In an industry where tradition meets innovation, Westheimer Brewery serves as a prime example of how industrial process automation can overcome significant challenges.
Faced with a declining workforce, outdated machinery, and the need for flexibility in a diversifying product line, Westheimer turned to automation to revitalize their operations.
Challenges Faced
- Labor Shortages: Finding qualified workers became increasingly difficult, threatening production continuity.
- Ergonomic Strain: Existing manual tasks were physically taxing for employees, necessitating a change.
- Outdated Equipment: Antiquated machinery often broke down, disrupting operations and impacting productivity.
- Need for Flexibility: With a growing array of products, the brewery required a system adaptable to new offerings.
Recognizing that modernization was essential, Westheimer made a strategic decision to automate its palletizing processes with the introduction of a Kawasaki CP500L robot.
The Automation Solution
The installation of the Kawasaki robot marked a significant turning point. Here’s how it addressed their challenges:
Enhanced Efficiency
The robot now palletizes at rates of up to 1,200 crates per hour, significantly improving throughput. This high performance allows Westheimer to maintain a streamlined process even with frequent product changes.
Ergonomics and Redeployment
By automating physically demanding tasks, the brewery has been able to redeploy workers to more suitable roles, improving job satisfaction and reducing fatigue.
Employees can now focus on areas that leverage their skills better.
Tool Flexibility
The robot’s ability to adapt through a tool-changing station has enabled Westheimer to easily switch between different products. This flexibility is critical for their operations, especially as they handle special orders and support craft breweries with varying requirements.
Reduced Downtime
The integration of advanced safety features means that employees can work safely alongside the automated systems. This seamless transition has minimized operational interruptions, allowing Westheimer to remain competitive in a crowded market.
Results and Future Plans
The investment in automation has already paid dividends, and the brewery plans to expand its robotic capabilities further.
The decision to utilize the CP500L robot is just the beginning of their journey towards a fully automated production line. With ongoing modernization, Westheimer Brewery aims to blend traditional brewing excellence with cutting-edge technology.
As Jörg Tolzmann, a key operator at the brewery, stated, “The new CP500L robot is a game-changer for us. It allows us to remain agile and efficient in a market that demands both speed and quality.”
In 2025, manufacturing survival demands more than human capability—it requires intelligent automation.
Westheimer Brewery reveals the transformative power of industrial process automation, where a robot palletizes 1,200 crates hourly, seamlessly addressing critical labor shortages.
We’ll map out the journey from manual, variability-prone stages to AI-driven precision, achieving 99% quality control—decoding the blueprint that separates industry leaders from followers.
See how foundational controls and cutting-edge quality checks can revolutionize your operational strategy.
Key Notes
What is Industrial Process Automation?
Industrial process automation represents a pivotal evolution in how we manage manufacturing.
By systematically integrating control systems, computers, and information technologies, organizations can significantly streamline their industrial processes.
This approach reduces manual intervention, enhancing efficiency, accuracy, and production consistency.
The importance of this evolution is underscored by the robust growth of the industrial automation market, which is projected to expand from USD 171.23 billion in 2022 to approximately USD 322.67 billion by 2030, with a CAGR of 8.2%.
As manufacturers recognize the benefits of automation, including improved operational workflows and reduced labor constraints, the drive towards automated solutions becomes essential for staying competitive in a fast-paced market.
Factory Automation vs. Process Automation
Understanding the differences between factory and process automation is crucial for any manufacturing leader or engineer.
Each serves distinct functions and requires specific implementation strategies:
Factory Automation
This type primarily focuses on discrete manufacturing processes where individual production steps are managed through Programmable Logic Controllers (PLCs) and robotics.
Typically, factory automation systems handle tasks such as:
Because of its focus on discrete tasks, factory automation is particularly effective in environments where parts and products can be counted and sorted.
Process Automation
In contrast, process automation targets continuous flow processes generally found in industries like chemical manufacturing or oil refining.
Here, systems are designed to monitor and control variables such as:
Utilizing Distributed Control Systems (DCS), process automation ensures that these variables remain within specified limits, resulting in safer and more efficient operations. In settings where consistency and quality control are paramount, process automation becomes indispensable.
By grasping the fundamental differences between these two types of automation, you can make informed decisions about which system best fits your operational needs.
For instance, if you’re overseeing a factory with manual assembly processes, transitioning to factory automation may yield immediate improvements in speed and quality.
On the other hand, if your operations involve complex chemical processes, investing in process automation will be essential to maintain safety and compliance standards.
Levels of Manufacturing Automation
Manufacturing automation is not a one-size-fits-all solution; it progresses through distinct levels, each representing increased technical sophistication and a decrease in manual intervention.
Understanding these levels empowers manufacturing leaders to assess their current automation state and plan strategic paths for advancement.
Level 0: Manual Operations
At the foundation of manufacturing processes lies manual operations, where human workers perform all tasks directly.
Here’s what this entails:
Production Characteristics:
Limitations:
Level 1: Basic Automation
Basic automation introduces essential mechanical assistance while maintaining significant human oversight.
Key elements include:
Control Systems:
Operator Role:
Operators are still instrumental for tasks such as machine setup, program selection, material handling, quality checks, and process adjustments.
Level 2: Partial Automation
At this stage, partial automation comes into play, establishing machine-driven processes with human supervision:
Automation Features:
Process Integration:
Level 3: Integrated Automation
Integrated automation links multiple automated systems under centralized control, fostering a seamless workflow:
System Architecture:
Technical Capabilities:
Level 4: Full Automation
Full automation means routine human intervention is minimized through complex control systems:
Advanced Features:
Control Structure:
Level 5: Autonomous Systems
The apex of manufacturing automation is represented by autonomous systems, which feature self-learning capabilities:
Technical Components:
Operational Characteristics:
Essential Industrial Automation Equipment
Control Systems: The Command Center
Control systems are pivotal as they serve as the brain of automated operations. They manage everything from basic machine functions to complex optimization processes.
The three primary types of control systems in industrial applications include:
1. PLCs (Programmable Logic Controllers)
These are the workhorses of industrial automation, executing predefined logic sequences for efficient machine control.
Technical Specifications:
2. DCS (Distributed Control Systems)
These manage continuous processes by utilizing a network of distributed controllers.
Key Features:
3. SCADA Systems (Supervisory Control and Data Acquisition)
SCADA systems provide extensive monitoring and control across entire manufacturing facilities.
Critical components include:
Sensors and Actuators: The Process Interface
Sensors and actuators bridge the gap between control systems and physical processes. Their effective selection is crucial:
Sensors Criteria:
Actuator Selection Factors:
Robotics Systems
Industrial robots play a significant role in automating tasks that require precision and speed. Their specification should consider:
Performance Parameters:
Integration Requirements:
Material Handling Equipment
Automated material handling systems are critical for efficient operations within manufacturing. Important design factors include:
Design Considerations:
Industrial Automation Software and Tools
Sophisticated software tools are essential for effectively monitoring, controlling, and optimizing manufacturing processes.
Here are the critical software components that drive successful automation implementations:
SCADA Software: The Central Nervous System
SCADA software functions as the primary interface between operators and automated processes, making it a vital element in manufacturing environments.
HMI Interfaces: Operational Control Points
Human-Machine Interfaces (HMIs) represent the tactical control layer where operators interact directly with automated systems. Their design centers on:
Manufacturing Execution Systems (MES)
MES software acts as a crucial bridge between shop floor automation and higher-level business planning systems.
Important features include:
ERP Integration: Business Process Connection
The integration of Enterprise Resource Planning systems is fundamental for connecting manufacturing processes with business operations.
Successful integration requires:
Data Analytics Platforms
Automation in modern manufacturing generates extensive data, necessitating advanced analytics tools for meaningful insights.
Advanced software solutions leverage robust data analytics and machine learning to enhance predictive maintenance.
By analyzing real-time sensor inputs, the software allows manufacturers to anticipate equipment failures before they occur—transitioning maintenance from reactive strategies to proactive measures.
This capability not only reduces unplanned downtime but also optimizes overall equipment effectiveness, ensuring smoother production flows.
Is Your Industrial Process Automation Falling Short on Precision?
Implementation Strategy for Industrial Process Automation
Implementing industrial process automation requires methodical planning and precise execution.
Each phase of the implementation process must pay careful attention to technical specifications, operational requirements, and system integration.
Here’s how to effectively navigate this journey:
Transforming Operations: Westheimer Brewery's Automation Success
In an industry where tradition meets innovation, Westheimer Brewery serves as a prime example of how industrial process automation can overcome significant challenges.
Faced with a declining workforce, outdated machinery, and the need for flexibility in a diversifying product line, Westheimer turned to automation to revitalize their operations.
Challenges Faced
Recognizing that modernization was essential, Westheimer made a strategic decision to automate its palletizing processes with the introduction of a Kawasaki CP500L robot.
The Automation Solution
The installation of the Kawasaki robot marked a significant turning point. Here’s how it addressed their challenges:
Enhanced Efficiency
The robot now palletizes at rates of up to 1,200 crates per hour, significantly improving throughput. This high performance allows Westheimer to maintain a streamlined process even with frequent product changes.
Ergonomics and Redeployment
By automating physically demanding tasks, the brewery has been able to redeploy workers to more suitable roles, improving job satisfaction and reducing fatigue.
Employees can now focus on areas that leverage their skills better.
Tool Flexibility
The robot’s ability to adapt through a tool-changing station has enabled Westheimer to easily switch between different products. This flexibility is critical for their operations, especially as they handle special orders and support craft breweries with varying requirements.
Reduced Downtime
The integration of advanced safety features means that employees can work safely alongside the automated systems. This seamless transition has minimized operational interruptions, allowing Westheimer to remain competitive in a crowded market.
Results and Future Plans
The investment in automation has already paid dividends, and the brewery plans to expand its robotic capabilities further.
The decision to utilize the CP500L robot is just the beginning of their journey towards a fully automated production line. With ongoing modernization, Westheimer Brewery aims to blend traditional brewing excellence with cutting-edge technology.
As Jörg Tolzmann, a key operator at the brewery, stated, “The new CP500L robot is a game-changer for us. It allows us to remain agile and efficient in a market that demands both speed and quality.”
Automate Your Quality Control Today
Frequently Asked Questions
How can industrial process automation improve overall safety in manufacturing?
Industrial process automation enhances safety by reducing reliance on manual labor for hazardous tasks, minimizing human error, and integrating advanced safety features that monitor operations continuously. This proactive approach helps prevent accidents and ensures a safer work environment for employees.
What are the key security considerations when integrating automation systems with cloud platforms?
Security priorities include encrypted data transmission, role-based access controls, regular security audits, and secure API endpoints. Manufacturing facilities should implement network segmentation and maintain detailed security protocols for remote access.
How can smaller manufacturers begin their automation journey with limited capital?
Start with targeted automation of critical bottlenecks rather than full-scale implementation. Consider software-based solutions that work with existing equipment, like AI quality inspection, which requires minimal hardware investment.
How should manufacturers prepare their workforce for automation implementation?
Create structured training programs covering both technical operation and troubleshooting. Cross-train employees across different automated systems and establish clear documentation for standard operating procedures.
Conclusion
Industrial process automation puts powerful capabilities within reach of today’s manufacturers.
From basic control systems to AI solutions, the right automation strategy drives quality, efficiency, and competitiveness. Success requires careful technology selection, systematic implementation planning, and proper integration across systems.
The Westheimer Brewery case shows how targeted automation solves real manufacturing challenges – from labor shortages to production flexibility. Their results point to automation’s central role in modern manufacturing excellence.
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