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Automation Risk Analysis

Will “Process Controller” be Automated?

Historical Context: Oxford Study (2013)

Ranked #670 of 702. Estimated risk: 98.0%

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AI Exposure Risk

56%

“Process Controller” will maybe be replaced by AI.

Based on the cognitive demands, communication requirements, and logical reasoning intrinsic to this occupation according to O*NET data, we project a 56% probability of disruption by generative AI and Large Language Models.

Automation & Robot Risk

54%

“Process Controller” will maybe be replaced by robots.

Evaluating the physical dexterity, repetitive motion tasks, and manual labor associated with this role, our analysis indicates a 54% likelihood of substitution by advanced robotics systems.

Personal & Financial Insights

Every occupation has a unique profile. For Inspectors, Testers, Sorters, Samplers, and Weighers, the Bureau of Labor Statistics and O*NET classify the day-to-day work broadly as: Inspect, test, sort, sample, or weigh nonagricultural raw materials or processed, machined, fabricated, or assembled parts or products for defects, wear, and deviations from specifications. May use precision measuring instruments and complex test equipment.

Avg. Annual Salary $51,670
Avg. Hourly Wage $24.84
Available Jobs (US) 591,180
Job Title & Hierarchy Code (SOC) Inspectors, Testers, Sorters, Samplers, and Weighers #51-9061
Wage vs. National Median
ℹ️

Data is based on the reference occupation: “Inspectors, Testers, Sorters, Samplers, and Weighers”

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Core Skills & Abilities

  • Interpret legal requirements, provide safety information, or recommend compliance procedures to contractors, craft workers, engineers, or property owners.

  • Stack or arrange tested products for further processing, shipping, or packaging.

  • Mark items with details, such as grade or acceptance-rejection status.

  • Discard or reject products, materials, or equipment not meeting specifications.

  • Administer tests to assess whether engineers or operators are qualified to use equipment.

  • Analyze test data, making computations as necessary, to determine test results.

  • Monitor production operations or equipment to ensure conformance to specifications, making necessary process or assembly adjustments.

  • Inspect or test raw materials, parts, or products to determine compliance with environmental standards.

  • Recommend necessary corrective actions, based on inspection results.

  • Write test or inspection reports describing results, recommendations, or needed repairs.

  • Measure dimensions of products to verify conformance to specifications, using measuring instruments, such as rulers, calipers, gauges, or micrometers.

  • Adjust, clean, or repair products or processing equipment to correct defects found during inspections.

  • Weigh materials, products, containers, or samples to verify packaging weights or ingredient quantities.

  • Compute defect percentages or averages, using formulas and calculators.

  • Disassemble defective parts or components, such as inaccurate or worn gauges or measuring instruments.

  • Remove defects, such as chips, burrs, or lap corroded or pitted surfaces.

  • Position products, components, or parts for testing.

  • Read dials or meters to verify that equipment is functioning at specified levels.

  • Notify supervisors or other personnel of production problems.

  • Compute usable amounts of items in shipments.

  • Inspect, test, or measure materials, products, installations, or work for conformance to specifications.

  • Record inspection or test data, such as weights, temperatures, grades, or moisture content, and quantities inspected or graded.

  • Monitor machines that automatically measure, sort, or inspect products.

  • Make minor adjustments to equipment, such as turning setscrews to calibrate instruments to required tolerances.

  • Compare colors, shapes, textures, or grades of products or materials with color charts, templates, or samples to verify conformance to standards.

  • Read blueprints, data, manuals, or other materials to determine specifications, inspection and testing procedures, adjustment methods, certification processes, formulas, or measuring instruments required.

  • Check arriving materials to ensure that they match purchase orders, submitting discrepancy reports as necessary.

  • Clean, maintain, calibrate, or repair measuring instruments or test equipment, such as dial indicators, fixed gauges, or height gauges.

  • Fabricate, install, position, or connect components, parts, finished products, or instruments for testing or operational purposes.

  • Grade, classify, or sort products according to sizes, weights, colors, or other specifications.

  • Collect or select samples for testing or for use as models.

Technologies & Software

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  • Selenium
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  • Qwen (Alibaba)
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  • Design of experiments DOE software
  • Rockwell Automation AI
  • Wilcox Associates PC-DMIS Inspection Planner
  • Siemens Industrial AI
  • Computer assisted design software
  • Claude (Anthropic)
  • Grok (xAI)
  • Dassault Systemes SolidWorks
  • Structured query language SQL
  • Microsoft Excel
  • The MathWorks MATLAB
  • IBM Notes
  • Nova (Amazon)
  • Mistral (Mistral AI)
  • Kimi (Moonshot AI)
  • ABB AI Robotics
  • ChatGPT (OpenAI)
  • Data analysis software
  • Statistical process control SPC data collection devices
  • Extensible markup language XML
  • Coordinate measuring machine software
  • Microsoft Office software
  • Inspection marking systems
  • Cybermetrics GAGETrak
  • Llama (Meta)
  • Medical condition coding software
  • Autodesk AutoCAD
  • Sight Machine AI
  • Mastercam computer-aided design and manufacturing software
  • Computer-aided inspection software
  • Minitab
  • Verisurf Metrology
  • Apache Pig
  • Cognex Vision AI
  • Data entry software
  • IBM Lotus Notes
  • DeepSeek
  • Tolerance analysis software
  • Microsoft Outlook
  • Dassault Systemes CATIA
  • Microsoft PowerPoint
  • Atlassian JIRA
  • Database software
  • Microsoft SharePoint
  • R
  • Depth gauges
  • Micrometers
  • Personal computers
  • Ductility testers
  • Shock testers
  • Calipers
  • Multimeters
  • Pi tapes
  • Thread gauges
  • Strain gauges
  • Continuity testers
  • Pulse generators
  • Compression testers
  • Manufacturing defect analyzers MDA
  • Plotters
  • Hydraulic pumps
  • Resistance meters
  • Signal generators
  • Measuring microscopes
  • Digital voltmeters DVM
  • Laser thickness gauges
  • Forklifts
  • Gloss meters
  • Moisture meters
  • Shear testers
  • Impact toughness testers
  • Plug gauges
  • Digital resistance meters
  • Pin gauges
  • Logic test systems
  • Digital resistance thermometers
  • Verisurf CMM Master
  • Frequency meters
  • Environmental chambers
  • Return loss calibrator RLC passive component testers
  • Tensile testers
  • Hydraulic lifts
  • Verisurf Master3DGage
  • Resistivity meters
  • Fatigue testers
  • Optical gauges
  • Eddy current flaw detectors
  • Beta gauges
  • Metallurgical microscopes
  • Utrasonic flaw detectors
  • Force transducers
  • Industrial bench scales
  • Frequency counters
  • Function generators
  • Viscometers
  • In-circuit testers
  • Null-balance acceleration instruments
  • Coordinate measuring machines CMM
  • Magnetic particle flaw detectors
  • Accelerometers
  • Height gauges
  • Penetrant flaw detectors
  • Verisurf 3Dgage
  • Hipot testers
  • Laser shearography flaw detectors
  • Magnetic induction acceleration instruments
  • Sampling oscilloscopes
  • Piezoelectric acceleration instruments
  • Creep and stress relaxation testers
  • Overhead cranes
  • Ammeters
  • Impact hammers
  • Conductivity meters
  • Printed circuit board PCB testers
  • Direct current DC power testers
  • Linear or mixed signal equipment
  • Capacitive acceleration instruments
  • Radiographic flaw detectors
  • Bubble leak testers
  • Hardness testers
  • Sorting machines
  • Power meters
  • Mass flow leak testers
  • Bit error rate testers BERT
  • Resonance acceleration instruments
  • Digital multimeters
  • Calorimetric leak testers
  • Holographic interferometers
  • Backplane testers
  • Optical comparators
  • Color spectrometers
  • Vibration and shaker systems
  • Eddy current probes

Alternative Job Titles