8 Benefits of Industrial Controls and Factory Automation

With the growing popularity of artificial intelligence (AI), numerous industries are beginning to see the advantages of increasing AI integration into various workflows. This includes many industries that have previously relied on manual processes, as automation can help optimize operations and improve cost efficiency.

Thanks to automation and advanced control systems, the industrial landscape is one of today's more rapidly evolving market sectors. Automation technologies have quickly become a cornerstone in achieving operational excellence through enhanced efficiency and elevated safe practices. Industrial controls offer numerous benefits that have completely transformed the manufacturing industry.

These technologies have become indispensable for modern companies, only growing in importance as engineers and designers continue to innovate and develop new digital solutions.

A Brief Look into Industrial Controls and Factory Automation

Industrial controls, or an industrial control system (ICS), is “an information system used to control industrial processes such as manufacturing, product handling, production, and distribution.” This electronic control system uses sensors, systems, networks, and other technology to automate processes efficiently.

Industrial controls are used in nearly every industrial sector and critical infrastructure such as energy and water treatment industries. With its rising use, the global industrial controls and factory automation market is expected to experience a compound annual growth rate (CAGR) of 8.16% from 2023-2027. Despite its forecasted rise in the coming years, ongoing fluctuating market demands, rising operational excellence (OPEX), and unpredictable labor costs has caused the market to face some challenges.  

AI, robotics, the Industrial Internet of Things (IIoT), and sensors can help mitigate these challenges, prompting growth despite industry problems. Labor shortages and the rising importance of OPEX can be alleviated with the aid of industrial controls and factory automation,  

1. Increased Efficiency and Productivity

One of the most significant and well-known benefits of industrial controls and automation is increased workflow efficiency and productivity. Automated systems can operate 24/7 without pause as well as handle repetitive tasks with consistent speed and accuracy. Continued operation reduces downtime and maximizes output, allowing companies to meet higher production demands without affecting quality or infringing on worker health and safety.

2. Enhanced Precision and Quality

Advanced control systems utilize sensors to deliver feedback to logic systems that monitor and adjust manufacturing processes in real-time, maintaining optimal conditions. These technologies ensure consistent quality repetitively, without the risk of human error impacting production. Should an error or lack of quality be detected, the ICS will alert workers to the problem before any product can be negatively affected. This precision is highly desired in critical industries, including aerospace, pharmaceuticals, and electronic components manufacturing.

3. Cost Reduction

Organizations often hesitate before utilizing factory automation or ICS due to the initial investment. Automated systems can be a costly expenditure that businesses may shy away from, especially during challenging market conditions. However, automation reduces labor costs, particularly for repetitive or hazardous tasks, allowing staff to be reprioritized to more complex challenges. Since automated systems are more precise when following tasks, material waste and energy consumption are highly reduced. Automated processes can save thousands, offsetting the initial investment and increasing company profitability.  

4. Improved Safety

Many industrial environments can be hazardous, with risks ranging from exposure to toxic substances to the operation of heavy machinery. Industrial controls can enhance worker safety by taking over dangerous tasks reducing the likelihood of accidents and injuries. Similarly, the sensors used by these systems can monitor environmental conditions and equipment status, providing early warnings of potential hazards and allowing for preventive maintenance. This can help organizations protect workers and ensure compliance with regulatory standards.  

5. Scalability and Flexibility

The modern market requires industries to be agile in rapidly responding to shifting market demands and technological advancements. Over the last several years, especially in the electronic components industry, many markets have been wracked by rapidly shifting trends, from high consumer demand to sudden and significant drops. Automation and ICS allow industries to scale fast and meet production demands quickly. Automated systems can be adjusted to meet new product specifications or volume without significant downtime or reconfiguration, enabling industries to meet demand through seamless scaling operations up or down efficiently.

6. Data Collection and Analysis

Another common aspect of ICS and automation is the capability to collect vast amounts of data generated by sensors, control points, and other components. These systems can then rapidly analyze the data, delivering advanced insights into operational performance and solutions for production bottlenecks. This data is crucial for efficient predictive maintenance, helping organizations learn when machines must be evaluated and fixed. Over a longer period, machine learning algorithms can enhance the data, driving insights that can promote continuous improvement by identifying areas for innovation.  

7. Sustainability and Environmental Benefits

Government and corporate commitments to sustainability are growing worldwide. With the signing of the Paris Agreement, many organizations are steadily increasing their efforts to meet net-zero emission goals. Industrial controls and factory automation can help organizations improve environmental sustainability through optimized production, which contributes to resource utilization and reduced waste. Automated systems can effectively follow environmentally conscious practices while reducing a company’s carbon footprint. Similarly, through data-driven insights, staff can identify new areas where resource use can be optimized, or unnecessary energy expenditures cut.  

8. Competitive Advantage

Companies that utilize industrial controls and automation save more after the initial investment and gain a significant edge over competitors. The global market is becoming more competitive, and adopting automated systems can give businesses the ability to deliver higher-quality products at a lower cost while responding to consumer demands faster. This helps organizations obtain a stronger position within their sector, while effectively increasing their market share. Without the downtime required by human staff, companies with automated systems can leverage their 24/7 capabilities to outpace competitors, allowing workers to dedicate more time more complex responsibilities.

Sourcengine’s Components for Efficient Control

Industries are revolutionizing their operations through industrial controls and factory automation, leveraging their benefits to drive efficiency, profitability, and safety. Technology continues to advance thanks to recent developments in generative AI, opening a new world of capabilities for industrial controls. Industrial control systems and automation are essential to modern-day manufacturing and will only increase in importance as new solutions help elevate production to the next level.

To help your organization obtain the parts they need to build a state-of-the-art industrial control system, Sourcengine offers over 1 billion parts from +3,500 franchised, authorized, and qualified third-party suppliers. Original equipment manufacturers (OEMs), contract manufacturers (CMs), and electronic manufacturing service (EMS) providers of any size can benefit from Sourcengine's global team of sales and sourcing experts.  

The best way to kick off your next development project is to upload your bill of materials (BOM) to Sourcengine’s integrated BOM management tool, Quotengine. Quotengine will identify offers that fit your BOM’s requirements, which can then be filtered depending on specifications such as price or manufacturer.  

If no offers are available or you would rather work directly with one of our excellent account managers, you can request an RFQ anytime.  

It’s time to start leveraging the power of automation!