【2025 Tech Essentials】The differences between custom automation and standard automation

Non-standard automation, as the name implies, refers to automated equipment or solutions that are “non-standard”. By “non-standard” here, it mainly refers to the lack of unified design, manufacturing, and acceptance standards established by national or industry standards. In simple terms, non-standard automation equipment is not designed for mass production; it does not come in standard models and is not ready to use out of the box. Instead, it represents an automated solution that is tailored to meet the customer’s specific requirements regarding manufacturing processes, product characteristics, and production capacity.

For example: standard automation equipment such as standard injection molding machines, CNC machining centers, and general-purpose robots (like those from ABB and FANUC with 6 axes). These devices come with specific models and fixed parameters, along with public user manuals; once purchased and calibrated, they can be used right away. Non-standard automated equipment: Such as an assembly line customized for a new product, testing fixtures, dispensing lines, or automatic screw-driving devices – the mechanisms, control programs, and operational procedures for these devices are all designed from scratch, as there are no ready-made models available.

The essence of custom automation is tailored automation solutions, where every step (from requirements, design, manufacturing, debugging to delivery) is full of variability.

The term “standard” here mainly refers to the following: 1️⃣ There are no unified industry-standard models; standardization parameters do not apply to such custom-made equipment, which is designed to serve the specific processes of particular customers, and therefore no standard model can meet their requirements. For example, if you design a screw-tying assembly line for Factory A, the screw model, torque requirements, loading and unloading methods, and production pace will all differ from those required by Factory B – this is what is meant by \"non-standard\". 2️⃣ There are no ready-made solution templates that can be directly applied; standard automation devices are often developed based on established solutions, with few design iterations. The mechanical structure, electrical design, and manufacturing process of non-standard equipment generally need to be redesigned. 3️⃣ Non-standard equipment that cannot be produced in bulk economically is basically manufactured in small batches or even as individual units; the design cost for each unit is high, and the amount of work required for debugging is substantial.

Non-standard does not mean “no technical standards”! The design and manufacturing of custom equipment must still comply with the **standards and safety regulations** in fields such as mechanics, electricity, pneumatics, and industrial control (such as GB, ISO, CE requirements), as well as the technical specifications set by the customer’s company. It just doesn’t have a unified model, but it’s by no means something done carelessly.

The non-standard automation industry has several distinct characteristics: 1️⃣ High degree of customization – almost every project is a new one. Even for the same type of product, different customers have varying requirements regarding process details, production rhythms, and quality control, which means we need to start over from scratch, beginning with demand research and solution design.

2️⃣ High degree of technical integration: Customized equipment often cannot be developed using just one single technology; it usually involves: ✅ Mechanical structure design (dynamics, force analysis, mechanism tolerances) ✅ Electrical control (PLC, motion control, robotics) ✅ Pneumatic/hydraulic systems (for actuation) ✅ Visual inspection, MES integration, data collection ✅ Software programming (industrial control configuration, host computers, data interfaces). This is also why teams working on customized equipment need close collaboration among specialists in mechanics, electrical engineering, software development, and debugging.

3️⃣ The project timeline is uncertain and the risks are high. As it is a \"non-standard\" product, there are many uncertainties throughout the processes of solution development, design, procurement, manufacturing, and debugging. Customer requirements may change, supply chain issues may arise, and difficulties in the on-site debugging process may occur; thus, the risks are much higher than those associated with the delivery of standard equipment.

Although non-standard automation is difficult to implement, involves long timelines, and carries high risks, it remains an essential component of the manufacturing industry. 🔹 The manufacturing industry is constantly evolving, with new processes and products emerging one after another: industries such as smartphones, new energy vehicles, photovoltaics, and semiconductors are developing at a rapid pace, and new products require new processes; custom automation precisely meets this need for constant change.

🔹 The trend toward automation and flexibility is evident: the market demands customized equipment with greater flexibility, faster line changes, and shorter delivery times, and non-standard automation offers advantages in terms of rapid response and personalized design.