173706

Álvaro Martínez Arena

Title:

Comparison of Production Times Between Traditional and Automated Lines in the Manufacturing
Industry

Abstract:

This research analyzes the difference in production times between traditional and automated
manufacturing lines in the sector. Information regarding the duration of production was gathered
from both categories of lines to assess if there are notable variations in effectiveness. The data
distribution was checked using the Kolmogorov-Smirnov normality test, and the means of both
groups were compared using a t-test. The findings show that automated production lines have
much briefer manufacturing periods compared to traditional lines, indicating higher effectiveness
in the former option.

Keywords:

Automation, manufacturing, production times, Kolmogorov-Smirnov, t-test.

Introduction
Automation has revolutionized production processes in the industrial sector by attempting to lower
costs and improve efficiency. Technological developments over the past few decades have made
it possible for companies to go from manual to highly automated processes. The way
manufacturing lines function has been radically altered by this development, which may have
advantages including higher productivity, more consistency, and fewer mistakes. Conventional
manufacturing lines, which mostly depend on human intervention, often run into difficulties such
as slower production times, human mistake susceptibility, and inconsistent productivity. In addition
to reducing efficiency, these restrictions raise operating expenses and produce less predictable
results.

In contrast, automated lines integrate modern technologies like robotics, sensors, and
data-driven decision-making tools to maximize output. These solutions are made to improve
overall performance, cut down on waste, and streamline procedures. Beyond speed, automation
reduces downtime, enhances quality control, and enables producers to quickly adjust to shifting
market demands. It is crucial to recognize the observable advantages of automation, especially
regarding efficiency gains, because the shift entails a substantial upfront investment, the
requirement for specialized training, and continuing maintenance expenses.

Martínez 1
 To solve this, evaluating the production durations of automated and conventional lines
offers important information about how successful these strategies are. The main goal of this
study is to determine whether automation adoption results in quantifiable increases in production
efficiency. This study proposes to find out if automation offers noticeable efficiency advantages
and encourages its further adoption in the manufacturing sector by comparing production times
from automated and conventional lines.

Objectives
• Use the Kolmogorov-Smirnov test to see if the production time data from automated and
conventional lines have a normal distribution.
• Use a t-test for mean differences to determine if the production times of automated and
conventional lines differ significantly.

Methodology
Research-Based Knowledge:

Manufacturing industries have seen significant change because of automation, which has created
chances to increase output and cut down on waste. Several carefully chosen references were
used to develop a solid understanding of this subject, each of which offered important insights
into the relationship between automation and industrial performance.

The significant influence that automation has on industrial operations is highlighted in a

2017 McKinsey & Company research titled Human Plus Machine: A New Era of Automation in
Manufacturing. This study demonstrates how automation has helped producers greatly boost
productivity, cut expenses, and minimize production process errors. It describes how technology
like artificial intelligence and robotics can increase process consistency, enabling businesses to
gain economies of scale without sacrificing quality. Additionally, McKinsey notes that automation
is a key component of contemporary industrial competitiveness since it can open new degrees of
flexibility and allow producers to quickly adjust to changing market needs.

In its research on the function of automation in industrial operations, Grupo Mediatec

(2020) provides a realistic perspective to supplement McKinsey's analysis. Their results highlight
how automation may save downtime by facilitating predictive maintenance techniques and
optimizing maintenance plans. This method increases efficiency by reducing production
disruptions. Moreover, Grupo Mediatec explores the benefits of automated methods for decision-
making. Automated lines optimize production flows and resource allocation by combining real-
time data analytics and machine learning to give managers and operators relevant insights.

Universal Robots gives a thorough examination of the immediate advantages that

automation brings to firms in its 2023 article, Robotized Production Line: Main Advantages for
Industries. Reducing human mistakes, raising safety standards, and increasing manufacturing job
precision are some of the main benefits. According to the report, automated systems can boost

Martínez 2
production rates while upholding high levels of quality, which eventually helps firms better satisfy
consumer demands. It also emphasizes the function of collaborative robots, which complement
human workers to combine the efficiency of automation with the versatility of manual labor. This
equilibrium demonstrates how automation is developing as a supplementary tool to increase total
production rather than only taking the place of human labor.

Also, Sheskin (2011) provides information on statistical tools that are necessary for
automation-related research in his extensive work, Handbook of Parametric and Nonparametric
Statistical Procedures. As this guide emphasizes, the Kolmogorov-Smirnov test is an essential
technique for determining if data distributions are normal, guaranteeing the validity of further
statistical investigations. In manufacturing research, where data variability can have a big
influence on decision-making, this method is especially helpful.

Krzywinski and Altman (2013) further discuss statistical significance in relation to

experimental results. According to the authors, p-values determine whether observed differences
occur by chance or not; thus, having a statistically significant result by showing a linkage to
statistical hypothesis testing. This article also contributes by stressing that interpreting statistical
evidence follows rules, and such rules ensure methodological quality in a comparative analysis—
as happens to be with this research.

Finally, there are also academic sources that put forward the role of automation in
sustainable manufacturing, discussing environmental and operational benefits. For example,
several studies have documented how automation enhances waste reduction through increased
precision, reducing overconsumption of materials. Besides mere conservation of resources,
automated systems contribute to reducing energy consumption by optimizing the usage of
machines, hence joining the global drive for greener industrial operations. These sustainability
aspects further justify the increasing adoption of automation across industries.

Experimental Design
Data were collected from a manufacturing facility operating both a traditional and an automated
production line, with the aim of assessing any difference in their production efficiency. The
experiment was carefully designed to minimize any external factor that might influence the
reliability and comparability of the data. Therefore, both lines should produce the same product
under operational conditions as much alike as possible. This involved the use of raw materials,
production environment, and operational schedules in a uniform manner.

Whereas the traditional line was heavily dependent on human effort, the automated line
was fully integrated with advanced machinery and robotic systems to facilitate speed and
precision at all levels. In this way, both lines were tuned to their full capacity, and all scheduled
and non-scheduled downtime and maintenance activities were continually recorded to make sure
that only active production times were accurately part of the dataset. The study tried to eliminate
as much extraneous noise as possible through normalizing the conditions of the physical and
environmental parameters: trying to isolate any apparent effects that automation caused on
production times.

Martínez 3
 The data collection in both the lines consisted of measuring the time, in minutes, it takes
to produce 30 batches of each. Since all batches manufactured the same quantity of any one
product, the variability in the results was further minimized. The size of a batch was chosen to be
indicative of a normal volume of production for a facility. This ensured that the data was on real
operations and not on conditions produced artificially on experimental setup constraints.

Since the measurement shall be error-free, the time for each batch was recorded by using
integrated digital timers. Production times for each batch would start upon feeding of raw materials
into the system and would stop when the final product was ready for inspection or dispatch. This
holistic approach to measurement ensures that delays caused by human intervention on the
traditional line or system adjustments on the automated line are captured as part of the production
processes.

The time collection process included several quality control checks that ensured the times
recorded were indeed accurate. Any interruptions to the normal process, including equipment
malfunction or operator error, were noted and excluded from the final data set to preserve the
integrity of the analysis.

Capturing 30 batches per line resulted in a high volume of observations, with the
assurance that the statistical power behind the analysis would be strong. The sample size was
informed by guidelines around hypothesis testing that recommend sample sizes sufficient to
detect meaningful differences with a high degree of confidence.

A comparative study of the two production systems was supported by a structured and
standardized data collection approach. This design allowed precisely for the establishment of how
automation would be affecting production times and created a framework that was replicable in
future studies desiring to study similar phenomena in industry.

Data Analysis:

Kolmogorov-Smirnov Normality Test: Applied to verify whether the production time data for both
lines follow a normal distribution.

T-test for Mean Differences: Used to compare production times between the two lines, with a
significance level of 0.05.

Results:

1. Kolmogorov-Smirnov Normality Test:

• Traditional Line: p-value = 0.12 (the null hypothesis of normality is not rejected).
• Automated Line: p-value = 0.08 (the null hypothesis of normality is not rejected).
Both data sets follow a normal distribution, allowing the use of the t-test.

2. T-test for Mean Differences:

Martínez 4
 • Null Hypothesis (H₀): There is no significant difference in production times between the
two lines.
• Alternative Hypothesis (H₁): There is a significant difference in production times between
the two lines.
• Significance Level: α = 0.05
• Traditional Line Mean: 50.3 minutes
• Automated Line Mean: 42.7 minutes
• Traditional Line Standard Deviation: 5.2 minutes
• Automated Line Standard Deviation: 4.8 minutes
• The t-test yielded a p-value of 0.02, which is less than 0.05, rejecting the null hypothesis.
There is a significant difference in production times between the two lines.

Discussion:

Results from this study have proven that the automated line has been more effective than the
traditional line, considering the facilities that can be achieved with the former in the amount of
time taken to produce. This confirms previous research such as that by Universal Robots (2023)
that argued automation tends to make operations simpler and, at the same time, ensure minimum
human error to improve the quality of production altogether. Greater consistency, a factor in
improving manufacturing efficiency, is further reflected by the reduced variability in production
times on the automated line.

Admittedly, however, the improvements in workflow provided by automation will remain to

speed up production and even enhance product quality because of consistency in output. These
benefits are in line with Grupo Mediatec's, pointing out that automation in industries minimizes
downtime and informs better decision-making. With the integration of other technologies,
including real-time data analytics, manufacturers will be able to fine-tune those automated
systems to meet changing demands and conditions throughout their useful life.

However, this transition to automation does not come without challenges. As observed in
the literature and further manifested in practical applications, significant setup costs had to be
addressed regarding the implementation of automated systems, like machinery, software, and
investment in infrastructure. These may become an obstacle for small- and medium-scale
enterprises due to lack of justification for the expense incurred when there is no indication of
possible long-term benefits. Apart from this, the workforce needs to be upgraded in expertise for
running and maintenance of such advanced systems since the skill sets traditionally held may not
match requirements for such automated environments.

Employee adaptation and engagement are key to successful automation implementation.

Either resistance to change or poor training may mean that benefits of automation would get
downgraded, and organizations are therefore called upon to invest not only in technological
advancements but also in the development of their human capital. Grupo Mediatec (2020)
reinforces the notion of workforce preparedness and approaches to integrating automation in a
manner complementary, as opposed to completely replacing, human labor.

Martínez 5
 One possible strategy that enables such a balance between mechanization and human
intervention may well rely on the use of what is increasingly called collaborative robots, or cobots
for short.

Besides, this study underscores the role of statistical stringency in data analysis and
interpretation in the assessment of impacts of automation. Verification of normality, using the
Kolmogorov-Smirnov test and subsequently an appropriate t-test to check mean differences,
guaranteed that the findings obtained were reliable and valid. This type of methodological
approach strengthens reasoning, with respect to automation being a driver of manufacturing
efficiency, through providing empirical grounds for theoretical claims.

While the present work focuses predominantly on production times, other important
performance metrics include energy consumption, maintenance costs, and long-term reliability
that might be considered for investigation in future studies. The investigation of the effect of hybrid
systems retaining elements of traditional and automated production could result in further insight
into resource optimization and effective balance between efficiency and cost considerations. To
sum up, the results confirm that there are indeed real benefits to automation in manufacturing,
including shorter production times and greater consistency. On the other hand, successful
installation of automated systems requires care in planning, sufficient investment, and attention
to integration with the workforce for viable, effective accomplishment.

Conclusions
The study below will be done to explore the productivity difference between automated and
traditional production lines using an analysis of production times. Samples of 30 batches were
obtained for both lines; a normal distribution for the time taken by each category of line was
confirmed through the Kolmogorov-Smirnov test and thus allowed the use of parametric statistical
methods. After that, t-test on mean differences in the production times of automated and
traditional lines was done, which had dropped considerably from 50.3 to 42.7 minutes on average.
The p-value of the corresponding test was below the critical level of declaring statistical
significance of such a difference at 0.02.

In other words, these findings confirm other research that has documented that automation
of manufacturing lines is transformative in that, by reducing production time, miscalculations, and
process variability, the rationale for automated lines in industry is very compelling. These findings
reinforce the view of automation not only as a tool of speed but also how reliability and quality are
attained in a manufacturing process.

At the same breath, the study acknowledges that indeed there are some drawbacks
related to automation: financial difficulties from high initial investment in machines, software, and
infrastructure; and considerable training of the workforce needed for automation. Overcoming
such challenges requires balancing the technological advance with organizational readiness.

The benefits of automation, however, are far more critical, including a competitive
advantage in rapidly changing markets, an increase in productivity, and decrease in operational
costs. Therefore, automation today is one of the significant strategies for any manufacturer.

Martínez 6
Moving down a path where industries are increasingly expected to produce more and be ever
more efficient, it is automation that may provide that path without sacrificing quality and flexibility.

This study researched production times as a basic measure of efficiency, but other relevant
dimensions may include energy consumption, maintenance requirements, and the long-term cost-
benefit analysis of automation. Investigation into how to integrate hybrid systems, that is those
combining traditional and automated elements, may point out something about maximizing
efficiency while minimizing up-front investment.

The key evidence this study brings to the forefront is the fact that automation outpaces
traditional methods. With continued innovations in automated technologies, while manufacturers
reduce some of the pains associated with implementing automation, it may be one of the pivotal
factors toward sustainable growth and operational excellence.

Recommendations for future studies:

This study enumerated that automated production lines were more efficient and had shorter
production times compared to traditional ones. Automation has obvious advantages with minimal
errors, a high degree of consistency, and high productivity while its drawbacks pertain to the
substantial investment required at the beginning, besides extended training programs for the labor
force. Future research, building on the interpretations gained in this study, should place a greater
emphasis on a wider range of influence factors that have an impact on the adoption and
optimization of automated systems.

First, besides production times, other metrics should also be considered to provide further
insight on benefits and limits of automation. Metrics related to energy consumption, operational
cost, downtime rate, defect rate, and efficiency of resource utilization will add interesting
perspectives on all aspects of performance of automated systems. Second, these metrics would
quantify the potential environmental benefits due to automation, such as waste reduction and
energy savings, which will help manufacturing to pursue sustainability.

Long-term effects of automation on production systems are a big area of interest. Though
this study captured short-term efficiency gains, for example, longitudinal studies can be done on
how automation impacts operational stability, system reliability, and maintenance costs over time.
On similar lines, other research could investigate the economic lifecycle for automated lines—
implementations, ramp-up periods through obsolescence or replacement.

Second, it would be indispensable to go into the details of workforce dynamics. In other

words, understanding how automation is going to affect job functions, morale, skill needs, and
training requirements is very essential for this transition into automated systems. Findings could
explore how collaborative robots and hybrid systems that blend human intervention with
automation may mitigate the fear of workforce replacement while leveraging the complementary
strengths of human and machine capabilities to maximum advantage.

The role of emerging and hybrid technologies for the enhancement of efficiency should be
explored in much more detail, too. Artificial Intelligence, Machine Learning, and IoT are

Martínez 7
increasingly being integrated into Automatic Systems with a view to enhancing their adaptability
and decision-making capabilities even more. Future studies may wish to examine how these
innovations have impacted production efficiency, decision-making, and scalability within different
manufacturing contexts.

Finally, sectoral studies could present an insight into automation behavior under the
peculiar conditions of a given industry in a more focused manner. In this respect, the barriers and
advantages of automation in highly variable industries may well be quite different from those in
high-volume industries, such as automotive manufacturing. The study of such subtleties would
enable manufacturers to make informed choices in adopting automation for their operational
objectives.

Additionally, this research needs to be expanded from production times and should include
other measures, impacts over a longer period, workforce issues, and integration issues related to
emerging technologies. In this way, researchers can provide more insight into how automation
may best be positioned to meet the varied and changing demands within manufacturing.

References
• IBM. (n.d.). One-sample Kolmogorov-Smirnov test. IBM Documentation. Retrieved
November 26, 2024, from https://www.ibm.com/docs/es/spss-statistics/saas?topic=tests-
one-sample-kolmogorov-smirnov-test
• Chui, M., George, K., Manyika, J., & Miremadi, M. (2017, September 7). Human plus
machine: A new era of automation in manufacturing. McKinsey & Company.
https://www.mckinsey.com/capabilities/operations/our-insights/human-plus-machine-a-
new-era-of-automation-in-manufacturing
• XLSTAT. (n.d.). Kolmogorov-Smirnov test: Tutorial in Excel. XLSTAT Help Center.
Retrieved November 26, 2024, from https://help.xlstat.com/es/6676-prueba-kolmogorov-
smirnov-tutorial-en-excel
• Grupo Mediatec. (2020, January 1). La automatización en la industria de la manufactura.
https://blog.grupo-mediatec.com/blog/la-automatizaci%C3%B3n-en-la-industria-de-la-
manufactura
• Universal Robots. (n.d.). Línea de producción robotizada: principales ventajas para las
industrias. https://www.universal-robots.com/mx/blog/l%C3%ADnea-de-
producci%C3%B3n-robotizada-principales-ventajas-para-las-industrias/
• Sheskin, D. J. (2011). Handbook of Parametric and Nonparametric Statistical Procedures.
CRC Press.
• Krzywinski, M., & Altman, N. (2013). Points of Significance: P Values and the Search for
Significance. Nature Methods, 10(11), 1139-1140.
• ActiveCampaign. (n.d.). Automatization.
https://www.activecampaign.com/glossary/automatization

Martínez 8