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Eliminate manual processes for greater efficiency and productivity.

Industrial Automation

Industrial Automation Systems can Improve your Operations

Generally speaking, automation is the use of control systems and information technologies to reduce the need for human interaction in the production of goods and services. Automation greatly decreases the need for human sensory and mental requirements, including decision making.

Extending that concept to industrial applications, industrial automation is the combination of various sensors, data collection hardware, controls, software, business rules and logic to improve efficiencies or reduce errors in a process. It applies business rules to operation equipment so people can focus on other duties.

Industrial automation is commonly used in:

  • Material handling (routing, sorting, packaging, palletizing)
  • Manufacturing (assembly, count, test, quality control)
  • Identification (labeling, marking)
  • Verification (weight check, height check, temperature check)
  • Process controls (pressure, temperature, humidity levels)

Improve real-time knowledge of operations

"Automating processes" frequently means adding an application server to the various sensors and data input devices, such as photo-eyes and bar code readers. Adding that server means the data is stored in a database on the network, in real-time, where you can get to it at any time via reporting.

Instant access reporting can show you everything that’s happening on your lines up until the time you run the report. If, for example, one of your manufacturing lines has been showing an increase in rejects, you can see it and send maintenance to investigate before something malfunctions and the line stops. You can also see which line is producing the most items—or the most rejects—and take notes of the efficiencies or get the problem employee some extra training. Real-time reporting offers very powerful information for any industrial line.

Automating conveyor lines

  • Use bar code scanners and conveyor controls to automatically route packages to different sections of the conveyor—commonly used for work-in-process, picking from racks and sorting to different carriers.
  • Use bar code scanners and print-and-apply systems to scan a carton, automatically print and apply shipping and contents labels, and then scan again to ensure the right label was applied
  • Use bar code scanners and signal beacons, audible alarms or email to notify someone if the bar code on a label doesn't match what the system is expecting
  • Use bar code scanners and in-line scales to ensure a package weighs within a set tolerance of what the system is expecting

Automating manufacturing equipment:

  • Automation can be used with PLCs (Primary Logic Controllers) to determine if a component passed or failed a test, and then automatically print the appropriate label
  • Automation can be used with legacy manufacturing equipment (non-networked) to obtain operation and production information, such as temperature and piece count, and make it available on the network in real-time

Automating security functions:

  • Automation can be used with access control using RFID badges with strategically-located RFID readers. Employee movement can be detected and sent to an application server to restrict access, unlock gates, automatically stop equipment, activate signals or send emails.
  • Use with sensors such as light curtains with application servers to stop equipment, activate signal beacons, log the time/date of occurrences and send emails

There are numerous applications for industrial automation. The goal is to examine repetitive or error prone processes and determine if automation can be used to improve it.

Industrial Automation can eliminate human interaction and errors, and greatly improve the efficiency of your business. Tell us where your problem is and the industrial automation experts at BarCode Solution Systems can present a solution to improve your processes.


Automation IQ™—Capture intelligence from your manufacturing processes

Industrial Automation/Print & Apply

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