Automation and mechanical engineering: how to successfully integrate robotics into an ERP system in manufacturing

Estimated reading time: approx. 8 minutes

TL;DR:

• Robots and ERP system are a harmonious pair, allowing a continuous flow of data and a dynamic response to changes in production.
• Resource planning facilitates the elimination of bottlenecks and the risk of delays.
• Integration reduces operating costs and enables better monitoring of KPIs.
• Gradual implementation and appropriate training increase the likelihood of success.
• Correct configuration systems and protocols is the key to smooth communication between the robot and the ERP.

Table of contents

• Why is the integration of robots into an ERP system so important?
• Key benefits of combining robotisation and ERP
• How to link robots to ERP systems - step by step
• The most common challenges and how to overcome them
• Example from practice: implementation of robotisation in a medium-sized company
• Use of SIASUN robots in ERP integration
• Summary and key messages

Introduction

Automation and mechanical engineering are areas that have been growing rapidly in recent years. Thanks to technological advances and the need to increase efficiency, more and more companies are choosing to implement robotisation in their production processes. However, it is worth bearing in mind that the purchase and installation of robots alone will not solve all the problems associated with the continuous monitoring of a company. In order to achieve the best results, it is necessary to integrate automation solutions, including robots, with the ERP (Enterprise Resource Planning) system.

In the following article, we explain why combining industrial robots with ERP software is the key to success in a modern manufacturing facility. You will also find out:

• What are the main benefits of this integration.
• What the practical steps of implementation look like.
• What challenges you may face and how to solve them.

Michale Automation has been involved in building machines and production lines and implementing robotic workstations in various industries for years. We support companies in integrating with IT systems, allowing for a smooth flow of real-time data and uninterrupted monitoring of key indicators. Take a look at our guide for business owners, production managers and others interested in carrying out an effective integration of automation with production management systems.

Why is the integration of robots into an ERP system so important?

Modern production is not only about high productivity and flexibility, but above all about the ability to respond to market changes at an express pace. Robotised production lines make it possible to:

• Reducing human error.
• Standardisation of product quality.
• Increasing the speed of selected production stages.

ERP systems, on the other hand, are the 'command centre' for the entire company - they collect data on orders, stock levels, production progress and even on payments or employee resources. Integrating automation technology (robots, cobots or various types of machines) into this system allows:

• Immediate exchange of information between the robots and the main management system.
• Ongoing monitoring of costs, production cycle times and resource availability.
• More efficient management of the production schedule, including automatic response to changes in demand.

The overall result is a more efficient use of resources, faster detection of problems and a significant minimisation of the risk of downtime.

Key benefits of combining robotisation and ERP

Here are some of the key benefits that are obtained when the implementation of industrial robots goes hand in hand with the implementation of ERP software:

• Continuous real-time data flow
  By linking robots to the ERP system, we gain immediate access to information on production progress, material usage and order status. As a result, company management can make quick decisions to increase or decrease production.
• Improved resource planning
  Integration eliminates the need for manual data entry, allowing better planning of material and machine availability. The system automatically 'sees' where there are deficits or surpluses and can modify schedules accordingly.
• Reduction in operating costs
  The flow of information without delays and repeated human intervention translates into a lower risk of errors and lower costs. The company is able to plan raw material purchases more accurately and reduce potential losses due to erroneous decisions.
• Ability to monitor performance indicators (KPIs)
  Good ERP systems have extensive reporting modules. With robot integration, all key data (e.g. number of finished products, downtime, OEE) can be tracked in one place.
• Increasing competitiveness in the market
  With automated and integrated production processes, the company is better prepared for dynamic changes and can respond more quickly to market needs.

How to link robots to ERP systems - step by step

Audit of production processes

The first step is always to carefully examine the current processes and assess where and how robotisation can support the company. At Michale Automation, we carry out an analysis of material flow, cycle times and existing system solutions. At this stage, we also determine whether integration with an ERP system will bring immediate benefits and which departments of the company will need to cooperate (IT, production, logistics, etc.).

Selection of appropriate technical solutions

Based on the results of the audit, specific robot types (e.g. industrial, welding, palletising, painting) and modules in the ERP system that will exchange data with the robots are selected. Worth noting:

• The communication interface and protocols the robot supports.
• The degree of scalability of the ERP system (can it cope with an increase in data volume).
• Middleware - enabling communication between the machine and the management system.

Implementation phase and integration tests

Once the architecture has been designed, one moves on to installing the hardware, software and to configuring the communication between the robots and the ERP system. Some of the tests can be carried out virtually (offline simulations and analyses), but the most authoritative tests will be those carried out in near-real conditions.

It is worth remembering that in intensive companies, you cannot always afford to stop the entire line for several days. Therefore, implementation is often carried out in stages, and in the case of lines consisting of multiple robots, the connection of one device to the ERP is tested first, and then more are gradually added.

Training and service support

Even the most advanced integration will have no long-term effect if employees do not know how to operate it correctly. It is therefore helpful to provide in-depth training in data management, the basics of robot programming or report configuration in the ERP system.

In addition, to ensure trouble-free operation of robotic workstations, it is advisable to make use of maintenance and regular inspection services. In this context, we recommend taking a look at our service and maintenance of robot workstations.

The most common challenges and how to overcome them

Incompatible communication protocols
Sometimes ERP systems and industrial robots operate on two completely different protocols. The way around this is to use middleware (so-called communication gateways) or to replace older robot controllers with newer models that support popular standards.

Competence barriers within the team
Many specialists in the production department are not necessarily familiar with the advanced functions of an ERP system and, conversely, some IT staff do not know how robots work. The solution is to train employees and create project teams made up of experts from different areas.

Need to modify processes
Before a robot enters a company, the production process is often designed with manual workstations in mind. The entry of automated solutions requires changes to the material flow and the production management model itself.

Costs and implementation schedule
Buying and integrating robots into an ERP system is an investment. For this reason, a specific ROI analysis is sometimes crucial. In robotic welding workstations, our customers often benefit from free ROI calculator - welding robotisationwhich allows them to accurately estimate the cost-effectiveness of implementation.

Example from practice: implementation of robotisation in a medium-sized company

Let us assume that a manufacturing company (approximately 150 employees) specialises in metal components for the furniture industry. Up to now, manufacturing has mainly been done by hand, which has caused problems with larger orders:

• Difficulties with timely delivery.
• Fluctuations in quality due to human error.

After an analysis, it was decided to implement robotisation of selected tasks (e.g. welding, stacking parts on a belt) and to integrate the machines into the existing ERP system. Here are selected effects brought about by such modernisation:

• Automatic data transfer
  The ERP system registers the demand for individual components and communicates the number of pieces to be produced to the robots. The robots, in turn, report to the ERP on the status of workmanship and potential downtime.
• Ongoing quality control
  Any non-conformity in welding is automatically flagged. This allows the quality control department to take over the defective product immediately and does not block the rest of the line.
• Reducing staff costs
  Robots are taking over the most repetitive tasks, while people are being moved to jobs that require more precision and commitment.
• Reducing production cycle times
  Before implementation, it took two days to produce one batch (e.g. 500 units). After integration, the automated line is able to complete an order in a dozen hours.

As a result, the company was able to introduce new products into the range without having to significantly expand its production department.

Use of SIASUN robots in ERP integration

At Michale Automatyka, we are the official distributor of SIASUN robots. They are distinguished by innovative software solutions that significantly facilitate integration into modern production management systems. SIASUN robots can be equipped with communication modules tailored to specific ERP protocols. This makes implementation shorter and less burdensome for the company.

Using SIASUN robots, our customers particularly praise:

• Simple configuration of a variety of tasks (from welding to packaging).
• Easy integration with vision systems and control software.
• The ability to monitor key indicators regardless of whether the production line is running continuously or at variable intervals.

For more information on specific SIASUN robot models and specifications, please see the product section: Siasun robot SR25A-12-2-01.

Summary and key messages

The integration of robotisation with ERP is the next step in the development of automation and mechanical engineering, especially for companies that want full control over the production process. Below are the most important points to remember:

• Always conduct a sound audit of your production processes and assess whether robotisation in a particular area will bring the expected return on investment.
• Take care of system compatibility - make sure robots and ERP software can communicate properly with each other.
• Do the first implementations in stages, testing the integration on smaller parts of the production line.
• Don't forget training - employees need to understand how to operate the integrated system to realise its full potential.
• Ensure service support and adequate IT infrastructure to avoid production downtime.

If you would like to find out more about our robotisation services, please visit Robotisation services.

In the interests of fully supporting businesses, Michale Automatics also offers comprehensive solutions for the construction of machines and production lines that benefit from harmonious collaboration with ERP systems. Additional information can be found on our website: Automation and mechanical engineering services.

Practical conclusions

• Regularly analyse performance indicators and optimise processes to continuously improve the efficiency of robots and the ERP system.
• Build interdisciplinary teams - engineers, IT and production line staff should work closely together.
• Keep systems up to date - both robots and ERP software require periodic updates to take advantage of all new technological developments.

Summary

Integration of robotic solutions into an ERP system provides a solid foundation for companies looking for new ways to grow, be flexible and improve product quality. It provides access to a complete picture of real-time production data and creates an environment in which changes can be implemented quickly and efficiently.

By implementing Michale Automation's modern solutions in your company, you are assured that all elements - from the robot itself to synchronisation with key data in the ERP system - will form a coherent and reliable whole.

We encourage you to use our other materials and articles to gain additional knowledge and inspiration about robot implementations in a variety of industry sectors. If you have additional questions, please feel free to contact us and share your experiences in the comments.

Thank you for reading!

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.