Britannica Sources used in this answer

Why must programmable automation be reprogrammed for each new product batch?

Created from Britannica articles using AI. AI can make mistakes, so verify using Britannica articles.

Jacquard loom engraving, 1874 — automation At the top of the machine is a stack of punched cards that would be fed into the loom to control the weaving pattern. This method of automatically issuing machine instructions was employed by computers well into the 20th century.

Programmable automation is specifically designed for producing goods in batches, typically ranging from several dozen to several thousand units at a time. Because the equipment is engineered to facilitate product changeovers rather than for the specialization of a single product, it must be reprogrammed and adjusted to accommodate the unique requirements of each new product style.1

The programmed instructions in these systems determine the specific actions, sequences, and set points necessary to achieve a desired result. Since each batch involves a different product style, the computer program stored in the system's computer memory must be updated to reflect the new specifications. This process inherently requires a period of nonproductive time for reprogramming and physical changeover, which is why production rates for programmable automation are generally lower than those of fixed automation.21