Industrial automation exists in two distinct worlds. The first is the conservative world, where businesses rely on straightforward automation solutions like robotic arms, pick-and-place systems, or collecting data from machines for analysis. In these environments, even small-scale automation is a radical step towards improved productivity.
The second world belongs to early adopters, where factories operate autonomously with robots building robots, and decisions are made by AI at the edge. This kind of lights-out manufacturing eliminates human involvement and pushes technology to its limits—think of futuristic settings like those in I, Robot or the fictional Cyberdyne Systems.
Most businesses, however, live somewhere between these extremes, using a blend of small automation tools and enterprise systems. For them, hyperautomation offers new opportunities to bridge the gap between enterprise technology (IT) and operational technology (OT).
What is Small Automation?
The concept of small automation emerged in 2019, introduced by PwC strategists Dan Priest, Kumar Krishnamurthy, and Alex Blanter. They defined it as the fast implementation of adaptable technologies to improve productivity by filling gaps left by enterprise systems.
While their focus was on IT technologies like RPA (Robotic Process Automation), machine learning, and natural language processing, small automation is also transforming OT. Examples of small automation include:
- Single industrial robots deployed on production lines.
- Inverter-controlled motors offering precise performance feedback.
- HMIs and PLCs managing real-time processes at the shop floor.
By connecting industrial tech stacks with enterprise systems, small automation has driven efficiency and profitability gains over the last decade.
Understanding Hyperautomation in Industrial Automation
Hyperautomation takes automation to the next level by aiming to automate every step of a process, reducing manual intervention as much as possible. It combines technologies such as BPM (Business Process Management), RPA, and AI-driven workflows to streamline operations.
Hyperautomation goes beyond automating individual tasks—it integrates entire workflows into unified digital platforms, providing real-time visibility and management. As Johan Jonzon, CMO of Crosser, explains:
“The goal of a hyperautomation strategy is to eliminate any unnecessary steps in the process of completing a task and automate those remaining. This streamlines business processes, reduces the need for human intervention, and increases business efficiency.”
How Hyperautomation and Small Automation Complement Each Other
Contrary to popular belief, hyperautomation and small automation are not opposing concepts. Instead, they are complementary, working together to streamline operations across IT and OT layers. While hyperautomation focuses on end-to-end process integration, small automation handles local and specific tasks efficiently.
For example:
- A company uses RPA to automate order processing and small automation tools like PLCs to control production equipment.
- Hyperautomation can bridge the two, allowing data from operational equipment to flow into enterprise systems seamlessly, ensuring smoother production planning and execution.
Real-World Application: From BoM to Production Orders
Consider a common scenario: a manufacturer creates a Bill of Materials (BoM) and uses it to generate a production order. With hyperautomation, this BoM could be automatically shared with parts suppliers. These suppliers could bid for the contract using automated systems, streamlining procurement without human involvement.
This workflow demonstrates how small automation at the production level—monitoring individual machines—can align with hyperautomation, which handles procurement, order generation, and supplier coordination.
Bridging the Gap Between IT and OT with Hyperautomation
The key to unlocking the full potential of automation lies in linking enterprise technology (IT) with operational technology (OT). Hyperautomation helps integrate these layers, ensuring that systems across the organization communicate effectively. This not only simplifies complex workflows but also creates scalable solutions for businesses looking to expand their automation capabilities.
For example, real-time machine data from OT systems can feed into ERP software, providing better forecasting and reducing downtime. Similarly, RPA bots can handle data-intensive tasks like scheduling, freeing up staff for higher-value activities.
Conclusion: Building the Future of Automation with Hyperautomation and Small Automation
While hyperautomation may sound like a futuristic concept, it is increasingly becoming a practical tool for businesses today. By combining small automation tools with hyperautomation strategies, companies can optimize their processes, reduce costs, and improve productivity.
Instead of viewing hyperautomation as an overwhelming leap, organizations can start small—implementing automation step by step and scaling up as needed. This approach not only keeps operations manageable but also reinforces the connection between enterprise and
