There is a long-standing debate about humans versus automation. Machines in manufacturing have revolutionized production processes, with faster and more precise operation. Especially redundant operations - which is a lot of what modern manufacturing entails. However, the potential for, and fear about job displacement remains a concern. In this article we will dive into finding a balance between technological advancement and human contribution.
The concern is real - as noted in the US port workers strike of 2024. A major concern among the port workers is technological advancements. They believe better, faster, smarter machines will make processes more efficient, and reduce the demand for union jobs. (While their concern is real, it is asking the wrong question, for sure, but we will get into that in a separate article.)
At Synthesis, we design and build custom machines, though not on the scale of handling millions of shipping containers. Yet, the concerns about humans versus automation are still true, even on a very small scale.
The Power of Automation with Custom Machines
Automation with custom machines can significantly improve production quality in manufacturing. When machines are made to do specific repetitive tasks, they can operate continuously without fatigue, and maintain high levels of accuracy and efficiency.
One example from our work is a custom measuring and cutting machine we designed and built for a customer. While we cannot talk about the intellectual property of the machine, in a nutshell, it measures lengths of material, then cuts it.
This process now takes 2 people to do what was often a 9 person job. (Not that it really took 9 people, but because it was a bottleneck to the rest of the work, they would often pull in other people around the shop to expedite things.) It was horribly inefficient to have highly paid skilled people running a tape measure and a knife. But this customer does not need it full time, only in spurts.
The new machine can now sit idle for a week and not worry about collecting a paycheck. When it is needed, it can do the job of 9 people about 5 times faster. This ends the bottlenecks in their processes, and allows the skilled workers to do the skilled things.
This kind of machine not only enhances product quality, but also reduces waste and operational cost. Simply put, it relieves workers from repetitive tasks, allowing them to focus on more complex, skilled, and human-centric activities.
You can see more examples on our Engineering Services Custom Machines page.
Benefits for Workers
One of the primary benefits of automating repetitive tasks is the positive impact on the workforce. By delegating mundane and repetitive jobs to machines, workers can focus on more strategic and fulfilling roles. Humans are far more suited to jobs requiring creativity, problem-solving, and critical thinking. Plus, these jobs provide so much more satisfaction. For instance, rather than spending hours on the assembly line, workers can be involved in overseeing production processes, maintaining equipment, or working on product design and improvement.
This shift not only enhances job satisfaction, but also promotes skill development, and greater self-worth. Workers can acquire new skills related to the operation and maintenance of advanced machinery, making them more valuable in the job market.
However, it is not all rosy in the human versus automation argument. Some people see automation as a threat (like the port workers). Usually, in my experience, it is because they are afraid of learning more or taking more responsibility.
As a Side Note: I saw a lot of this while working with Ford Motor Company. On one occasion, I was helping to troubleshoot and fix a machine. It was mostly working, but was creating a burr. Some of the workers were so annoyed at my interruption of their mindless, repetitive work - even as I was trying to help them make good quality parts. I think they lost the vision of why they were even employed - while trapped in their "sit and spin" routine.
It does not have to be humans versus automation. They should work together. To me, the example of the Ford union workers is a good place to displace employees that do not want to participate in the company goals. I would be doing them a favor by getting them out of the mental / emotional rut.
The Need for Human Oversight
Despite the advantages of automation, human oversight remains crucial in manufacturing. Custom machines, while highly efficient, require human intervention for setup, programming, and maintenance. Skilled technicians are essential to ensure that machines operate correctly. Skill is also required for troubleshooting issues that may arise. This human-machine collaboration ensures smooth production, and prompt resolution of deviations or malfunctions. This is not a humans versus automation paradigm, but as humans with automation.
As a designer of machines, I can say there are certain tasks which are really complex for machines to handle effectively. For example, tasks that require a high degree of dexterity, involve sensory evaluation, or subjective judgment are best performed by humans. I have yet to see a machine that is truly creative.
There is a balance, always, in the cost for complexity with a machine, versus the cost of labor and skill for a human. Dividing the tasks, and managing the budgets often leads to the best of both worlds in human interaction versus automation in a custom machine. Truly, even in this world of AI, human skills remain irreplaceable, and human innovation remains indispensable.
The Cost of Complexity
While custom machines are ideal for repetitive and high-volume tasks, the cost gets higher as the complexity goes up. For many small companies, the cost can be prohibitively expensive for custom machines with complex operations. Maybe this article should be about cost versus automation rather than humans versus automation?
The initial investment in designing, engineering, and building a custom machine is substantial. Then, as these machines get more sophisticated, the number of sensors and actuators and programming begin to soar. And, there is the maintenance, etc. which add to the overall cost.
It is important to understand the goals of the machine, and how using it will recover the costs. For many companies, making a less complicated machine that does only the most critical or time consuming tasks, will help the budget and make the desired strides forward. A simplified machine relies more on the human in conjunction with the automation.
Striking a Balance
At Synthesis, our goal is to find the right balance with humans versus automation. We understand that each manufacturing environment is unique, so our approach works to meet the specifics of our clients. By combining the strengths of both custom machines and human workers, we aim to optimize efficiency while finding ways to fit the budget.
In scenarios where production volumes are low or tasks are highly variable, it is often cost-effective to rely on skilled human workers. For instance, in custom manufacturing or prototype development, the flexibility and adaptability of human workers can easily outweigh the benefits of automation. Therefore, it is essential to carefully evaluate the cost and the benefits when deciding whether to automate a particular process.
When we see these situations in work we are asked to quote, we often suggest special fixtures or custom tools to assist people with the tasks rather than going to full automation. That usually has a much better balance of humans versus automation anyway.
Positive Impacts of Automation with Custom Machines
- Increased Efficiency: Custom machines can operate at high speed, with greater precision, leading to increases in production and lower defect rates.
- Cost Reduction: Automation often reduces labor costs, and can minimize waste. If the machine has a good ROI, it will contribute to an overall cost savings, or production cost reduction.
- Enhanced Safety: Machines can handle dangerous tasks, reducing the risk of workplace injuries and creating a safer work environment.
For one customer who was struggling with high injury rates, the custom machine significantly reduced the medical expenses, including lowering their insurance rates. With healthier employees, there was a lot less labor turnover and thus less investment in training and new hire expenses. The medical costs alone paid for the new custom machine even before considering the higher throughput and improved quality. (Basically all 3 of the items in the list above.)
Challenges and Considerations
- Job Displacement: The transition to automation can lead to job losses, particularly for low-skilled workers. While this is usually regarded as a negative, the positive side happens when companies assist good workers to acquire new skills and be productive on a higher level - usually with higher pay.
- High Initial Costs: The engineering development and installation of a custom machine requires significant investment of both time and money. While ROI can is often very attractive, it may not be feasible for all manufacturers.
- Maintenance and Downtime: Automated systems require regular maintenance, and downtime can disrupt production. Skilled technicians are essential to minimize these disruptions. Hiring the skills, or bring them up in house is also not cheap.
At Synthesis, we have seen these challenges handled in a number of different ways. Some people decide not to deal with it, and continue in the normal ways. Others embrace it full on. Then there are all the others between. In my opinion, the worst is to over examine the possibilities to the point where it paralyzes the action. Issues of continuing to fuss about it for years, never making a decision, give the worst outcome.
Humans Versus Automation Conclusion
Certainly, automation with custom machines can represent a significant advancement in manufacturing. It offers numerous benefits for efficiency, accuracy, and safety. However, it is vital to consider the implications - not only for the cost of implementation, but for the workforce as well. At Synthesis, we are committed to designing and building custom machines that strike a balance (that we decide on together), between automation and human expertise.
We invite you to explore the specifics of your products and projects with us. Our team of engineers is dedicated to finding innovative solutions to enhance your manufacturing processes while ensuring the well-being of your workforce. Contact Synthesis to discuss how we can assist in achieving your production goals.
By thoughtfully integrating automation into your operations, you can unlock new levels of productivity and quality. Afterall, innovation - whether in product or process - is A Best Business Strategy. It creates a competitive edge in an ever evolving market. Let's work together to create a future where technology and human ingenuity go hand in hand for the betterment of all.