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Hyperautomation & Small Automation: Bridging the Gap Between Factory Floors and Enterprise Systems
Two Worlds of Industrial Automation
The landscape of industrial automation is often split into two distinct realities. On one end, there’s traditional automation—think pick-and-place robots, basic data collection, and PLC-controlled processes. Many manufacturers still operate here, where even simple automation can be transformative.
On the opposite extreme lies the futuristic vision: fully autonomous “lights-out” factories where AI-driven machines communicate and make decisions with minimal human involvement. This is the world popularized in sci-fi films—a highly connected, intelligent ecosystem that still feels out of reach for many.
Most manufacturers, however, operate somewhere in between.
Most manufacturers, however, operate somewhere in between.
What Is Small Automation?
The concept of “small automation” was introduced by PwC strategists in 2019. It refers to the use of flexible, adaptable technologies that fill gaps within existing systems. While originally applied to software like RPA and machine learning, small automation is equally relevant in an operational technology (OT) context.
Examples include:
A single collaborative robot performing repetitive tasks
Inverter-controlled motors offering precise feedback
HMIs and PLCs running localized processes
Small automation makes big automation achievable—one practical step at a time.
How Hyperautomation Complements Small Automation
Hyperautomation refers to the end-to-end automation of complex business processes using advanced tools like AI, RPA, IoT, and BPM. It might sound like it belongs only in high-tech environments, but it doesn’t have to.
When combined with a small automation approach, hyperautomation can help bridge IT and OT systems. Instead of overhauling entire operations, companies can use hyperautomation to connect and enhance existing automated processes—making them smarter, more efficient, and more integrated.
Real-World Use Case: From Bill of Materials to Automated Bidding
Consider a typical manufacturing process: a company creates a Bill of Materials (BoM) to generate production orders. With a hyperautomation strategy, that BoM can be automatically shared with suppliers. From there, AI-driven systems can even solicit and evaluate bids—dramatically speeding up procurement and reducing manual intervention.
This isn’t science fiction. It’s an example of how hyperautomation and small automation can work together to eliminate friction, save time, and boost efficiency.
Conclusion: Unite, Don’t Divide
Hyperautomation shouldn’t deepen the divide between IT and OT. Instead, it should serve as the bridge that brings them together. By pairing a hyperautomation strategy with a small automation approach, manufacturers can achieve new levels of productivity, flexibility, and intelligence—no science fiction required.
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