Common Challenges in Industrial Automation and How Precision Machining Solves Them. Industrial automation has helped manufacturers increase efficiency, reduce costs, and improve product quality. However, keeping automated systems running smoothly requires overcoming several common challenges—many of which stem from poorly machined components that lead to downtime, inefficiencies, and costly repairs.
Read on to see some of the the top industrial automation challenges and how precision CNC machining helps resolve them.
Common Challenges in Industrial Automation and How Precision Machining Solves Them
Tolerance & Accuracy Issues
Automated systems operate with tight tolerances, where even a 0.001-inch deviation can cause misalignment, affecting production efficiency. Poorly machined components result in:
- Misfitting parts that disrupt automated workflows.
- Alignment issues in robotic arms and actuators.
- Inconsistent product quality in automated manufacturing.
How CNC Machining Solves This:
- Multi-axis CNC machining produces high-tolerance components with ±0.0005-inch accuracy.
- Computer-controlled precision ensures repeatability, making every part identical.
- Advanced measuring tools (CMM analysis) verify dimensional accuracy before shipping.
Wear & Tear on Moving Parts
Automation systems run 24/7, leading to constant wear on moving parts like gears, actuators, robotic arms, and conveyor rollers. Over time, this results in:
- Friction-related damage that affects performance.
- Heat buildup causing premature part failure.
- Frequent maintenance & costly downtime to replace worn components.
How CNC Machining Solves This:
- Uses high-strength materials like stainless steel, titanium, and hardened alloys to improve durability.
- Precision machining of smooth surfaces minimizes friction and wear.
- Custom coatings (anodizing, heat treatments) extend the lifespan of automation components.
Component Compatibility & Integration Issues
One of the biggest issues in automation is the misalignment or improper fit of components within a system. When parts don’t integrate correctly, it can cause:
- Mechanical failures in robotic automation.
- Production slowdowns due to constant adjustments.
- Higher costs from reworking or replacing incompatible parts.
How CNC Machining Solves This:
- Custom machining to exact client specifications ensures seamless integration.
- Advanced CAD/CAM programming guarantees perfect fitment before production.
- Prototyping and test runs validate compatibility before large-scale production.
Supply Chain & Downtime Delays
Many manufacturers rely on offshore machining suppliers, which can lead to:
- Long lead times delaying production.
- Inconsistent quality control in automated parts.
- Difficulty sourcing replacement components when needed.
How CNC Machining Solves This:
- U.S.-based production at Roberson Machine Company ensures faster delivery and reliable supply.
- Quality control that adheres to ISO 9001 and AS9100 certifications guarantees consistency in every batch.
- On-demand production means critical automation parts are always available.
Balancing Cost & Quality
Many businesses choose cheaper, lower-quality parts to reduce upfront costs—but this often results in:
- Frequent part replacements, increasing long-term expenses.
- Higher failure rates in automated systems.
- Production inefficiencies due to downtime and maintenance.
How CNC Machining Solves This:
- Investing in high-quality precision machining minimizes part replacements.
- Tightly controlled machining processes maintain consistency and durability.
- Cost-effective solutions from Roberson Machine Company ensure long-term savings.
Why CNC Machining is Key to Automation Success
Industrial automation systems require high-precision, durable, and reliable components to function efficiently. From ensuring tight tolerances to enhancing part longevity, CNC machining plays a critical role in overcoming common automation challenges.
Looking for precision-machined components to improve your automation system? Call 573-646-3996 or request a quote online today!
