Automation and mechanical engineering in the manufacturing plant. A comprehensive guide to successful integration

Estimated reading time: approx. 10 minutes

TL;DR

• Automation and mechanical engineering are key to increasing productivity and competitiveness in modern manufacturing companies.
• Careful process analysis, needs identification and planning are the foundations for the successful integration of new solutions.
• Integration with ERP and MES systems enables monitoring of key parameters - from productivity to material consumption.
• Training and service are essential to keep machines running and prevent long downtimes.
• Robotisation works well in many areas, from welding and painting to packaging and palletisation.
• Working with an experienced integrator, e.g. Automation Michale, guarantees support at every stage of implementation.

Table of contents

• Introduction
• First steps into automation and mechanical engineering
• Project planning and selection of suitable machinery
• Integration of machines in an existing production line
• Commissioning and optimisation of automated workstations
• Robot technologies and expansion possibilities
• Practical tips for investors
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Today, automation and mechanical engineering are one of the key pillars in the development of modern manufacturing companies. In times of intense competition and rising labour costs, entrepreneurs are looking for solutions that can ensure higher productivity, reduce costs and guarantee the high quality of manufactured products. Proper planning of the automation process not only improves efficiency, but also ensures the long-term scalability of production.

In the rest of this article, we outline the main steps in integrating automation and mechanical engineering systems into a company. You will learn how to define business objectives, plan the technical design, prepare the production line for implementation and the benefits of working with an experienced supplier such as Automation Michale. The company has been involved in the design, construction and integration of machines and production lines for years and is the official distributor of robots SIASUN, enabling world-class robotic solutions.

First steps into automation and mechanical engineering

Identification of business needs and objectives

The first and most important step in preparing for the implementation of automation and mechanical engineering is to precise definition of needs and business objectives. Measurable indicators and expectations need to be set for the investment to deliver real benefits:

• Scope of production: Are you looking to increase volume, improve quality or perhaps reduce labour costs?
• Type of processes: What operations do you want to automate (welding, packaging, painting, assembly of parts) and what will be their impact on the entire production line?
• Human resources: How many employees can be redeployed to other tasks through automation?
• Budget and ROI: Define a budget and a return on investment plan to optimise the project's profitability.

It is also worthwhile to analyse the so-called pain points, i.e. problems such as low reproducibility of quality, frequent downtimes or lack of qualified staff. Automation and mechanical engineering can significantly reduce these difficulties.

Analysis of production processes

Another element is detailed analysis the current state of production processes. Relevant questions include both technical and logistical issues:

• What is the flow of materials in the plant?
• Do the machines run a full 24-hour cycle, or is there frequent downtime?
• Which activities are performed manually and to what extent can they be automated?

On the basis of such an analysis, a production flow map is created, identifying where robotisation or machine modernisation will bring biggest savings. However, not always all processes need to be automated at once. A gradual implementation allows costs to be spread out and additional funds to be raised for the successive development of the machine park.

Project planning and selection of suitable machinery

Specification and design of automation systems

Once the necessary information has been gathered, the design specificationwhich defines the machine types, scope of work and integration and safety requirements. This document becomes the roadmap for the entire implementation. The more detailed the specification, the lower the risk of amendments and misunderstandings in later stages.

Choice of supplier of control systems and robots

In parallel with the design, it is worth considering best technology solutions and the right manufacturers. Often companies rely on tried-and-tested brands of industrial robots or PLCs, although less popular solutions can also work, especially if their cost is more attractive.
W Automation Michale We offer a wide range of machines and services in the field of automation and robotics. As a result, we provide full service support and access to world-class solutions - we are an official distributor of robots SIASUNwhich guarantees high quality and reliability.

Prototype construction and testing

In more complex projects involving mechanical engineering on special request, it pays to create a prototype or at least a digital model (e.g. a 3D simulation). This will allow initial tests of performance, ergonomics or safety, even before production of the final devices. In this way, the risk of design errors is significantly reduced.

Integration of machines in an existing production line

Preparation of plant infrastructure

At this stage, it is necessary to adequately adaptation of infrastructure plant. Sometimes this requires minor changes in equipment layout or an increase in production space. An integration company such as Automation Michale, he then works closely with the maintenance department and management, performing, among other things:

• Assessment of power, ventilation and cooling requirements.
• Analysis of available space and transport routes.
• Overview of security systems, including gates, curtains and sensors.

Earlier planning of possible upgrades to the hall can significantly reduce implementation time, eliminating production downtime on the day of installation.

Communication interfaces and master systems

Good integration means that the new machines will communicate with the rest of the line and with overarching IT platforms (ERP, MES). Introducing IoT solutions and the right sensors makes it possible to remote monitoring key parameters such as operating speed, temperature or wear and tear.

Connection to existing IT systems

Modern production systems require the transmission of data on the number of pieces produced, quality or cycle time. Integration of machines with a central reporting system provides continuous insight into the line's efficiency and enables rapid response to deviations. It is also important to ensure the compatibility of communication protocols (EtherNet/IP, Profinet, Modbus) and data protection, especially when information transfer takes place in the cloud.

Commissioning and optimisation of automated workstations

On-site assembly and pre-testing

Once the infrastructure has been prepared, it is time for the machines to be delivered and installation to begin. Specialists check cabling, security and carry out the first tests. Advanced systems, such as workstations robotised welding or packaging, require the programming of robot motion trajectories and process parameters. Examples include setting the speed and type of filler in welding or the stacking sequence in palletising processes.

Training of staff and development of procedures

The implementation of new technology involves the need to employee training in the operation and maintenance of machinery. The scope of training includes:

• Maintenance and diagnostics of the equipment, including basic servicing.
• Safety and emergency rules.
• Drawing up technical documentation and procedures to facilitate rapid restoration of the line in the event of a fault.

Parameter optimisation and continuous improvement

The real benefits of automation and mechanical engineering only become fully apparent after a period of optimisation. Worthwhile on a regular basis:

• Analyse performance indicators and data from master systems (ERP/MES).
• Adjust equipment parameters to improve efficiency or reduce raw material consumption.
• Make use of the warranty and after-warranty service to ensure the continued operation of the machines.

Automation Michale also supports customers after the start of production, providing ongoing service and advice so that each line can be systematically improved.

Robot technologies and expansion possibilities

Use of industrial and collaborative robots

Industrial robots generally increase speed i precision many processes, and help reduce human error. Integrating robots into the production line makes it possible:

• Robotisation of welding, which improves the repeatability and quality of joints.
• Automation of packaging and palletisation, reducing the risk of product damage.
• Implementing robots for painting and sanding, which works well with high aesthetic demands.

If you would like to explore the topic further, we recommend our offer
Robotics and systems integration services.

Distribution of SIASUN robots by Michale Automation

As an official distributor of robots SIASUN we offer state-of-the-art high-precision units. They work well in many industries, including metal or food. Examples include
SIASUN SR25A robot, designed for tasks requiring a high degree of accuracy and repeatability.

Service and maintenance of automated workstations

A common mistake is not to maintenance strategies new machines. Regular maintenance and fast service response to irregularities minimise downtime. W Automation Michale we offer flexible service packages for companies wishing to maintain the highest production efficiency. For more information about the service, see
Service and maintenance stands.

Practical tips for investors

ROI calculation and cost analysis

A key issue for most investors is turnaround time from the outlay incurred. Careful investment planning and the right choice of processes to be automated increase the chance of a quick return. Assessing cost-effectiveness helps:

• Key performance indicators (KPIs) - e.g. cycle time, waste reduction.
• Tools for calculating ROI or TCO (Total Cost of Ownership).
• Detailed consideration of maintenance, upgrade and training costs.

Implementation schedule

Delays in implementation can increase costs and reduce competitiveness. That is why time planning implementation should include:

• Establishing milestones: completion of the project, delivery of machines, acceptance tests.
• Time buffer for possible documentation modifications.
• Matching the installation date to the period when the company can afford to reduce production.

Agriculture and the food industry - specific challenges

In sectors such as food and agriculture, standards of hygiene, food safety and ease of machine cleaning are key. The design of workstations must take into account frequent cleaning and disinfection, and controls should be protected from moisture.
In agriculture, on the other hand, automation is becoming increasingly popular sorting and packagingwhich streamlines the processing and dispatch of goods. Robotisation can work here for a variety of processes, e.g.
robotisation of welding.

Practical conclusions and recommendations

Highlights in a nutshell

• Thorough needs analysis: Identify the business objectives and problems you want to eliminate.
• Detailed design: A good specification means less risk of errors and delays.
• Integration with IT systems: Enables monitoring and better management of production.
• Staff training: New technologies require new knowledge and procedures.
• Service and maintenance: Regular maintenance of the machines guarantees less breakdowns and stable production.

How to put the knowledge gained into practice

1. Compile an analysis of current production performance and key indicators.
2. Compare the results with the requirements of the market and the capabilities of your employees.
3. Choose the processes where automation will bring the quickest and easiest return.
4. Specify the budget and planned payback time (e.g. 2-3 years).
5. Contact experts (engineers, integrators) to create a detailed schedule.
6. Provide training for operators and maintenance staff.
7. Monitor performance indicators after launch and make incremental improvements.

Summary

Automation and machine building is an investment that can completely change the face of a production facility. However, success in this area requires careful planning of every step - from process and needs analysis, through machine selection and integration with existing systems, to staff training and regular maintenance. Companies opting for automated production lines gain a competitive advantage, reduce lead times and increase the quality of the products offered.

If you want to introduce fully automated machines and robotic workstations into your plant, contact Michale Automation. Our team's experience in industrial systems integration, special machine building and robot deployments SIASUN will help you achieve your goals quickly. We provide support at every stage of the project: from specification preparation, installation and training to ongoing service.

We also encourage you to read other articles on our blog and to share your experiences in the comments. Sign up for our newsletter to receive the latest information on trends in robotics and the machine tool industry - so your company is always one step ahead.

FAQ

How long does it take to implement automation in a company?
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 or longer for extensive projects and large integrations.

Does automation mean redundancies?
More often than not. Automation usually frees the team from monotonous tasks, allowing them to focus on more strategic and developmental tasks. Many employers choose to retrain employees in new technologies.

Does robotisation only pay off for large companies?
Nowadays, the cost of purchasing and maintaining robots is falling, making their implementation increasingly accessible to small and medium-sized companies as well. While large companies have a larger production scale, smaller plants can also benefit from flexible and modern solutions.