Grader av automation - en triologi (del 2) kopia
The simplest and perhaps most common automation that comes to mind when talking about automation is the robot, but there are many different types of solutions that help a person to relieve both body and mind.
Part 1 described the difference between physical and cognitive automation;
Physical automation is when the body gets help, this can for example be that you get help with carrying, placing, screwing etc
Cognitive automation is when the mind gets help, this can be, for example, remembering where screws should be located, which screws should be used and when to do what.
In this part, these degrees will be divided into seven different levels of automation and a combination, the so-called Levels of automation matrix (or LoA-Matrix) is described.
Part 3 provides a more detailed description of how the matrix can be used as a tool for measuring and analyzing degrees of automation.
Automation is not binary, more levels are needed for a more detailed and accurate measurement and analysis in the industry
Why are more degrees needed, is it not enough to say that a station is automatic or manual?
Chalmers has made over 2000 measurements of various tasks in different industries and has had interviews, observations and workshops for over ten years in automation degrees. Three important things that can have major consequences due to not having a sufficiently detailed analysis of a station are:
- A station contains at least 3 times more tasks than previously thought and that is stored in the companies' systems, this applies to manufacturing (machine handling), painting, paint departments and final assembly
- A station contains many different types of tools, fixtures and machines that humans use even if the station is considered manual
- A station very rarely contains updated, easily accessible and easy-to-use instructions, which means that people often use their own experience when performing their task.
These three things can have consequences on quality, time, cost, work environment, ergonomics, education, etc.
By looking at both the physical and the cognitive part of a task in more detail, much of human work can be improved and thus increase social sustainability.
In the physical part of automation, four of the seven levels are those that are usually counted as manual, within these levels differ both the degree of help that a person receives and the type of tool.
To some extent, level five can also sometimes be counted as a manual station because certain types of static machines usually need a lot of help from a human to, for example, load and unload the machine.
In the cognitive part, it is more about knowledge information and data and how this can be presented to a human or machine. The first three levels can be both paper-based or digital, while the other four levels are usually digital solutions.
Below is a more detailed definition and examples of the different levels.
Seven levels of physical automation
Seven different degrees of automation have been developed where grade 1 is the lowest degree of automation, here the task is performed without the aid of automation, completely manually. The higher the degree used the more the help of automation.
Physical automation | Levels | Definitions and examples |
| Totally automatic | 7 | A machine that can perform more than one task and that can update its code automatically (for example, self-driving trucks) |
| Flexible workstation | 6 | A machine that can perform more than one type of task (for example, a robot or CNC machine) |
| Static workstation | 5 | A machine that can perform a specific task (for example a column drill) |
| Automatic hand tool | 4 | A tool that needs human intervention for control / placement, for example, but can be used without muscle power for one or more different tasks (e.g driven screwdriver; battery or pneumatic) |
| Flexible hand tool | 3 | A tool that needs human muscle power to function that can be used for several different tasks (for example screwdriver with different bits) |
| Static hand tool | 2 | A tool that needs human muscle power to function that can be used for a specific task (for example screwdriver or Allen key) |
| Totally manual | 1 | The human uses her body to perform the task (for example, the hand) |
Seven levels of cognitive automation
Seven different degrees of automation have been developed where level 1 is the lowest degree of automation, here the task is performed without the aid of automation, completely manually. The higher the level used the more the help of automation.
Cognitive automation | Levels | Definitions and examples |
| Totally automatic | 7 | The automation / system uses data from a system to optimize the task without human intervention (for example machine learning or other autonomous systems). Digitized |
| Intervention | 6 | The automation / system monitors given approved levels and intervenes if these are below or exceeded without a human having to act. Digitized |
| Monitoring | 5 | The automation / system monitors given approved levels and marks whether these are under- or exceeded (this can be done, for example, with state lights or that a signal is sent to a person who needs to act in some way). Digitized |
| Questioning | 4 | Automation / system needs human approval to continue the given work cycle (e.g pick-to-light systems, safety buttons, etc.) usually digital systems |
| Teaching | 3 | Automation describes how a task should be performed in the best way and which tools should be used (for example WES or other types of instructions). Does not have to be digital, can also be paper-based instructions |
| Decision-making | 2 | The automation / system describes what is to be done and which components are to be included (for example a work order). Does not have to be digital, can also be paper-based work orders |
| Totally manual | 1 | The human uses her mind to perform the task (for example experience from this or similar task) |
Combination of physical and cognitive automation - The Levels of automation matrix
To be able to measure and analyze a task or station, a tool has been created to combine these two types of automation. The degree of automation matrix can be used to see what help is used today and what different solutions companies should start looking at to achieve their KPIs mentioned in part 1.
Part 3 provides a step-by-step description of how the matrix can be used
If you want to know more about methods that can be used for both division of tasks in a station and selection of automation, you can contact Åsa Fast-Berglund (asa.fasth@chalmers.se) and she can lecture about this.
You can also buy the book Smart automation where these two methods (task allocation and automation strategies) are included as two methods out of seven.
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