It is usually believed that automation results in consistent quality and increased productivity. What has been your experience?

You can say that synonym for consistency is ‘Automation'! That's the reason the growth rate in automation field has defied all odds and is clocking 15 percent to 20 percent while the growth rate is at single digit for other sectors. The sensors (called eyes of automation) and the PLCs and all other controllers (called brain of automation) together take care of quality, pace and consistency.

Take this simple example of from the beverage industry: Normally, a person sits and check following…Missing cap of bottle, Missing bottle itself, height of liquid, printed label, foreign body inside bottle etc. He can be efficient but after all he is a human being and can miss it once in a while. If this faulty bottle reaches market then normally case is put up by the rival companies. All these problems can be avoided by sensors as well as vision systems and with no failure rate at all. This also enhances production with minimum downtime and also enhances the ability to work at very high speed. Slowly, the industry is understanding the need of automation.

How do automated systems help in keeping track of goods flow?

Automated systems can help in keeping inventory at an automatic retrieval of material from a warehouse. Barcoding and RFID are other options for identification and keeping track of flow of goods. Most of the new generation sensors and vision systems are web-based and can be operated directly by typing IP address in the laptop and one doesn't need a CD or program separately.