When planning automation investments, manufacturers face a fundamental architectural decision: build standalone automation cells or integrate complete production lines? Each approach has distinct advantages, and the right choice depends on your specific situation.

Understanding the Options

Automation Cells

An automation cell is a self-contained workstation that performs a specific manufacturing operation or set of related operations. Cells include:

  • One or more robots or automation devices
  • Fixtures and tooling for the operation
  • Local controls and HMI
  • Safety guarding as required
  • Often, built-in quality verification

Products enter the cell, receive processing, and exit—typically with manual material handling between cells.

Integrated Production Lines

A production line connects multiple operations into a continuous flow. Lines include:

  • Multiple processing stations
  • Automated material transfer between stations
  • Centralized or distributed controls
  • Comprehensive safety systems
  • End-to-end process monitoring

Products enter at one end and progress through all operations without manual intervention.

Cost Comparison

Initial Investment

Cells typically require lower initial investment:

  • Smaller scope means smaller purchase
  • Less engineering for integration
  • Simpler installation
  • Faster commissioning

Lines require larger upfront investment:

  • Multiple stations in a single project
  • Complex integration engineering
  • More extensive installation
  • Longer commissioning period

However, the total cost to automate the same operations is often similar—cells just spread the investment over time.

Engineering Costs

Cell projects have lower engineering complexity:

  • Self-contained scope
  • Standard interfaces
  • Less coordination required
  • Simpler controls architecture

Line projects require more engineering:

  • System-level integration
  • Coordinated material flow
  • Complex controls networking
  • More extensive documentation

Installation Costs

Cell installation is typically straightforward:

  • Single location placement
  • Independent utility connections
  • Minimal floor preparation
  • Quick startup

Line installation is more involved:

  • Multiple connected stations
  • Coordinated material handling
  • More extensive utilities
  • System-level startup

Flexibility Comparison

Product Changes

Cells offer more flexibility:

  • Single cell can be modified without affecting others
  • New cells can be added for new products
  • Cells can be repurposed for different operations
  • Easier to accommodate product variations

Lines are less flexible:

  • Changes affect the entire line
  • Product variations require system-wide adjustment
  • Adding products may require line modification
  • Line balance constrains cycle time options

Volume Scaling

Cells scale incrementally:

  • Add capacity one cell at a time
  • Reduce capacity by idling cells
  • Match capacity to demand gradually
  • Minimize stranded investment

Lines scale in larger steps:

  • Capacity is determined by line design
  • Expanding requires significant modification
  • Underutilization wastes investment
  • Overcapacity is difficult to address

Future Changes

Cells are more adaptable:

  • Technology upgrades can be done cell-by-cell
  • Cells can be relocated or sold
  • New processes can be added independently
  • Experimentation is lower risk

Lines are more permanent:

  • Technology upgrades affect entire system
  • Lines are difficult to relocate
  • Changes propagate through system
  • Experimentation disrupts production

Efficiency Comparison

Throughput

Lines typically achieve higher throughput:

  • Optimized material flow
  • Balanced cycle times
  • Minimal transfer time
  • Continuous operation

Cells may have lower throughput:

  • Manual handling between cells adds time
  • Buffer inventory between operations
  • Potential for WIP accumulation
  • Less optimized material flow

Quality

Lines offer better quality control:

  • Integrated inspection throughout
  • Immediate feedback to upstream stations
  • Full traceability from start to finish
  • Consistent process sequencing

Cells may have quality gaps:

  • Inspection may occur only at cell level
  • Defects may not be detected immediately
  • Traceability requires additional systems
  • Process sequence depends on routing

Labor Efficiency

Lines require less labor per unit:

  • Minimal material handling
  • Centralized monitoring
  • Efficient operator utilization
  • Lower labor cost per piece

Cells require more labor:

  • Material handling between cells
  • Multiple monitoring locations
  • Less efficient operator utilization
  • Higher labor cost per piece

When to Choose Cells

Automation cells are the better choice when:

Starting Automation Journey

If you're new to automation:

  • Lower initial investment reduces risk
  • Organizational learning occurs gradually
  • Success builds confidence for expansion
  • Mistakes are contained to individual cells

Production Volume Is Uncertain

When demand is unpredictable:

  • Capacity can be adjusted incrementally
  • Investment can be matched to actual needs
  • Flexibility hedges against uncertainty
  • Exit strategy is easier if needed

Multiple Products With Different Processes

When product mix varies significantly:

  • Different cells for different products
  • Routing flexibility accommodates variations
  • Changeover isolated to affected cells
  • New products added without system changes

Facility Constraints

When floor space is limited or irregular:

  • Cells can fit in available spaces
  • Layouts can be adjusted to constraints
  • Growth can occur in multiple areas
  • Existing equipment can be accommodated

Phased Investment

When capital is constrained:

  • Invest in highest-priority operations first
  • Add capabilities as budget allows
  • Demonstrate ROI before expanding
  • Spread investment over time

When to Choose Lines

Integrated production lines are better when:

High Volume, Stable Production

When running large quantities consistently:

  • Optimization pays off at volume
  • Investment is fully utilized
  • Efficiency gains are substantial
  • Line design can be optimized

Quality Is Paramount

When quality requirements are stringent:

  • Integrated inspection catches defects early
  • Full traceability is built-in
  • Process control is comprehensive
  • Quality data is complete

Labor Availability Is Critical

When finding operators is challenging:

  • Minimum labor per unit produced
  • Less dependence on operator skill
  • Reduced hiring requirements
  • Lower turnover impact

Speed to Market Matters

When fast response is essential:

  • Shortest possible throughput time
  • Minimal work-in-process inventory
  • Quick response to customer orders
  • Predictable delivery times

Process Sequence Is Fixed

When operations must occur in specific order:

  • Enforce required sequencing
  • Prevent process errors
  • Ensure consistent flow
  • Simplify scheduling

Hybrid Approaches

Many successful automation implementations combine elements of both:

Cells Connected by Conveyors

Multiple automation cells linked by automated material transfer:

  • Retains cell flexibility
  • Reduces manual handling
  • Maintains cell-level independence
  • Enables future expansion

Lines with Flexible Sections

Production lines with modular, changeable sections:

  • Core operations in fixed line
  • Variable operations in flexible modules
  • Adaptation without full redesign
  • Balance of efficiency and flexibility

Parallel Cell Groups

Multiple cells performing the same operation:

  • Scales capacity without complexity
  • Maintains redundancy
  • Balances workload automatically
  • Simplifies maintenance

Making the Decision

Evaluate Key Factors

Consider your situation across dimensions:

Factor Favors Cells Favors Lines
Volume Lower/variable High/stable
Product mix High variety Limited variety
Investment timing Phased Single project
Flexibility need High Lower
Labor availability Adequate Constrained
Quality criticality Standard Stringent

Consider Your Trajectory

Think about where your business is heading:

  • Growth expectations
  • Product roadmap
  • Technology changes
  • Market dynamics

Consult Experienced Partners

AMD Automation has implemented both automation cells and integrated production lines across industries. We help clients evaluate options objectively based on their specific circumstances.

Our experience spans automotive, medical devices, aerospace, and other industries where both approaches deliver value in appropriate situations.

Not sure which approach fits your needs? Contact us for a consultation. We'll evaluate your requirements and recommend the architecture that best serves your manufacturing goals.