a few different types of custom automation at this stage. The most common method involves top-loading cases vertically, which is typical for bags, bottles, cartons, flow packs, pouches, and sachets. To create a smaller footprint when packaging, a method referred to as side load case packaging entails mainly packaging retail cartons or other structured products horizontally. Wrap-around case packaging offers the lowest cost, using precut flat sheets that seal the sides of the product; this method is often used for canned beverages or foods.

Tertiary Packaging Automation

This final stage of packaging automation – also described as end-of-line packaging – prepares products for shipment to retail outlets or warehouses. Protecting shipping, this method allows products to be moved easily in bulk. Though mechanical palletizers have been around for decades, flexible automation uses robotic palletizing systems for greater efficiency. While generally more reliable, their flexibility and smaller footprint make them more desirable in manufacturing. Engineering these systems allows them to perform multiple tasks, sometimes even simultaneously, including packaging products, loading boxes onto pallets, and wrapping pallets in shrink wrap.

Source Tagging

Source tagging is the application of electronic article surveillance (EAS) tags or labels, applied onto or within a product during packaging or manufacturing. Automating this process saves time, with hard tags used for source tagging clothing while adhesive labels typically go on inflexible merchandise. Many of these tags or labels use radio-frequency identification (RFID) or similar technology to protect items against theft or reorder items automatically when stock gets low. RFID tags can also be used on packaging to track their location within the supply chain.

When introducing electronic ID tags, it’s important to understand:

Precise purpose for tags or labels
At which frequency tags or labels will operate
Conditions under which they’ll be operating
Scanning equipment to be used to read them
Length of lifecycle for tags or labels
Expected lifecycle of the label or tag

Source tagging adds value to a product, as retailers don’t then need to add anti-theft devices themselves, while this procedure is made much quicker due to automation. Engineering RFID tags into packaging also improves the speed of processing orders and accuracy within inventories. Their use in packaging and logistics helps manufacturers automate workflows, data collection and processes, along with helping to identify bottlenecks and improve visibility throughout the supply chain. When large volumes of goods require quick shipping and receiving, an electronic tag that details all contents of a pallet will save manufacturers time. And it does this without one box having to be opened or moved.

Source tagging doesn’t come cheap, however. Costs go well beyond acquiring tags or labels. Tagging merchandise and goods requires investing in automated equipment, changes to processes, new design features and the labor involved in installation of these systems. However, as these systems become more common in the packaging industry, these electronic tags are being reused and recycled.

Automated Labeling

Manufacturers use labels to identify and market their products. Manual labeling systems usually are either inflexible or only accommodate labels within a certain size range. Conversely, automated labeling systems work for a wide range of label sizes. Having a single machine configured for a diverse assortment of product types and sizes allows greater flexibility during the packaging process.

While automated labeling is commonly used by manufacturers for packaged products and in the packaging industry, automatic labelers have become increasingly more flexible in what they can do. Those that integrate robots within a flexible manufacturing system into their automated labeling systems offer numerous benefits.

These automated labeling machines will often feature capabilities that include:

AI that enables a robotic arm to act intelligently within its programming while placing labels.
Implements designed to keep from damaging the product.
Label dispenser/applicator to dispense and apply labels of varying dimensions.
Machine vision camera systems to allow them to accurately and precisely place labels, even on randomly placed products.
Memory storage within the labeler with figures on calibrating the machine for labeling different products.
Motor for roller or other implements to apply labels.
A user interface permits the human operator to adjust, monitor, control, and load configurations.

Stored calibration information allows operators to set machines for a single label, then recall these settings when needed again. Labeling machines also need to consider such things as the pressure needed for precise application and speed of operation necessary to keep up with the production line. Considering the advantages for manufacturing, automation for labeling processes allows factories to label products in batches economically enough to compete with mass-produced labeling.

Flexible Automation Solutions by EAM

EAM Inc. has provided custom automation solutions for manufacturers since 1967. Our automation expertise has been applied to medical and food processing production lines. From integrating robots with machine vision capabilities onto factory floors to automated labeling and source tagging of products, EAM provides manufacturers and packaging companies with automated capabilities that allow them to improve their production lines’ efficiency, speed and accuracy.

To learn more about the flexible automation examples and the automation solutions we can provide to increase the profitability of your business or factory, contact us today.