27th June, 2025
By Adam Gatt

What Is Industrial Automation? A Complete Guide for Manufacturers

Industrial automation is an increasingly popular concept in manufacturing, and for a good reason. Automation has revolutionised manufacturing by enabling smarter, faster, and safer production processes.

Across Victoria, manufacturers are leveraging automation tools to boost productivity, reduce costs, and stay competitive. This guide helps manufacturers understand the fundamentals of industrial and plant automation, its benefits, and how to start their automation journey.

What Is Industrial Automation?

Industrial automation refers to the process of operating industrial machinery with minimal human intervention. This includes the use of computers, programmable logic controllers (PLCs), robotics, and various information technologies.

At its core, automation replaces tedious manual tasks with automated controls, producing consistent, high-precision jobs without errors. The manufacturing industry has made significant progress from manual labour. Today’s smart automation integrates smart data and control to reduce time spent on the manufacturing floor.

Types of Industrial Automation

Based on production needs, there are different types of automation that manufacturers typically adopt:

Fixed Automation

Common in high-volume assembly lines, fixed automation utilises a fixed sequence of processing with specific equipment.

Programmable Automation

Found in batch production, these systems allow reprogramming of machines (e.g., CNC machines or batch mixers) to handle different tasks.

Flexible Automation

Using robotic arms or multi-axis systems, flexible automation can switch between tasks quickly without major reconfiguration. It is ideal for products needing frequent changes or customisation.

Integrated Automation Systems

Various automated systems, such as PLCs, SCADA, robotics, and IIoT platforms, are connected into a cohesive network for centralised monitoring.

Core Components of Industrial Automation Systems

Manufacturing automation solutions typically comprise several key elements:

PLC (Programmable Logic Controllers)

PLCs are the backbone and hardware of many automation systems that control the plant's machinery operations.

SCADA (Supervisory Control and Data Acquisition)

SCADA is a software platform that collects data from PLCs and field devices, providing operators with real-time data.

HMI (Human Machine Interface)

HMIs are intuitive interfaces (i.e. touchscreens or software panels) through which operators interact with automated systems.

Sensors and Actuators

Sensors detect variables like temperature, pressure, and proximity, while actuators (i.e. motors, valves, pneumatic cylinders) convert the sensor’s data into motion.

Industrial Networks and Communication Protocols

Industrial protocols facilitate data exchange between controllers, HMIs, SCADA systems, and IIoT gateways.

Robotics

Industrial robots (i.e. articulated arms) handle manual tasks such as welding, material handling, and assembly.

IIoT (Industrial Internet of Things)

IIoT platforms connect machines and sensors to analytics systems, enabling users to track predictive maintenance and energy monitoring, among other applications.

Benefits of Industrial Automation for Manufacturers

Industrial automation brings significant advantages to Australian manufacturers, including:

Increased Efficiency

Automated processes run 24/7 with consistent cycle times and minimal supervision.

Improved Product Quality

Automated controls produce repeatable operations, which reduce defects and ensure uniform quality.

Worker Safety

Automation can reduce hazardous or ergonomically challenging tasks, such as lifting heavy loads and extreme temperature exposure.

Lower Operational Costs

While the initial expenses on automation can be significant, it reduces labour costs and unplanned downtime over time.

Better Data Collection Control

Integrated systems collect real-time data that manufacturers can use to swiftly troubleshoot issues and optimise resources proactively.

Scalability and Flexibility

Many automation architectures are flexible, allowing manufacturers to scale capacity up or down and adapt to changing demands.

Challenges and Considerations

If you’re planning on automating your industrial plant, here are several considerations to know:

Initial Investment and Expectations:

Automation projects require some initial capital for hardware, software, integration, and potential facility upgrades. Manufacturers should conduct a thorough cost-benefit analysis and consider return-on-investment (ROI) timelines that are realistic.

Training and Upskilling

As manual tasks are shifted to automated processes, operators and technicians must be trained in programming, troubleshooting, and the maintenance of automation systems. Investing in workforce development ensures employees can adopt and sustain these new initiatives smoothly.

Integration with Existing Systems

Old equipment or machinery may present compatibility challenges with new automation hardware and software. Assess your existing infrastructure and implement your integration strategies in stages to mitigate disruption.

Cybersecurity in Connected Environments

As automation systems connect to networks and IIoT platforms, they can be susceptible to cyber threats. Consider implementing stronger cybersecurity measures such as firewalls, secure authentication, and regular vulnerability assessments to protect your operations and data.

Maintenance and Technical Support

Automated systems need ongoing maintenance, software updates, and fast technical support. Partner with a trusted manufacturing automation expert to maintain your automation systems well and ensure your process is running smoothly for peace of mind.

Industrial Automation Use Cases

Aus-Tech recently supported a transformer and main switch upgrade in a production facility in Victoria. We installed an advanced automatic transfer switch (ATS) to seamlessly switch between grid power and generator supply during outages. Read more about our case study here.

How to Get Started with Industrial Automation

Adopting automation in your manufacturing facility can be done by following these structured steps:

Assess Current Processes

Map existing workflows in your facility, identify manual or repetitive tasks, and prioritise areas that have the highest potential for improvement. This could be improvements in efficiency, quality, or safety.

Set Clear Automation Goals:

Define measurable objectives such as production targets, defect reduction percentages, or safety KPIs. Well-defined goals can guide your selection of technology and project scope.

Choose the Right Automation Partner

Look for experienced Australian providers in industrial automation, especially those familiar with local manufacturing environments and standards. For manufacturers in Victoria, a partner like Aus-Tech can help provide tailored solutions and on-the-ground support.

Pilot Projects and Phased Implementation

Start with a small-scale pilot to test your choice of automation. Then use these lessons learned to refine your approach before a wider rollout. This phased approach minimises disruption and allows the workforce to adopt it gradually.

Measure and Optimise Results

Once the process is set up, collect data such as cycle times, downtime occurrences, energy usage, and maintenance incidents. This will allow you to continuously refine your automation machinery, update training programs, and expand your projects to other areas of the plant.

Conclusion

Industrial automation has become a must for modern, competitive manufacturing. By adopting automation that’s tailored to their needs, manufacturers can achieve a safer, more efficient operation.
Aus-Tech is a team of industrial automation experts in Australia that can help you skyrocket your productivity with tailored solutions. With over 40 years of experience, we design, implement, and maintain automation systems for manufacturers across various industries.
Contact our team today to learn more about our automation solutions.