Automatic machines in the face of staff shortages - how to reduce production costs?

Estimated reading time: 8 minutes

TL;DR

• A way to reduce costs and maintain production continuity.
• Robots and automated machines are taking over repetitive and dangerous tasks.
• Before implementing automation, it is worth performing an ROI analysis.
• Automation does not eliminate employees - it reallocates them to higher-level tasks.
• The right supplier simplifies implementation and provides service support.

Table of contents

• Introduction
• Challenges of modern production and the role of automated machines
• What are automatic machines and why should you invest in them
• Example of the use of automated machines in practice
• Step by step - implementing automated machines in your company
• How to measure profitability - calculating ROI for automated machines
• Why bet on Michale Automation - comprehensive support and experience
• Most common concerns and questions related to automation
• Prospects for the development of automation and robotics in Poland
• Practical conclusions and recommendations for companies
• Summary
• FAQ

Introduction

In recent years, increasing staff shortages have been spending sleepless nights for managers of manufacturing companies. The competitive market forces companies to optimise costs and increase productivity, which directly affects their ability to remain profitable. Automated machines - the key to modern automation and robotisation - come to the rescue. In this article, we will explain the benefits of automated machinery solutions, how they are implemented step-by-step in a production facility and what financial effects an investment in automation can have. You will also learn how the Michale Automatyka brand, the official distributor of SIASUN robots, helps companies to become independent from the problem of staff shortages and effectively reduce production costs.

Main content

Challenges of modern production and the role of automated machines

Staff shortages are not only the cost of finding and training employees, but also the risk of delays due to long deployment times, absenteeism and staff turnover. Many companies face the dilemma of whether to invest in outsourcing or whether it is better to use automated machines. It is worth knowing that the second solution often allows:

• Maintain quality and repeatability of processes without interruptions due to staff turnover.
• A stable, predictable supply chain.
• Reduce reliance on human factors (errors, absences, extended onboarding).

According to industry data, up to 10-15% of all employees in the Polish industry are temporary staff, which makes employee change frequent. It also means additional costs, such as:

• Health and safety training.
• Recruitment and verification of competences.
• Sick leave and holidays.

Automated machines take over repetitive, tedious or dangerous tasks, thus reducing the impact of factors beyond their control that increase operating costs.

What are automatic machines and why should you invest in them

Automated machines are integrated mechanical and electronic systems that enable specific sequences of tasks to be performed with little or even no human input. In the case of the manufacturing industry, simple workstations such as packaging equipment are involved, as well as complex production lines with a high degree of automation.

Main benefits of implementing automated machines

1. Reducing labour costs:

• Elimination of some physically demanding posts.
• Reduction of hardship bonuses.
• Constant machine availability (24/7), resulting in higher productivity.

2. Reducing production cycle times:

• Elimination of manual operations, which are sometimes slower and subject to the risk of errors.
• Possibility of multi-shift work without additional downtime.

3. improving the quality of manufactured products:

• Repeatability and precision, especially in detailed tasks (e.g. welding, packaging).
• Minimising human error during assembly or machining processes.

4. Optimisation of human resources:

• Staff can be redeployed to more complex tasks, such as quality control or maintenance.
• Increasing employee satisfaction by relieving them of monotonous effort.

How to understand the profitability of an investment
In order to assess whether automated machines are actually beneficial to a company, it is worth considering the ROI (Return on Investment). It is estimated that, with well-chosen automation, in many cases the return on investment can be achieved within 2-3 years, which, from the point of view of the long-term development of the company, represents great value.

Example of the use of automated machines in practice

Many managers ask themselves: in which processes will automation bring the greatest benefit? The answer is: where there is a high repetition of tasks, low product variety or risk of human error.

Packaging automation

The packaging process can be tedious and requires the coordination of many steps, such as folding cartons, labelling, weighing or grouping products.

• The use of automatic packaging machines reduces time by 20-30%.
• Damage to packaging is reduced, leading to a reduction in material losses.
• It is easier to maintain standards of quality and timeliness in deliveries to the customer.

Want to learn more about the benefits of packaging automation? Take a look at Robotisation of packaging - there you will find information on specific implementation examples and devices.

Automation of welding processes

Welding is another area where automated machines, including robots, can significantly reduce the scale of costs and the risk of errors:

• Precision weld stitches, reducing rework to a minimum.
• Eliminating the risks associated with workers' exposure to harmful welding fumes.
• Adapting welding parameters to the type of material so that high repeatability can be maintained while improving product quality.

If there is a major need in your company to improve your welding processes, take a look at the Robotisation of welding.

Step by step - implementing automated machines in your company

The implementation of automated machines is a multi-stage transformation that is not limited to the purchase of the relevant equipment. The preparation of the infrastructure, the choice of software, the training of employees - these are all elements that influence the success of the entire project.

Step 1 - Analysis of production processes and setting of objectives

Before deciding on a specific solution, conduct a detailed analysis of your facility's processes. Consider which areas:

• They consume the most human time.
• They generate the greatest material losses.
• They are most vulnerable to human error or cause health and safety risks.

On this basis, develop a list of priorities and performance indicators (KPIs) that you want to improve. These could be: reducing cycle times, reducing quality deficiencies or reducing complaints.

Step 2 - Supplier selection and technology alignment

Once you know your requirements, turn to a supplier that specialises in the integration of automated machines and robots. Michale Automation offers a comprehensive approach:

• Design and construction of customised machinery and production lines.
• Industrial automation - including control cabinets, control and monitoring systems.
• Implementation of robotic workstations based on SIASUN robots.

It is essential that the supplier can provide both hardware and implementation support - such implementation includes full integration with existing systems, staff training and after-sales service.

Step 3 - Implementation and testing

Before full-scale production is launched, an extremely important phase is system testing. As part of this phase:

• The interaction of the new machine with the individual process links (e.g. vision system, ERP software, safety sensors) is checked.
• Simulations of various production scenarios are run to detect possible bottlenecks.
• Operators are trained so that they understand the logic behind the machine and are able to rapidly rearm the machine if the product range changes.

Step 4 - Commissioning and optimisation

Once the initial tests have been successfully completed, the automatic machines enter normal operation mode. In the first few weeks, the key is:

• Monitoring of production performance indicators (OEE, number of downtimes, number of breakdowns).
• Gathering feedback from operators and the maintenance department.
• Making minor modifications to machine parameters (e.g. feed speed, torque of individual tools).

Remember that, if done correctly, optimisation can increase productivity by an additional 5-10% within several weeks of the official start of production.

How to measure profitability - calculating ROI for automated machines

The question of the cost-effectiveness of automation arises for many business owners and managers: how do you know that it will really pay off? A basic tool is the ROI (Return on Investment), which can be roughly calculated by dividing the annual savings from machine deployment by the total investment cost and then multiplying the result by 100%.

Example:
Cost of implementing automated machines: £1,000,000.
Annual savings from freeing up some labour, reducing errors and avoiding downtime: PLN 300,000.
ROI = (300 000 / 1 000 000) × 100% = 30%.

In practice, however, it is important to take into account so-called hidden costs, such as downtime during installation, as well as potential expenses for maintenance and spare parts. It is worth using ROI calculators developed for specific processes - e.g. in welding, packaging or painting. A sample calculator is available at ROI calculator.

Why bet on Michale Automation - comprehensive support and experience

Michale Automatics is a company dedicated to building machines and production lines, automating processes and implementing robotic workstations. What's more, the brand is an official distributor of SIASUN robots, one of China's largest industrial robot manufacturers. Why should you trust them?

Experience and wide range

• Realisations for various industries: food, metal, furniture or chemical.
• A skilled team of designers, automation and roboticists.
• The ability to design a 'bespoke' solution - from a simple automatic machine to a complex production line.

Service and maintenance stands

Even the best machine requires regular maintenance and possible operational repairs. That is why Michale Automation offers service support throughout the entire life cycle of the machine. If required, you can read the details service and maintenance of posts.

Dedicated offers for the robotisation of various processes

From welding, packaging and painting to stacking and grinding, each of these processes has its own characteristics, and choosing the right robot and tooling influences the optimal results. Depending on your needs, Michale Automatika can also offer SIASUN robots with the right capacity and degree of sophistication.

Most common concerns and questions related to automation

Despite the apparent advantages of automated machines, there are still some entrepreneurs who regard them with distaste. The most common doubts are as follows:

Will the machine completely replace the worker?

In many cases, the implementation of automated machines does not mean eliminating staff altogether, but simply redeploying them to other duties. Monotonous and repetitive tasks are carried out by the machine and staff can focus on quality control, supervision or other more creative areas.

How to deal with implementation costs?

Although the purchase of new automated machinery is a considerable expense, there are various forms of financing (investment loan, leasing, EU funds). A solidly prepared business plan and ROI calculations can significantly facilitate obtaining financing from a bank or government institutions.

What if something breaks down and production stands up?

An adequate service plan and the availability of spare parts minimise the risk of long-term downtime. In addition, advanced diagnostics on automatic machines allow early response to potential faults.

Prospects for the development of automation and robotics in Poland

According to statistics from a report by the IFR (International Federation of Robotics), the global robotisation market is growing by several per cent year on year. Poland, although still behind Western European countries in this respect, is catching up dynamically.

There is also increasing talk of so-called Industry 4.0, where the role of automated machines is being enhanced:

• Big Data and real-time analysis of production data.
• Artificial intelligence (AI) in robot control.
• Integration with ERP/MES systems, enabling fully automated production management.

This is all an area where Michale Automation is leading the implementation work, combining SIASUN robots with advanced production line management systems.

Practical conclusions and recommendations for companies

• Identify the areas most prone to errors or staff shortages.
• Make detailed cost-effectiveness (ROI) calculations, taking into account all key cost factors.
• Choose a trusted provider to guide the company through the entire process - from analysis to integration testing to service.
• Provide adequate training for production and maintenance staff.
• Don't be afraid to bet on innovation - automated machines not only reduce costs but also ensure higher quality products.

Summary

Automatic machines are an effective remedy for the growing challenges of the Polish manufacturing sector, especially in the context of staff shortages and pressure to reduce costs. They ensure process stability, improved quality and greater competitiveness in the market. Michale Automatyka, acting as the official distributor of SIASUN robots, provides comprehensive solutions: from the initial process analysis to the commissioning and service of the machines.

If you are interested in optimising costs or significantly improving a selected process in your company, be sure to check out the opportunities offered by different types of robotisation. Implementing automated machines proves to be more beneficial in the long term than outsourcing most processes - the key is to plan the investment well and support a professional team in the implementation.

Follow our upcoming articles for tips on implementing specific robotic solutions and inspiring project examples. If you have questions or would like to start a conversation about automating your facility, contact us today. With a well-thought-out strategy, you will gain a competitive advantage and make your business more resilient to fluctuations in the labour market - all thanks to reliable robotic machines.

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?
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.