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Bridging the Gap: Small Automation and Hyperautomation in Modern Manufacturing
Automation exists in two contrasting realms. On one side lies the conservative, day-to-day world of “small automation,” where incremental advancements such as pick-and-place robots or machine data collection are still considered revolutionary for many businesses.
On the other side is the futuristic realm of hyperautomation—where machines create machines in fully autonomous environments, decisions are made at the edge by AI systems, and human intervention is minimal. Think of sci-fi-inspired factories where robots dominate, as depicted in Hollywood films like I, Robot or the imaginary enterprises of Weyland-Yutani and Cyberdyne Systems.
Yet, most industries today operate in a middle ground. While small automation has become commonplace, hyperautomation remains an aspiration. This balance of practical implementation versus futuristic ambition shapes the current state of manufacturing and business operations.
What is Small Automation?
The concept of small automation gained prominence in 2019, when strategists from PwC described it as “the fast implementation of flexible and adaptable technologies that fill the gaps left by current enterprise systems.” These systems aim to boost productivity and efficiency without requiring massive overhauls.
In practice, small automation includes innovations like robotic process automation (RPA), machine learning, and natural language processing on the IT side. In operational technology (OT), small automation manifests through single industrial robot installations, inverter-controlled motors, or the integration of HMIs (human-machine interfaces) and PLCs (programmable logic controllers) to monitor and control processes.
By linking enterprise systems with industrial systems, small automation has already delivered substantial productivity gains, allowing businesses to automate repetitive tasks and bridge gaps in their technology stacks.
Hyperautomation: A New Frontier
Hyperautomation takes automation to the next level, eliminating unnecessary processes and automating the rest. It leverages advanced technologies like AI, machine learning, and RPA to create seamless, autonomous workflows.
According to Johan Jonzon, CMO and co-founder of Crosser, hyperautomation seeks to optimize processes by reducing human intervention and streamlining workflows. These workflows can be centrally managed through digital platforms, providing transparency and efficiency across the enterprise.
While hyperautomation might seem like an ambitious leap, it builds on the foundations of small automation, extending its reach into complex business and operational environments.
Linking Small Automation and Hyperautomation
The relationship between small automation and hyperautomation is not one of opposition but compatibility. Together, they form a continuum of progress, where businesses can scale their automation efforts incrementally without disruption.
For example, consider a manufacturing company creating a Bill of Materials (BoM). In a small automation setup, the BoM might trigger a production order. Hyperautomation could take this further—automating the process of sharing the BoM with suppliers, bidding for parts, and finalizing contracts using RPA or BPM (Business Process Management) tools.
Such integration transforms automation into a more dynamic, adaptable system, reducing inefficiencies and driving profitability.
Practical Applications of Hyperautomation
Hyperautomation offers endless possibilities for real-world applications:
- Dynamic Supply Chain Management: Automatically sourcing components, negotiating contracts, and tracking inventory levels.
- Data-Driven Maintenance: Predictive maintenance systems that analyze machine data to schedule repairs before breakdowns occur.
- End-to-End Manufacturing: Fully integrated production systems that optimize processes from raw material procurement to product delivery.
By layering these applications on top of small automation systems, companies can unlock new levels of efficiency and scalability.
Conclusion
The journey from small automation to hyperautomation is not about replacing one with the other but about building a bridge between them. Businesses that integrate these strategies can transform their operations, linking enterprise and industrial technologies in meaningful ways.
As automation continues to evolve, the middle ground between conservative small-scale systems and cutting-edge hyperautomation will likely define the future. By embracing both approaches, companies can move closer to a world where automation not only enhances productivity but redefines how we work.
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