Adaptive automation for high-mix, multi-product manufacturing lines

Unplanned downtime is one of the most costly challenges in manufacturing. Jhankar Dutta, Regional MD, Southern and Eastern Asia, BER Automation, spoke about how softwaredriven automation fundamentally changes how downtime is managed-shifting operations from reactive troubleshooting to proactive and predictive control.

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How is B&R addressing the demand for flexible automation across multi-product manufacturing lines?

Manufacturing today is defined by variety, not volume alone. Customers expect faster changeovers, shorter batch sizes, and greater product customisation–without sacrificing quality or productivity. As a result, flexibility has become a fundamental requirement rather than a competitive advantage.

B&R addresses this shift through its concept of adaptive manufacturing, where machines are designed to dynamically respond to changing production demands. Our software-centric automation platform enables manufacturers to quickly and efficiently configure, scale, and reconfigure production lines. With modular software components such as Mapp Technology, OEMs can reuse and adapt functions like motion control, safety, robotics, and recipe management across multiple machine variants.

Complementing this software approach, B&R's advanced mechatronic systems enable economical production of small batches and even individualised products. Intelligent transport solutions–such as ACOPOStrak, SuperTrak, and ACOPOS 6D–move workpieces independently through machines, without rigid timing constraints. Individually controlled shuttles allow instant format changes while maintaining high throughput.

Thanks to modular machine design and the use of digital twins to simulate new processes, production lines can be reconfigured quickly for new products. Features such as flexible track layouts, parallel processing, dynamic product flow merging and splitting, and precisely synchronised robotics enable efficient management of high product variability. The result is a single production line capable of handling multiple product variants with minimal mechanical changes–supporting mass customisation without compromising productivity or quality.

What role does software-driven automation play in reducing downtime on the shop floor?