Automated production lines: how to integrate them with ERP and MES systems

Estimated reading time: 7 minutes

TL;DR

• Automation makes it possible to significantly increase the efficiency and quality of production.
• Integration with ERP and MES systems ensures better data flow and resource optimisation.
• Cloud computing makes it easy to scale and access data on the fly.
• Implementing automation requires an audit, appropriate architecture and sound staff training.
• The support of experienced experts, like the Michale Automatics team, makes the whole process quicker and easier.

Table of contents

• Introduction
• Automated production lines - why develop them
• The role of ERP and MES systems in production management
• Trends in the integration of automated production lines with ERP and MES
• Step by step integration - practical tips
• Case studies and examples
• Why choose Michale Automation
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Automated production lines have been a cornerstone of modern industrial plants for many years. In times of intense market changes and increasing competition, their role is becoming even more important. By fully or partially automating production, it is possible not only to increase the volume of products manufactured, but also to improve product quality and process stability. However, to fully exploit the potential of automation, integration with ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) systems becomes crucial.

In the following article, we will outline the key benefits of combining automated production lines with ERP and MES systems, discuss the trends associated with this type of integration and explain how to carry out the entire process step by step. You will also learn what to look for to ensure that your investment pays off quickly and how Michale Automatika can help you with this.

Main content

Automated production lines - why develop them

What are automated production lines

In the most general terms, automated production lines are systems of machines and equipment that perform specific activities in a sequential manner, with minimal human intervention. Today's automated workstations often include industrial robots, conveyors or inspection stations based on vision systems. Their main purpose is to speed up production, improve repeatability and reduce errors due to the human factor.

Key benefits of automation

• Increasing productivity - The implementation of automation allows processes to be speeded up, often by as much as 30-40% compared to working solely manually.
• Improved quality - machines perform tasks with a high degree of repeatability, which significantly reduces the number of failures.
• Reduced labour costs - In a few years' time, the investment in robots and automated lines can result in significant savings, especially for high production volumes.
• Support in labour shortages - In situations where skilled staff are hard to come by, automation becomes a key solution.

The role of ERP and MES systems in production management

Characteristics of ERP systems

ERP (Enterprise Resource Planning) systems are IT solutions that allow for the comprehensive management of a company's resources. They include, among others, financial, sales, warehouse or human resources modules. Thanks to ERP, it is possible to:

• Real-time inventory tracking,
• Planning of materials needed for production,
• Order management and product distribution.

The role of ERP in the integration of automated production lines is to enable a seamless flow of data between the production area and other company departments (e.g. logistics, accounting).

MES systems - what they do

MES stands for Manufacturing Execution System. It is a tool that monitors and controls production processes directly on the line. The main function of MES is:

• Collection of data from machinery and equipment,
• Real-time tracking of production progress,
• Analysis of the efficiency and effectiveness of operations,
• Reporting of errors and quality discrepancies.

In practice, integration with an MES system allows production to be managed dynamically and to react more quickly to possible deviations such as machine downtimes or component shortages.

Trends in the integration of automated production lines with ERP and MES

Cloud computing and production support

Increasingly, companies are choosing to use cloud computing to collect and process production data. This solution provides:

• Scalability - The data storage area can be increased or decreased as required,
• Availability - information is available online from various locations and devices,
• Reduction of infrastructure costs - there is no need to maintain extensive server rooms on site.

In the context of ERP and MES systems, the cloud enables the rapid exchange of data between multiple sites of one company or between external suppliers and subcontractors.

Use of AI and Big Data

Analytics platforms, based on artificial intelligence (AI), are able to predict machine downtime based on historical data or indicate when maintenance or part replacement is required. With this:

• Costs associated with unplanned failures are reduced,
• Increases the lifespan of equipment,
• Better planning of the production schedule is possible.

Large data sets (Big Data) go from the machines to the MES system, which updates the information in the ERP in real time, facilitating resource planning and order management.

Step by step integration - practical tips

Audit of needs and existing infrastructure

In the first instance, it is useful to analyse the current situation in the plant in detail:

• What equipment and lines are already automated?
• Does the company have an ERP or MES system in place?
• What upgrade opportunities are available in the budget and timetable?

At this stage, it can be helpful to consult Michale Automation, which has been supporting companies in automation and the construction of production lines for years (see more: Robotisation at Michal Automatics).

Connection architecture and component selection

Once the needs have been identified, it is time to plan the network infrastructure and select the individual components:

• Industrial robots or cobots if human-machine collaboration is needed,
• Control systems compatible with the target MES system,
• Interfaces for data transfer to the ERP (e.g. communication modules or OPC UA servers).

It should also be determined which modules in the ERP and MES systems will be used and which reports will be generated. When designing the architecture, it is crucial to consider the potential for future expansion of the plant.

Testing, implementation and training

Once we have the design in place, it is worth performing initial module tests. If everything goes well, you can start implementing the changes on the lines. The last important step is thorough training of the employees who will be working with the new systems. As a rule, this includes:

• Operation of machines - so that those employed are able to supervise automatic stations,
• Data management in ERP and MES,
• Rapid fault diagnosis and basic maintenance.

The professional approach to training results in a smooth start-up and less downtime.

Case studies and examples

Optimisation of SIASUN robots - case study

Among others, industrial robots of the SIASUN brand, whose official distributor in Poland is Michale Automatyka, stand out on the market. The combination of advanced robots with an extensive MES system makes it possible to monitor the operating status of all stations in real time and remotely manage production parameters.

An example is the line in which the SIASUN SR25A-12-2-01 robot (for a detailed description, see here: SIASUN Robot SR25A-12-2-01) is responsible for palletising heavy components. Integration with the MES system allows the AGV to be called up automatically when a pallet is full. Information about the pending order is immediately sent to the ERP system, which records the task and updates the stock.

Maintenance and service in the light of integration

An important aspect with automated lines is the maintenance and efficient servicing of machines. Implementing appropriate notifications and service plans in the ERP system helps to plan downtime and ensure production continuity. For example:

• The system can generate automatic messages about upcoming equipment maintenance,
• Information on the parts needed can be automatically exported to the purchasing department.

The Michale Automation team also offers service and maintenance services to increase the life of stations and reduce the cost of breakdowns (check: Service and maintenance stands).

Why choose Michale Automation

Comprehensive integration support

Michale Automation specialises in the design, construction and implementation of automated production lines. We are also a certified distributor of SIASUN robots, so we offer complete solutions - from selecting the right robot, to integration with ERP and MES systems, to testing and team training.

In doing so, we support clients at every stage of the project, providing assistance in the following areas:

• Design of line layouts,
• Programming of machinery and equipment,
• Adapting processes to Lean Manufacturing,
• Integration with vision systems that enhance precision and quality control,
• After-sales, warranty and post-warranty service.

Individual approach and adaptation to needs

Michale Automation's engineering team adapts production lines to the specific requirements of the industry and the characteristics of the customer's processes. For example, for companies involved in high-volume production, robotisation of repetitive production often works well (you can read more about this at: Robotisation of repetitive production).

Our solutions can be flexibly modified as your business grows. If, over time, it becomes apparent that more capacity is required, there is no need to invest in completely new lines, but rather to expand existing systems.

Practical conclusions and recommendations

• Start with a comprehensive audit. Find out which areas of production are most in need of automation or modernisation.
• Remember the internal IT infrastructure. To integrate automated lines with ERP and MES systems, you need stable network connections and appropriate interfaces.
• Plan an adequate budget for implementation and training. People are a key element in the success of automation - even the best line can be blocked by a lack of operator competence.
• Look for flexible solutions. Even if today you only need welding or assembly processes, tomorrow you may want to automate the packaging or stacking of products on pallets.
• Don't forget about service and maintenance. Well-planned maintenance is a guarantee of production continuity and lower costs in the long term.

Summary

The integration of automated production lines with ERP and MES systems is the key to efficient and competitive production today. Today's market demands not only a price advantage, but also high quality and the ability to adapt quickly to change. An integrated production line, supported by advanced IT tools, becomes flexible and provides an opportunity:

• better management of resources,
• responding more quickly to market needs,
• reducing errors and downtime,
• better product quality control.

If you are considering upgrading your plant with automated production lines, do not hesitate to seek expert advice. At Michale Automation, we have a wealth of experience in building machines and production lines and integrating robots into existing systems. Contact us to find out how we can work together to develop a design tailored to your needs and take you safely through the steps from analysis to installation and servicing.

We also encourage you to take a look at the other articles and resources available on our website, and if you have questions, please leave a comment or contact us directly. We'd love to help you develop your business so that modern technology can even better support your daily production tasks.

FAQ

How long does it take to implement automation in a company?
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?
Nowadays, the costs of this type of investment are falling and flexible solutions mean that smaller companies can also reap real benefits from automation. It all depends on the specifics of the processes and the scale of production.