Automating assembly: step-by-step to increased efficiency and reduced costs

Estimated reading time: 8 minutes

TL;DR:

• Automated assembly speeds up production and ensures consistent quality
• Good planning and selection of appropriate systems is the key to success
• Integration with ERP/MES enables real-time monitoring
• High initial investment pays for itself quickly with larger production volumes
• Appropriate staff training enhances the benefits of implementation

Table of contents

• Introduction
• What is assembly automation?
  • Benefits of assembly automation
  • Where is automation most commonly used in assembly?
• How do you prepare your company to implement assembly automation?
  • 1. Analysis of current process and identification of needs
  • 2. choosing the right type of automation
  • 3. choice of partner and appropriate equipment
  • 4 Design and validation testing
  • 5. Staff training and line commissioning
• How to integrate assembly automation with other systems?
  • Integration with ERP/MES systems
  • Integration with vision and AI systems
• Key aspects of ROI in assembly automation
  • Reducing labour costs and errors
  • Reducing production time
  • Increasing production flexibility
  • Support for ROI calculation
• Examples of assembly automation solutions in practice
  • Robotisation of small parts assembly
  • Assembly line with palletising and packaging robots
  • The use of cobots in automotive parts assembly
• The most common challenges in implementing assembly automation
  • High initial investment
  • Lack of qualified personnel
  • Integration into existing systems
  • Organisational resistance
• Practical implementation tips
• Summary of key information
• Conclusions and recommendations
• Summary
• FAQ

Introduction

Assembly automation is an increasingly common theme in modern production facilities. The growing demand for fast and precise order fulfilment, as well as pressures related to labour costs and maintaining quality, mean that businesses are looking for solutions to increase their competitiveness. Therefore, in this article, we will take a look at how assembly automation can affect the development of your business, why it is so important and how to implement it in your industrial processes step by step. You will also learn what technological solutions will help integrate automation systems into existing production lines and what to look out for when planning your investment.

Who is this article for?
- For owners and managers of manufacturing companies looking for ways to reduce costs.
- For engineers and automation specialists who want to gain a better understanding of the technology and tools involved in robotic assembly.
- For those considering the first implementation of automation in an industrial plant.

After reading, you will learn:
- What are the advantages of assembly automation and why should you be interested in it.
- What the process of implementing robotic assembly looks like in practice.
- What elements to look for when planning cost-intensive automation investments.
- What tools and solutions to look for in order to achieve an optimal return on investment (ROI).

We look forward to reading!

What is assembly automation?

Assembly automation involves the use of machines, robots and specialised control systems to perform tasks that were traditionally performed by humans. This allows the assembly process to proceed faster and the quality of the final product to become more repeatable.

Benefits of assembly automation

1. Increased productivity - robots and machines can run continuously, reducing downtime and shortening the production cycle.
2. Precision and repeatability - automated assembly stations eliminate errors related to the human factor.
3. Lower labour costs - Investing in robots or automation systems can save money in the long term, especially with high production volumes.
4. Scalable - when demand for specific products increases, automated lines can easily increase production capacity.
5. Better working conditions - relieving workers of monotonous and repetitive tasks improves ergonomics and occupational safety.

Where is automation most commonly used in assembly?

• Automotive industry - assembly lines with welding robots and workpiece handling manipulators.
• Electronics industry - precision assembly of integrated circuits, soldering of electronic components.
• Food industry - packaging, product stacking and labelling.
• Manufacture of machinery and equipment - assembly of structural components with a high degree of joint accuracy.

How do you prepare your company to implement assembly automation?

The process of introducing assembly automation in a company is a complex task that requires adequate preparation and analysis. The following are the most important stages of implementation.

1. Analysis of current process and identification of needs

The first step is a sound analysis of the current production system. It is worth forming a working team of representatives from different departments (e.g. production, logistics, maintenance) to assess:

• Where is the process most time-consuming or unreliable?
• Which stages in the assembly cycle generate the most complaints or lack stability in quality?
• What are the labour costs and is there potential to increase productivity?

2. choosing the right type of automation

Not all automation has to involve complex robots or manipulators. Sometimes semi-automatic solutions that support the operator's handling are sufficient. On the other hand, in the case of high volumes and repetitive tasks, full robotisation of the workstation is definitely preferable.

Examples of the types of automation used in assembly:

• Semi-automatic assembly lines with minimal human input.
• Fully robotic assembly lines (6-axis robots, SCARA robots, cobots).
• Workstations with vision systems for quality control and component positioning.

3. choice of partner and appropriate equipment

Implementing automation requires the support of an experienced integrator and technology solutions provider. Michale Automatics is a company that has specialised in the construction of machines and production lines and industrial automation for years. As an official distributor of
SIASUN robots
we offer a wide range of solutions for robotic assembly in various industries.

Important aspects when choosing a partner:

• Experience of projects of a similar nature.
• Assistance in the selection of suitable robots and peripherals (e.g. force sensors, grippers).
• Capable of comprehensive turnkey implementation - from design to integration to staff training.

4 Design and validation testing

A 3D model and simulations of the robotic workstations are created before production or changes are made to an existing line. It is also checked that the robot setup parameters (e.g. speed, torque, range of motion) are suitable for the application.

5. Staff training and line commissioning

Even the best solution will not deliver the expected results without properly prepared employees. Operator training and maintenance courses help to minimise the risk of downtime or costly breakdowns.

How to integrate assembly automation with other systems?

Today's companies are increasingly operating on advanced IT platforms such as ERP (Enterprise Resource Planning) or MES (Manufacturing Execution System). Their integration with assembly automation makes it possible to track the process in real time, monitor key indicators (KPIs) and react quickly to any deviations.

Integration with ERP/MES systems

By combining assembly automation with ERP/MES software, you can:

• Monitor the status of the production line in real time.
• Collect data on production efficiency and quality.
• Improve resource planning according to the availability of raw materials.
• Automatically generate orders for components when their stock level reaches a programmed threshold.

Integration with vision and AI systems

• Quality control - CCTV cameras check that all components are fitted correctly.
• Workpiece position monitoring - The vision system allows robots to accurately detect and pick up parts with irregular shapes.
• Machine learning - The use of artificial intelligence can help analyse production data and detect anomalies early.

Key aspects of ROI in assembly automation

Implementing automation is an investment that generally involves a significant financial outlay. More often than not, however, the returns on such investments (ROI) are clear, especially in companies with high production volumes. Here are the key elements that determine the profitability of automation:

Reducing labour costs and errors

Reducing the number of workers in highly repetitive assembly tasks and improving quality are the two main drivers of ROI. The costs of errors and complaints can be much lower when a robot takes over the most critical points in the process.

Reducing production time

Robotised assembly stations speed up order processing, opening up the possibility of handling more orders without the need to expand the infrastructure.

Increasing production flexibility

Robots can be easily reprogrammed for new tasks or products. This makes it easier to respond to dynamic market changes.

Support for ROI calculation

It is worth considering the use of specialised tools for calculating cost-effectiveness, such as
ROI calculator
in the robotisation of welding processes - similar counting principles can be transferred to other areas (e.g. assembly).

Examples of assembly automation solutions in practice

Assembly automation can take many forms, depending on the nature of production and the needs of the company.

Robotisation of small parts assembly

It is ideal for the electronics industry and precision applications (e.g. chip assembly). Thanks to the robotic arms equipped with highly sensitive grippers, operators do not have to perform the same operations repeatedly.

Assembly line with palletising and packaging robots

In many production facilities, a key stage of assembly is also placing the finished product in packaging and preparing it for shipping. Palletising robots work well when we are talking about large sizes and mass quantities of products.
More information on
robotisation of packaging
can be found in the dedicated offer.

The use of cobots in automotive parts assembly

Cobots (collaborative robots) are increasingly popular machines that work side-by-side with humans. They prove themselves particularly useful where a high degree of flexibility is required and where the entire process has not been modularly designed exclusively for full robotisation.

The most common challenges in implementing assembly automation

Despite the numerous benefits, the automation of assembly is often preceded by overcoming certain barriers and difficulties.

High initial investment

A large capital expenditure (CapEx) is sometimes perceived as a significant risk by management and business owners. The solution may be to implement in stages or to obtain funding from external sources (e.g. leasing, EU grants).

Lack of qualified personnel

Not all employees have the knowledge to program robots or operate advanced mechatronic structures. That is why training and post-implementation support are so important.

Integration into existing systems

Fitting new machines into the current infrastructure and established processes can be time-consuming. The key is the flexibility and experience of the robot integrator.

Organisational resistance

A change in staffing structure, fear of losing jobs or the need for changes in employees' daily routines can cause resistance. It is worth ensuring transparent communication and justifying the need for automation, taking into account the benefits for staff (e.g. improved safety and ergonomics).

Practical implementation tips

If you are planning to introduce assembly automation in your plant, consider the following recommendations:

• Start with the most sensitive processes: Select those areas where you incur the most costs or have the most downtime.
• Opt for modularity: If you are unsure of the scale of the investment, implement the automation in stages and flexibly scale according to the effects.
• Consult the project with experts: The specialists at Michale Automatics will help you select solutions to suit your production profile. Take a look also at
  an offer covering robotisation in its broadest sense
  .
• Use the tools available: Simulations, production cycle planning software, ROI calculators - all will help to reduce risk.
• Plan comprehensive training: Plan time in the implementation schedule for learning how to operate, maintain and diagnose faults.
• Monitor performance and update targets: Immediately after implementation, measure key indicators (e.g. cycle time, unit costs, number of defects) and make improvements.

Summary of key information

• Assembly automation is driving productivity gains and cost reductions in companies across a range of industries, including automotive, electronics and food.
• Before implementation, it is worth conducting a sound analysis of current processes and considering which areas are most loss-making.
• It is important to choose a partner that guarantees comprehensive support, from design to integration to training.
• Potential challenges include the high cost of investment, the need to adapt staff and fear of organisational resistance.
• The key to success is a good plan, the right analytical tools and a long-term view of evaluating the return on investment.

Conclusions and recommendations

• Identify business objectives and carry out an extended analysis before deciding on the shape of the automation.
• Pay attention to the flexibility of robots and the possibility of modifying the line in the future.
• Long-term return on assembly automation is often higher than in other areas of production, especially when the company is facing staff shortages or quality instability.
• Don't forget regular service and maintenance:
  servicing and maintenance of stations
  help avoid costly downtime.

Summary

Assembly automation in industry is one of the most effective ways to improve competitiveness and production quality. Modern robotic technologies, integration with ERP/MES systems and properly planned implementation processes mean that companies can not only significantly increase productivity, but also improve working conditions and minimise unit costs.

If you are considering implementing these innovations in your plant, start by identifying the most problematic areas. Then develop an implementation plan and consult with an experienced robotics and industrial automation partner. Michale Automation offers comprehensive support in the design and construction of production lines and, through its partnership with SIASUN, can provide solutions best suited to your industry.

We encourage:

• Analyse robotic integration service offerings within the broader industrial automation field.
• Self-calculate the profitability of a potential investment using available ROI calculators.
• Contact us if you need an individual consultation or would like to learn about real-life implementation examples.

Thank you for reading the article - we hope you have found practical tips and inspiration to further develop your manufacturing facility. If you are looking for further material on robotisation, we also invite you to browse our other blog articles and visit our services page:
OUR OFFER.

Good luck with your assembly automation!

FAQ

How long does it take to implement assembly automation?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simple solutions to several months for extensive projects and large integrations.

Does automation mean redundancies?
Usually no. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies use this to retrain and develop their team professionally.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to turn to robotisation. Costs are coming down and flexible solutions can deliver a favourable return on investment even for smaller operations.