How to integrate assembly systems into an existing production line - step by step

Estimated reading time: approx. 7 minutes

TL;DR:

• Assembly systems significantly speed up and standardise the production process.
• Proper analysis and planning is the key to successful implementation.
• Robots and cobots can increase efficiency and improve ergonomics.
• Implementation costs pay off quickly with well-chosen solutions.
• Regular maintenance and staff training extend the life of the systems.

Table of contents

• Introduction
• What are mounting systems?
• Why integrate assembly systems?
• Step-by-step integration of assembly systems into an existing line
• Challenges and barriers to the implementation of assembly systems
• Practical application examples for assembly systems
• Guidelines for implementing assembly systems
• Practical conclusions / summary
• Completion
• FAQ

Introduction

Assembly systems are one of the key elements in modern manufacturing. Properly designed and integrated into the production line, they can significantly reduce manufacturing time, reduce operating costs and increase product quality. In an era of intensive automation and increasing market competition, the role of assembly systems is growing every year. In this article, you will learn exactly what assembly systems are, what their step-by-step implementation process looks like and what benefits you can gain by choosing to integrate them into your production line.

After reading the article:

• You will understand the basic principles of assembly systems.
• You will learn how to properly plan and implement an installation system to avoid costly mistakes.
• You will learn practical tips to help you get the most out of automation.

What are mounting systems?

Assembly systems are a set of tools, components, devices and methods that enable the fast, reproducible and accurate joining of individual components in a given production process. Such a system may include:

• Conveyor and conveyor lines.
• Load-bearing structures (e.g. frames, hangers, threaded rods, brackets).
• Pneumatic, electric or manual tools (depending on the degree of automation).
• Specialist planning and control software (MES/ERP).
• Robot modules, cobots (collaborative robots) or vision systems.

These components - combined with a well thought-out design with an emphasis not only on assembly itself, but also on safety and ergonomics - form a complete solution to support the manufacturing process.

Examples of mounting system components

• Hanger US 3 or US 5 with FT-head (used, among other things, for routing and suspending cables or machine parts from the ceiling),
• Threaded rod G 1000 (a popular load-bearing component in various industries),
• Wall-hanging brackets (provide a stable base for mounting additional components).

Although the names of the specific components sometimes vary from supplier to supplier, their task is always similar: to support fast and precise assembly regardless of the size or complexity of the production.

Why integrate assembly systems?

Introducing assembly systems into a production facility is an investment that pays off on many levels. Here are the key benefits of integration:

1. Reducing lead times
   Automation and standardisation of processes translate into higher productivity. As a result, orders can be delivered faster while maintaining or even improving quality.
2. Cost reduction
   A well-designed system reduces the number of assembly errors, which automatically reduces costs associated with complaints and corrections. At the same time, it optimises space utilisation and facilitates work organisation.
3. Improving ergonomics and safety
   Minimising manual operations translates into a reduced workload for employees, which is particularly important in industries where operators spend long hours at assembly stations.
4. Production flexibility
   Integrated assembly systems can be easily modified in the event of increasing market requirements, which cannot be said of fully manual solutions.

Step-by-step integration of assembly systems into an existing line

Analysis and planning

The first step is always to define business and technical objectives. It is necessary to specify what we want to achieve, such as increasing productivity by 20% or reducing production costs by 15%. On this basis, an audit of the existing line is carried out, checking:

• Current assembly solutions (manual, semi-automatic, fully automatic).
• Potential bottlenecks (e.g. material flow too slow).
• Spatial layout of production halls (aisles, places where hangers, bars, transport modules can be installed).
• Staff availability and competence (will the team need additional training?).

It is also at this stage that a decision is made on the extent to which integration is to include, for example, linking robots to a vision system or integration with ERP systems that track production progress and inventory in real time.

Choice of technology and components

Once we know the needs and constraints, we move on to the selection of specific elements. We can opt for:

• Standard hangers and brackets, such as the US 3 hanger, US 5 hanger or AW 15 FT wall-hanger bracket, if our process requires a simple suspension system for transport lines.
• Robots and cobots (e.g. from SIASUN) for advanced assembly applications requiring repeatable precision.
• Fully integrated modules for pneumatic or electrical assembly depending on production characteristics.

It is worth remembering that for more complex configurations, it is useful to consult with specialists from a company specialising in the construction of machines and production lines, such as Michale Automatyka. This will help avoid mistakes at the solution selection stage and reduce implementation time.

Implementation and testing

The next step is the implementation phase, which includes the installation of all physical components and control systems and their configuration. During installation, care should be taken:

• Installation safety (correct fixing of hangers, brackets, threaded rods, etc.).
• Compliance with the design specification (is everything in the right place in the line).
• Machine-to-machine communication (especially important if integrating ERP/MES software).

Once the new system is installed, a series of tests are carried out - both 'dry' and under real conditions. These include verification of the accuracy of the installation, the speed of the new system, as well as its resistance to unforeseen situations (downtime, failures).

Employee training

Even in the most automated process, man remains the key link. Appropriate staff training in the operation of new assembly stations is therefore essential. This generally includes:

• Discussion of health and safety principles in the context of automated lines.
• Practical training in the use of control panels and equipment.
• Tips for solving minor malfunctions and technical problems.

At Michale Automatika, training is usually conducted in the form of practical workshops, allowing operators to master the operation of new equipment much more quickly.

Optimisation and maintenance

The final stage of assembly system integration usually involves what is known as Continuous Improvement Process optimisation. Even the best assembly system requires periodic maintenance and adjustment. It is worth keeping up to date:

• Analyse production data from reporting systems to detect potential downtime and bottlenecks.
• Liaise with the service department, which will take care of the maintenance of the machines and subsystems (you could consider using an offer, such as servicing and maintenance of stations).
• Update software if the line is integrated with IT systems and robots.

Challenges and barriers to the implementation of assembly systems

Initial cost

The implementation of a new assembly system always involves costs, not only for the purchase of machinery or components, but also for the possible expansion of the infrastructure. However, it is worth taking a long-term view of this investment. In most companies, the rate of return (ROI) already appears after 1-2 years, especially if the line is running at high speed.

Failure to adapt solutions to needs

A common mistake is to choose over-engineered solutions (e.g. installing too many robots in a process that does not require as much automation). Selecting the right assembly modules for real needs is crucial to ensure that the financial outlay and business benefits are in the right balance.

Lack of qualified personnel

Assembly systems, especially those that are highly automated, can require specialist knowledge. If a company does not have a maintenance department with experience in robotics or automation, it is worth partnering with an external integrator and scheduling training.

Integration with software

In more advanced plants, today's assembly systems not only 'physically' connect components, but also transmit data to production management systems (ERP/MES). If such a solution is planned, it may be necessary to ensure that communication protocols and data standards are compatible with each other.

Practical application examples for assembly systems

Food industry

In food processing plants, assembly systems are mainly useful for packaging and sorting processes. A common solution is the integration of conveyor belts with robotic modules, responsible for the automatic stacking of products into packaging. If you are interested in robotisation in this area, we recommend the following robotisation of packaging.

Metal and surface treatment industry

For assembly processes involving metal components, stable brackets and threaded rods are ideal for holding heavier components. Many times companies in this sector add welding robots to the process. In this case, assembly systems help to precisely position and hold the parts to be welded. If you are interested in the topic of welding automation, you can see robotisation of welding.

Furniture and white goods industry

In these sectors, preparing components for further assembly and assembling them into finished products plays a major role. With height-adjustable assembly systems for workstations, the workspace can be easily adapted to the dimensions of the components, which contributes to improved ergonomics and reduces potential downtime.

High-volume production in various sectors

In the case of mass production, when a plant performs hundreds or thousands of repetitive operations per day, automated assembly systems can save hundreds of man-hours. To further simplify and speed up these operations, it is worth looking at robotisation of repetitive production.

Guidelines for implementing assembly systems

• Opt for scale and modularity: A sensibly designed assembly system should be expandable as the company grows.
• Work with experts: If you do not have an in-house automation department, consider establishing a longer-term relationship with an external integrator. One such partner in Poland is Michale Automatyka, which deals with the conscious expansion of production lines and the implementation of robotic workstations.
• Remember to test and maintain: Regular maintenance, the replacement of wear and tear components (e.g. bolts, nuts, rods), as well as periodic health and safety tests are the foundations for the long-term performance of assembly systems.
• Involve the team: Before the launch itself, invite key staff for training and presentations. The better they understand the project, the greater the chance of its success.

Practical conclusions / summary

Highlights and recommendations

• Tailor your assembly system to the scale and specifics of your industry. Avoid both under- and over-automation.
• Begin with a thorough analysis of the current process, including key indicators such as cycle time at the assembly station or the number of production errors per month.
• When implementing a new system, make sure you have a training plan in place right away. It is the people who will operate, supervise and maintain it.
• Don't forget about ongoing maintenance and continuous optimisation. Mounting systems will only become an effective tool for the long term if they are properly serviced.

How can you implement these solutions at home?

• Prepare an initial improvement plan and collect figures (e.g. staffing costs, complaint levels, line changeover times).
• Consult with industry experts to discuss the project concept and select the most favourable technological solutions.
• After implementation, remember to carry out regular checks and tests so that the mounting system always remains in top condition.

Completion

Integration of assembly systems is one of the most effective ways to increase competitiveness in the industrial sector. Properly selected and implemented solutions not only reduce production time, but also minimise the risk of breakdowns or complaints. At Michale Automatika, which has been involved in machine building, production line design and the implementation of industrial robots for years, we believe that the intensive development of automation is inevitable - and well-designed assembly systems are one of its foundations.

If you would like to find out more, I encourage you to contact the experts in this field. You can also visit the services - robotisation on our website to see what opportunities full or partial assembly automation opens up for you. Remember that the ever-increasing demands of the market speak for making every process - including assembly - as efficient, safe and scalable as possible.

Thank you for reading the article. We hope that the knowledge contained here will help you to plan and improve your production processes even better. If you have questions or would like to share your experiences, please feel free to comment and share the article. You can also subscribe to our newsletter to keep up to date with the latest trends in automation and robotics. Good luck with the integration of assembly systems!

FAQ

How long does it take to implement assembly systems?
Implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simpler solutions to several months when the project requires advanced integration and extensive testing.

Will automation replace workers in the assembly process?
This is not the goal. Automation most often supports employees by relieving them of monotonous or physically demanding tasks. This allows them to focus on tasks that require supervision, creativity or quality control.

Are assembly systems also viable for smaller companies?
Yes, more and more small and medium-sized enterprises are choosing to introduce automated solutions. With the right components and modular design, it is possible to achieve a favourable return on investment even with smaller production volumes.