Automatic systems - how to successfully integrate different solutions in a modern factory

Estimated reading time: 10 minutes

TL;DR:

• The integration of different automated systems affects data consistency and reduces the response time to deviations.
• Key components include PLCs, industrial robots, SCADA systems and MES/ERP software.
• Implementing integration requires an audit, good communication architecture design and pilot testing.
• AI and vision solutions allow processes to be automated to an even higher level.
• Professional service and maintenance of systems is the key to avoiding downtime and maintaining stable production.

Table of contents

• Introduction
• What are automated systems and why should they be integrated?
• Key elements of automated systems in a manufacturing company
• Practical tips - how to approach the integration of automated systems?
• The most common integration problems and how to deal with them
• Impact of automation integration on costs and efficiency
• Collaboration of robots with AI and vision systems - does it pay off?
• Case study - successful integration in a sample manufacturing company
• Where to look for support in integrating automated systems?
• How to plan the service and maintenance of integrated workstations?
• Summary of benefits and recommendations
• Summary
• FAQ

Introduction

Automatic systems are becoming a cornerstone of modern production. With ever-increasing market expectations and the need to reduce costs, manufacturing companies are increasingly investing in a variety of solutions based on advanced automation and robotisation. However, simply implementing individual machines or robots is not enough to achieve full efficiency. It is crucial to integrate all the elements into one coherent ecosystem - so that data flows smoothly and production lines can run smoothly and efficiently.

In this article, we take a look at what the integration of automated systems is all about, why it is so important, and what benefits can be expected by any manufacturing company that takes a holistic approach to the subject. You will also find out what practical steps are worth taking to ensure that automated systems actually deliver savings, quality indicators increase and process scalability improves.

What are automated systems and why should they be integrated?

Automatic systems are solutions that use controllers (e.g. PLCs), sensors, actuators, industrial robots and appropriate software to carry out repetitive tasks in the production process autonomously. This reduces human error, optimises workflow and increases productivity. Examples of automated systems include assembly lines equipped with welding robots, packaging machines or robotic palletising stations.

Although each automation installation usually operates on its own software and communication protocols, integration here is about 'understanding' the different solutions - so that all the components of the production line exchange data in real time. This avoids a situation where the measurement system does not 'know' what operating parameters have been imposed by the PLC. As a result, downtime is eliminated, safety is increased and full insight into the overall process is gained.

Benefits of comprehensive integration

• High data integrity. Integration eliminates the need to manually transfer information between jobs and systems.
• Faster decision-making. With an up-to-the-minute view of machine parameters, we can react instantly to any deviations in quality.
• Easy to scale. Instead of configuring individual systems separately, the integration allows changes to the entire line or the addition of new devices with a single click.
• Increased security. The integrated automatic system is able to detect conflicts in the data and alert the operator to abnormalities.

Key elements of automated systems in a manufacturing company

A number of automation support solutions can be found in many companies. Here are the most important of these:

PLCs

PLCs (Programmable Logic Controllers) are the 'brains' of industrial automation systems. They receive signals from sensors, process them according to preprogrammed algorithms and then send commands to the actuators (e.g. robots or actuators). PLCs often act as the primary communication point in a factory - hence the seamless connection of controllers to further components (e.g. SCADA systems, MES) is crucial.

Industrial robots and robotic workstations

Industrial robots perform repetitive tasks such as welding, packaging or material handling. Within the company Michale Automation we implement SIASUN robots, which are characterised by high flexibility and ease of integration with other systems, as well as high precision. In robotic production stations (e.g. for painting or grinding), on the other hand, the robot can interact with vision cameras or other machines, helping to automate lines from start to finish.

SCADA systems

SCADA (Supervisory Control and Data Acquisition) systems are high-level software that enables surveillance and data collection from distributed equipment in a plant. By integrating SCADA with robots and PLCs, we achieve a comprehensive real-time view and can react to alerts or failures in an instant.

MES/ERP software

Today's manufacturing companies use MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) class solutions to manage orders, production planning or stock levels. Only when automatic systems are integrated with them does it become possible to track the progress of production in real time - from receipt of the order to dispatch of the finished product.

Practical tips - how to approach the integration of automated systems?

While the benefits of implementing integrated systems are enormous, the process requires diligence. Below are typical steps and recommendations to help avoid surprises.

Step 1 - Audit of existing infrastructure

Before you do anything, make an analysis of what is already in your factory. Make a thorough inventory of all equipment: controllers, industrial robots, vision systems, SCADA and MES solutions. It is worth paying attention to:

• Software versions and communication protocols used (e.g. OPC UA, Modbus).
• Possible technical limitations (e.g. older systems may require communication gateways).
• The way data is transferred between machines and their documentation.

Step 2 - Communication architecture design

It is important to choose a target standard for data exchange and create a consistent architecture. If you plan to introduce a new robot, it is worth making sure that it will work with an existing PLC, for example. You can bet on the OPC UA protocol or MQTT, which allows easy communication in distributed environments.

Step 3 - Optimal selection of integration software

Sometimes it is necessary to implement dedicated software to integrate different systems into a single visualisation and reporting platform. Integration platforms available on the market (e.g. Wonderware, TIA Portal) allow machine configuration and information exchange to be managed centrally. This gives operators a single 'window' to control the entire line.

Step 4 - Pilot tests

Before the full line is put into normal production mode, it is useful to carry out a testing phase under near-real conditions. These can be so-called 'pilot projects' to detect configuration errors and prepare the team for future challenges.

Step 5 - Continuous improvement and development

Automated systems are subject to change as new orders or product range modifications occur. This is why it makes sense to develop an ongoing process for monitoring key performance indicators (KPIs) and a plan for regular maintenance of equipment. In many plants, services such as:

• Automatic backup of PLC programmes.
• Robot inspection and calibration schedule.
• Production data reporting and analysis system.

The most common integration problems and how to deal with them

Problem: Different protocols and standards

Long-standing production facilities often still operate equipment from a time when closed solutions, not adapted to modern protocols, were prevalent. In such a situation:

• Consider using communication gateways or protocol converters to connect old machines to newer generation systems.
• Plan your migration in the long term; if the integration is very complex, it is sometimes worth betting on new equipment to exploit the full potential of automation.

Problem: Lack of a qualified team

Even the best project will not succeed without people who can properly program and then operate automated systems.

• Organise staff training, especially those who will be operating robotic workstations on a daily basis.
• Work with experienced integrators. Company Michale Automation offers full support for the implementation of new machines and production lines - both from a technical and training perspective.

Problem: Lack of coherence between departments (IT/OI and production)

When implementing automation, there is often a 'conflict' between the IT department and the production department (so-called OT - operational technology). It is necessary to develop a common language, understand the requirements of each department and establish clear cooperation procedures. Otherwise, duplication of solutions or communication bottlenecks can occur.

Impact of automation integration on costs and efficiency

Companies that have successfully implemented the integration of automated systems generally boast a clear increase in key indicators. Examples:

• By 20-40% shorter production cycle time.
• Reduction in downtime by up to several tens of per cent (thanks to automatic alerts from SCADA systems and rapid response).
• Better quality control - welding or painting robots complete tasks by working directly with video cameras.
• Improved employee safety through remote control and monitoring.

At the same time, the integration brings real-time tracking of current costs, material consumption levels and key performance indicators. Decisions to start an additional line, redeploy staff or make schedule changes become easier to make based on concrete numbers rather than conjecture.

Collaboration of robots with AI and vision systems - does it pay off?

Modern trends in Industry 4.0 are not just about integrating basic controllers and machines. We are increasingly hearing about the use of artificial intelligence algorithms and advanced vision systems (vision systems). When combined with robots, these can achieve a much higher level of automation and autonomous decision-making.

Examples of applications

• Intelligent sorting - The robot works with a camera that recognises product shapes and colours. The AI system decides in real time which container the item should go into.
• Automatic quality inspections - vision cameras detect defects that are not visible to the naked eye, such as microcracks.
• Machine learning in the welding process - the algorithm itself optimises the welding parameters based on the history of minor adjustments reported by the operator.

Does it always pay off?

AI and vision system implementations involve investment in additional software, hardware and a skilled team. However, for companies that manufacture products in processes that are difficult to control (e.g. things that require multi-step quality control), such solutions can give a significant return on investment.

Case study - successful integration in a sample manufacturing company

Imagine a medium-sized factory in the metal industry that has developed piecemeal over the years. It owned:

• Two welding robots operating independently of each other.
• Packaging lines with their own PLCs.
• ERP software, which, however, had no real-time insight into production processes.

It was not until the integration project was commissioned by the team Automation Michale allowed:

• Combine robots into a coherent quality control system where welding parameters are automatically reported to the controlling department.
• Run a centralised SCADA system that collects data from the packaging lines and allows performance to be monitored with a high degree of accuracy.
• Use an additional reporting platform (MES) that automatically communicates with the ERP to keep the available stock up to date and provide information on the completion of production batches.

The result? A 50% reduction in the time needed to handle quality reports, a 25% increase in production line efficiency and a reduction in order dispatch delays associated with missing data.

Where to look for support in integrating automated systems?

Not every manufacturing company has its own automation department and programmers who can handle the design of complex communication architectures. In such a situation, it makes sense to enlist the help of an experienced integrator - a company that specialises in building machines and production lines from scratch and in combining different solutions into a coherent whole.

Automation Michale has been supporting companies in the comprehensive implementation of robotic workstations and automation projects for years. We are also an official distributor of SIASUN robots, which makes it easy to offer customers state-of-the-art machines tailored to the realities of a specific plant.

How to plan the service and maintenance of integrated workstations?

Combining the most diverse machines into one ecosystem also requires a proper service programme. After all, any failure at one point can affect the entire line. Key activities:

• A service contract providing for constant monitoring of the condition of the machines and a rapid response time in the event of a breakdown.
• Regular software updates - PLC, SCADA and possible AI modules.
• Periodic analysis of performance reports to detect anomalies even before they develop into major outages.

If you are interested in service care, you can use the offers from Michale Automationwhich has a dedicated department for after-sales service. Well-planned service translates directly into stable operation of the integrated automated system.

Summary of benefits and recommendations

- A holistic approach, rather than implementing individual robots: Single automations only have a limited effect. It is only the integration of different devices and platforms that makes comprehensive production improvements possible.

- Increased productivity and reduced costs: Automatic systems that exchange data efficiently can speed up production by up to 20-40%. We reduce labour costs, facilitate scaling and minimise downtime.

- Accurate quality control and real-time analysis: The ability to monitor the process 'here and now' allows deviations to be responded to quickly and repetitive errors to be avoided in production batches.

- Stable foundations for future implementations: Integration makes it easier to introduce new machines, robots and software (e.g. AI) in future years, as a common communication platform already exists.

- Staff training and competence: Even the best robots or PLCs cannot replace a skilled operator. It is worth investing in team development and ensuring open collaboration between IT, production and automation departments.

Summary

Today, automated systems are the undisputed drivers of Industry 4.0: they eliminate human error, support production flexibility and achieve higher quality rates at lower costs. However, for these technologies to truly fulfil their role, they need to be properly integrated and jointly managed - from robots to controllers to MES and ERP solutions.

It is crucial to carry out a detailed audit of the infrastructure early on in the implementation, design a coherent communications architecture and ensure that the integrated workstations are serviced. A good plan backed up by working with an experienced integrator - such as a automation company Michale - pays off in the form of higher productivity, lower costs and a stable technological future for the factory.

If you want to learn more about the potential of robotisation, take a look at our services section Robotisation and see how we can help your company implement effective and modern solutions. You can also take a look at our range of robotic workstations (e.g. robotisation of welding) or contact for service or maintenance.

If you have questions, we are happy to help. Please feel free to get in touch, subscribe to our newsletter and leave a comment with your own experiences of integrating automated systems.
Good luck in creating an integrated automation ecosystem that will take your production to the next level!

FAQ

How long does it take to implement the integration of automated systems?
The implementation time depends largely on the complexity of the factory processes and the number and age of the machines. It can be a few weeks for simpler projects, and up to several months for large investments and extensive infrastructure.

Does integration require a lot of money?
The initial cost can be significant, especially when older equipment needs to be upgraded. However, the effects in terms of reduced downtime, improved quality and better production control mean that the investment usually pays for itself quickly.

Does the integration of automated systems only apply to large companies?
Definitely not. Current solutions are increasingly flexible and scalable, so that smaller and medium-sized companies can also benefit from full machine and software integration.