Bridging the Gap: How “Small Automation” is Shaping the Future of Manufacturing

Bridging the Gap: How “Small Automation” is Shaping the Future of Manufacturing

In today’s industrial landscape, automation exists in two very distinct worlds. On one side, there is traditional, conservative automation, and on the other, visionary, AI-driven factories of the future. Most companies operate somewhere between these extremes, and this is where the concept of small automation comes into play—providing practical solutions to bridge the gap between these worlds.

1.Two Worlds of Automation

Conservative Automation

Many companies still operate in this world. Tasks like basic pick-and-place operations or collecting machine data for simple analysis are seen as radical steps. Automation is focused on enhancing existing manual processes rather than reinventing them.

Visionary, AI-Driven Factories

At the opposite end of the spectrum, we see futuristic environments—lights-out factories where robots build robots, AI algorithms control production lines, and machines communicate autonomously at the edge. Think of sci-fi scenes like I, Robot, or fictional corporations like Cyberdyne Systems and Wayne Enterprises.

2.Where Most Manufacturers Stand

The reality for most manufacturers is somewhere in between.

ERP systems and automated production equipment hum in the background.

Small automation tools are often used daily, but large-scale, autonomous systems remain aspirational.

Companies seek flexible solutions that enhance productivity without the massive investment required for full-scale transformation.

3.The Concept of “Small Automation”

First introduced in strategy+business magazine in 2019 by PwC strategists Dan Priest, Kumar Krishnamurthy, and Alex Blanter.

Defined as:

"The fast implementation of flexible and adaptable technologies that fill the gaps left by your current enterprise systems — enabling new levels of productivity."

Though originally focused on software tools like:

RPA (Robotic Process Automation)

Natural Language Processing (NLP)

Machine Learning (ML)

The same principle can be extended to operational technology (OT).

4.Small Automation in Operational Technology (OT)

Single Industrial Robot installation for a specific task.

Inverter-controlled motors offering precise feedback and dynamic performance.

Human-Machine Interfaces (HMIs) and PLCs managing and optimizing smaller-scale processes.

Targeted upgrades that bring immediate productivity gains without overhauling entire systems.

5.Why Small Automation Matters

Cost-Effective: Delivers high ROI with minimal disruption.

Scalable: Can evolve into larger automation frameworks over time.

Adaptable: Fits within existing infrastructure and complements enterprise-level systems.

Enables Innovation: Allows teams to experiment and optimize incrementally.

The future of manufacturing is not purely about massive AI-driven transformation. For many, the journey begins with small automation—the practical, achievable steps that can bridge today’s capabilities with tomorrow’s ambitions. Whether you're looking to automate a single process or lay the foundation for future smart factories, embracing small automation is a smart, strategic move.

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