Production automation is one of the most important trends in today’s economy. Only a decade ago, many companies treated it as a technological curiosity, today it is becoming a necessity. Rising labour costs, pressure for efficiency and global competition are forcing companies to implement modern solutions. In 2023, more than 541,000 new industrial robots were installed worldwide, demonstrating the scale of change that is taking place in production facilities.
However, the development of automation is not limited to robots. Digital twins, artificial intelligence, 5G technologies or OPC UA and TSN communication standards are becoming increasingly important. These make production more flexible, predictable and safe. It is the combination of mechanics, IT and data analytics that sets the direction in which 21st century industry is heading.
Definition and scope of manufacturing automation
Manufacturing automation is a set of technologies and processes that allow manual operations to be replaced by automated control systems and robots. In practice, it encompasses a wide range of solutions – from classic industrial robots and human collaborative cobots to vision systems, autonomous transport vehicles, predictive analytics and artificial intelligence.
The integration of IT and OT, i.e. IT systems and operational technology, plays a key role today. Platforms such as OPC UA and UAFX enable a consistent flow of data from sensors on the shop floor to ERP systems or the cloud. This makes it possible not only to control processes in real time, but also to analyse them in terms of productivity, costs and quality.
It is worth emphasising that automation is not a one-off investment, but a continuous process. New technologies make it possible to continuously optimise production, increase its scale and improve worker safety. It is an evolution that is changing the way entire industries operate.
Figures that speak for themselves
Figures from the International Federation of Robotics (IFR) clearly show that automation is becoming a global standard. In 2023, there will already be more than 4.28 million industrial robots in operation worldwide, an increase of 10% on the previous year. The average robotisation density has reached 162 robots per 10,000 employees, and in the most advanced countries the rate is several times higher.
China remains the largest market, accounting for more than half of all installations. Europe recorded an increase of 9%, reaching almost 92,000 new installations, and the Americas saw more than 55,000 robots installed. The biggest beneficiaries of automation are the automotive, electronics and metal and machinery industries.
Projections indicate that the number of installations will remain at a similar level in 2024, only to start growing rapidly again from 2025 onwards. It is therefore clear that the automation of production is not a temporary trend, but a long-term development.
Technologies changing the face of industry
A new wave of innovation is taking automation to an even higher level. Digital twins make it possible to create virtual copies of factories that can be tested and optimised even before production begins. An example of this is BMW’s virtual factory, where digital simulations reduce the time it takes to plan and implement new processes. Siemens is implementing similar solutions in collaboration with NVIDIA, combining photorealistic 3D models with data analysis and artificial intelligence.
Deterministic connectivity is also becoming increasingly important. TSN (Time-Sensitive Networking) technologies and private 5G networks allow real-time data transmission with guaranteed minimal latency. This is crucial in high-precision applications such as robot control or vision systems for quality control.
Also important are cobots, or collaborative robots, which can work side-by-side with humans thanks to new safety standards. Their role will grow with the development of the Industry 5.0 concept, which relies on greater integration of man and machine.
ROI and profitability of automation
One of the most frequently asked questions when implementing automation is: does it pay off? Studies show that the average payback period for robotisation is between 18 and 24 months. In some cases, especially in the electronics industry, the ROI is as high as 1,200%, with productivity gains in excess of 30%.
The benefits are not only increased productivity, but also improved quality, reduced errors and reduced material waste. Automation also increases workplace safety by eliminating risky activities previously performed by humans. This translates into lower absenteeism and reduced costs associated with accidents.
However, the final outcome depends on the right fit between the technology and the company’s needs. Therefore, it is crucial to analyse processes before implementation, select the right integrators and monitor performance indicators such as OEE or FPY.
Safety and regulation
The increasing scale of automation requires new regulations and safety standards. In 2025, the updated ISO 10218 standards for industrial robot safety will come into force. In addition, the ISO/TS 15066 guidelines regulate the operation of cobots in direct interaction with humans, specifying, among other things, permissible contact forces.
Cybersecurity regulations are becoming equally important. ISA/IEC 62443 or NIST SP 800-82 standards indicate best practices for securing industrial systems against hacking attacks. In Europe, the EU’s AI Act regulation, which will take effect in 2026 and introduce new rules for the use of artificial intelligence in industry, is also crucial.
It is also worth remembering Machinery Regulation 2023/1230, which will replace the existing Machinery Directive from January 2027. The new regulations introduce requirements for cyber security and artificial intelligence already at the design stage of machinery and equipment.
People at the heart of Industry 5.0
Automating production does not mean eliminating humans from the manufacturing process. On the contrary – in the concept of Industry 5.0, it is the employee who is at the centre of attention. Modern technologies are to support his or her activities, improve ergonomics and increase safety.
Cobots become a natural partner, taking over monotonous or dangerous tasks and leaving humans in control of creative and decision-making processes. At the same time, the idea of reskilling and upskilling, i.e. raising the competence of employees to operate and program new systems, is developing.
Organisations such as the World Economic Forum highlight that automation and robotisation will have a key impact on the labour market by 2030. Companies that invest appropriately in human resource development will gain a competitive advantage and better cope with the industrial transformation.
Summary
The automation of production is the future of industry and it is happening before our eyes. Numbers, innovations and regulations show unequivocally that the direction is irreversible. Robots, digital twins, artificial intelligence and 5G connectivity are changing the face of factories, making them more efficient, safer and more flexible.
The key challenge remains getting the technology right and preparing people to work with machines. Industry 5.0 puts humans at the centre, and automation is to be a tool that supports, not replaces. Companies that understand this philosophy and bet on conscious implementation will be the leaders of the new industrial era.