5 myths about the robotisation of manufacturing broken down into facts and figures

TL;DR:

• Robotisation is not just for large companies - SMEs are also implementing robots due to lower costs and the availability of support.
• The cost of a SIASUN robot starts at £95,000; return on investment: 1.5-3 years.
• Industries most frequently robotised: food, packaging, metal, plastics, chemical, electronics.
• Robotisation does not eliminate jobs, but supports staff in case of shortages and redeploys workers to more advanced tasks.
• Deployment usually takes several weeks; operators learn how to operate in a few days.
• Robots improve safety, quality and repeatability, minimise errors and costs.
• The robotisation market in Poland is growing by around 9% per year.

Does robotisation really mean expensive, lengthy projects only for the biggest players? In practice, we most often hear the same five myths that hinder companies' growth and block automation implementations. The following article shows facts and figures. We break down each of the circulating opinions, based on concrete data, customer experiences and examples from many industries. Find out what robotisation really delivers!

Myth 1: "Robots are only for big companies".

The belief that the robotisation of production is the domain of only the largest plants has dominated the landscape of Polish industry for years. Is automation only for large production plants? To the best of our knowledge and experience - no. More and more small and medium-sized enterprises (SMEs) are recognising not only the availability, but also the tangible benefits of implementing robots. Modern technology and competitive prices mean that robotisation is no longer a luxury and is becoming a viable development tool for smaller companies as well. This is evidenced by the numerous implementations taking place in various sectors, where the flexibility of the solutions makes it possible to optimise processes even with limited resources.

The reality of investment in the SME sector

In what situations do robots work well for small businesses? Experience shows that the decision to robotise is not only driven by the needs of large-scale production, but increasingly by the desire to increase repeatability, quality stability and reduce losses due to errors. In the SME sector, simplicity of implementation and quick return on investment are becoming paramount. Examples from the market show that an investment in a robot - e.g. for packaging, palletising or machine operation - makes it possible to shorten the production cycle by as much as 30%, and the payback time is often between 1.5 and 3 years. It is worth noting that the choice of dedicated solutions for smaller production lines allows the investment to be spread over time, reducing financial risk. The availability of support programmes and the possibility of leasing or subsidies also make the investment decision easier. Detailed information on the solutions available for SMEs can be found on our website under the tab robotisation.

Which industries are most rapidly implementing robotisation?

In Poland and other Central European countries, SMEs from the automotive, food, packaging, plastics and metal processing most often turn to automation. In these sectors, the repetitive nature of processes and quality requirements mean that even a single station equipped with a SIASUN robot at the production line is able to deliver significant savings and productivity improvements. An example: a food company employing 40 people implemented a packaging robot, increasing its order fulfilment rate by 25% and reducing complaints by half. In the metal sector, the robotisation of welding or grinding processes eliminates operator fatigue while ensuring the repeatability of each workpiece. It is in these industries that the fastest financial and quality effects are seen following the implementation of robots.

Flexibility of robotic production workstations

The biggest advantage of modern robotic workstations is their scalability - the system can be expanded as the company grows and production needs increase. Robotised workstations are designed so that it is easy to change programmes, handle different products and even move them between lines. This means that the barrier to entry into technology is no longer as high as it once was, and implementing a robot does not require a complete overhaul of production. In practice, even a plant with a workforce of a dozen can deploy a robot for machine operation or quality control and start to benefit from advantages that were reserved only for large companies a decade ago. Robotisation today offers the opportunity to dynamically adapt to market changes without incurring high fixed costs and without losing flexibility of operation.

Myth 2: "It's too expensive"

There is a recurring perception that industrial robotics is an unaffordable expense. In practice, the implementation of robotisation is becoming more and more accessible, and when you rely on proven solutions such as SIASU robots, the investment starts to pay off more quickly. It is worth weighing up the costs against the real benefits, such as reducing errors or saving human labour. In recent years, more and more factories in Poland have chosen flexible financing solutions and taken advantage of support programmes to make cost-effectiveness a reality and not just a dream.

How much does it cost to implement manufacturing robots?

The purchase price of a single robotic station depends on the complexity of the tasks, the customer's requirements and the level of integration with other systems. For example, the price of SIASUN robots with an infeed of 2010mm starts at £95,000.

The cost of implementation is the sum of several elements: the price of the robot itself, the integration into the existing line, the cost of training and any infrastructure redesign. What is often overlooked are the savings resulting from automation - for example, a significant reduction in the fixed costs associated with employing operators in repetitive positions. In practice, the payback time on investment in industrial robots today averages between 1.5 and 2 years. This result is confirmed by companies that have invested in robotisation using solutions such as SIASUN SR25A and dedicated integration systems.

Savings from automation

The biggest financial benefits of robotisation are the reduction in the proportion of human labour costs and the costs associated with production errors. Robotisation reduces downtime, waste and rework, which can generate significant financial losses on an annual basis. Robotic machines operate continuously with high repeatability, which translates into stable production quality.

The impact of robotisation on companies' financial performance

Robotisation is having a tangible financial effect not only on large corporations, but also on medium-sized and smaller manufacturing companies facing pressure on costs and quality improvements. In many cases, an increase in operating margins can be seen after only a few months due to a reduction in labour costs and waste.

When deciding to invest in robotisation, companies also have access to support tools, such as funding from national and EU programmes, which can cover part of the expenses - another argument for not being afraid of initial costs. Analysing real data, it is clear that robotisation is not only profitable for the largest factories. Any factory can optimise costs, improve quality and increase production flexibility, as long as it chooses the right solutions and partners.

Myth 3: "Robots eliminate jobs".

Many managers and business owners wonder whether the introduction of a robot on a production line means that mass redundancies are necessary. The topic of automation raises concerns that robots are taking jobs away from people, which can lead to unrest among workers and managers. Therefore, it is worth looking at the concrete data and the changes that are taking place in the labour market with the development of robotisation to separate the facts from the myths.

Robotisation as an answer to labour shortages

Does the introduction of the robot result in mass redundancies? According to data from the industrial sector, the answer is no. In Poland, many manufacturing plants are already facing a shortage of skilled workers, especially in regions with a booming economy. In such a situation, an investment in robotic workstations means filling staff shortages rather than cutting jobs. The use of robots makes it possible to maintain expected production levels even when recruitment of new staff is difficult. In a survey of the European market, as many as 72% companies implementing robotisation indicated that their main motivation was the need to keep production flowing with increasing difficulty in hiring people. The data from the factories working with our company confirm this trend - robotisation does not lead to mass redundancies, but makes better use of the potential of the available teams.

Freeing professionals from monotonous tasks

The occupations most susceptible to automation are those based on repetitive, monotonous tasks - for example, packaging, sorting or simple assembly operations. However, the implementation of robots does not mean the elimination of jobs, but a change in their nature. Employees who previously performed repetitive tasks get the chance to develop in new areas such as robot programming, operation and maintenance of automated workstations or quality control. Companies that invest in new technologies are increasingly creating positions that require higher technical and analytical skills. At the same time, there is a demand for maintenance specialists and process engineers, as well as trainers to prepare the workforce for working with modern machinery. It is the adaptation of employees to new challenges that is proving crucial to the success of the digital transformation.

Improving occupational safety through automation

How is the role of humans in automated production changing and what competences will be needed in the future? In companies using robotisation, workers are increasingly less likely to perform dangerous, 'dirty' or highly strenuous tasks. Robotised workstations are taking over tasks involving heavy lifting, working at high temperatures or contact with chemicals. This improves occupational safety and decreases the number of accidents. The human role is shifting towards supervision, analysis of production data and process optimisation. Employees need to develop technical skills - operating control panels, analysing sensor data or the basics of robot programming. Soft skills are also becoming increasingly important: team communication, the ability to learn new technologies and flexibility in action. The transformation of production does not mean the end of work for people, but its evolution - with an emphasis on development and upskilling.

Myth 4: "Implementation is a long and complicated process".

Many production managers still think that implementing robots is a process that takes many months and requires complexity at every stage. In our practice, implementations go more smoothly than people who have not previously had contact with automation assume. The most common barriers to implementing robotisation are the fear of difficult integration with the infrastructure already in place, the inexperience of the team and the uncertainty associated with employee adaptation. However, barriers to implementing robots are most often a lack of knowledge about the possibilities of automation, reluctance to change among staff and confusion about the stages of the process. Our observations show that with the right support and clear communication, most of these obstacles can be overcome at the investment planning stage.

Individual approach to job design

Each plant has its own specificities, so the design of a robotic workstation starts with a thorough analysis of production needs and an evaluation of available solutions. Engineers at Michale collect detailed data to match the workstation with the processes to be automated. This avoids integration problems-the robot is not 'pasted' into the line by force, but becomes a natural part of it. The implemented robotic systems can interact with different machines, sensors or software, which significantly reduces implementation time. The project team anticipates potential collisions or downtimes and eliminates them already at the digital simulation stage, before the station hits the production floor.

Intuitive operation and technical support

Is it difficult to integrate robots? According to our implementations to date - not if modern tools and dedicated support are used. The workstations are designed with ease of use in mind, even for operators without IT training. Graphical interfaces and clear control panels allow the workstation to be managed without programming from scratch. Michale's support team is available at every stage of implementation and afterwards. If needed, specialists help solve ongoing problems remotely or on site, and software updates can be delivered automatically.

Training and adaptation in companies with different levels of competence

How long does the implementation process take and can any employee learn to operate robots? To answer precisely: a typical deployment of a robotic workstation in a manufacturing company takes several to several weeks, and most operators master basic operation after just a few days of training. The process of deployment of operators begins with practical training on actual workstations - instructors from our company conduct both group and individual classes, adapted to the knowledge level of the team. Adaptation goes quickly, as the robots are equipped with guided learning functions or ready-made task libraries. A well-planned implementation minimises the need for downtime and allows the existing production team to take over the new responsibilities smoothly. The consultancy support and experience of our implementation teams means that even companies with no previous exposure to robotisation quickly achieve the full effectiveness of their new positions.

Myth 5: "Automation is reserved for select industries".

There is often a perception that the robotisation of manufacturing only applies to industries such as automotive or electronics. In practice, however, it is observed that robotic solutions are becoming available and cost-effective for an increasingly wide range of companies, including small and medium-sized enterprises in various sectors. In Poland, there is a growing number of implementations that show how flexible and scalable automation can be - regardless of the size of the plant or industry.

Flexibility of process-specific solutions

Is automation exclusively the domain of the automotive industry? Definitely not. Today, automation is being implemented in food production, metal processing, the chemical industry and the electronics sector. The key lies in the flexibility of industrial robots, which can be configured for specific tasks, production lines and environmental conditions. These robots work in precision assembly as well as in harsh processing or packaging environments.

Customising workstations to meet individual customer needs is standard. In our work, we meet companies that expect not only standard solutions, but also advanced functions such as product quality recognition, personalisation of packaging or handling of non-standard material formats. Scalability allows systems to expand as production grows, which translates into a competitive advantage and a rapid response to changing market needs.

From an automation perspective, every industry can benefit from the implementation of robotic solutions - from cost reductions to quality improvements to increased workplace safety. Proper integration increases process repeatability and eliminates errors that generate losses and complaints. Such effects are appreciated by companies in the food, steel or chemical industries alike.

In which industries do robots perform best?

An analysis of deployments in Poland confirms that automation knows no industry boundaries. In the food sector, robots support packaging, sorting and palletising processes, reducing lead times and the proportion of human error. Steel plants are investing in robots for welding, cutting and painting processes - where human labour carries a high health risk.

The electronics sector uses robots for component assembly, testing and quality verification, where repeatability and high precision are important. In the chemical industry, where sterility and safety are required, robots take over the tasks of dosing, weighing and packaging hazardous substances.

Cases of robot deployments confirm that even small-scale companies are able to achieve a rapid return on investment - for example by reducing labour costs and production losses. Projects in which robots perform tasks in several different production departments, supporting the company's flexibility in a changing market environment, are also becoming increasingly common.

Industries considered 'traditional' until recently are increasingly willing to take advantage of the opportunities offered by robotisation. Tailor-made solutions, whether for batch production or short runs, show how wide the potential for automation is in Polish companies.

Summary: Facts and trends in robotisation in Poland

Robotisation in Poland is now not a trend, but a clear change that is driving industry and production. More and more factories are choosing to implement robots not only because of market pressures, but also for the sake of stability, savings and competitive advantage. On a day-to-day basis, we can see how automated production lines translate into tangible benefits: shorter lead times, better repeatability of processes and greater human safety. Global trends that for a long time seemed distant from Polish realities are today part of the digital transformation of most modern plants.

How fast is the robotisation market growing in Poland?

Market data shows that the growth rate is currently around 9% per year, which gives Poland a leading position in this part of Europe in terms of dynamics. According to statistics on the development of robotisation in Poland and Europe, not only is the number of installed robots increasing, but also the percentage of companies investing in modern workstations. This is due to the growing awareness that automation is no longer an option, but a necessity for companies competing in the international market. Plants that invest in robots gain flexibility and resilience to change, allowing them to respond more quickly to market demands.

Benefits of individually designed workstations

Experience shows that individually designed workstations maximise the potential of each production line. Personalisation of the workstations makes each operation run faster and with fewer errors. Robots offer the possibility of easy adaptation to new tasks, which is crucial in changing production. More and more companies are opting for bespoke solutions, allowing new technology to be implemented without disrupting existing processes. This approach translates into efficiency gains of up to several tens of per cent in the short time the new system is in operation.

How does robotisation affect the quality and safety of work?

Robotisation eliminates human error and maintains consistent high product quality. In practice, it can be seen that the implementation of robots reduces complaints and downtime on the production line. Cost optimisation follows naturally: automation allows labour costs to be reduced without the need for redundancies, which is important for companies facing a shortage of skilled workers. Robots take over repetitive and hazardous tasks, protecting people from injury and making the factory more comfortable. The competitive advantage of companies using robotisation comes not only from lower production costs, but also from better quality and faster turnaround times.

The robotisation market in Poland will continue to grow, and companies that choose digital transformation will gain a real advantage over other industry players.

Summary

Myths about automation do not hold true in real production. Our customers are proving that automation works in both small and large plants. Robotic workstations improve quality, save labour time and increase safety at every stage. Investments pay off faster than many expect, and support is available for any factory. Automation is not just for one sector - every factory can scale and adapt. Automation means clear benefits, not risks. In our view, now is the best time to act.