Machine automation in practice: how to prepare a company for implementation

Estimated reading time: approx. 8 minutes

TL;DR:

• Machine automation is the key to reducing costs and improving production quality.
• Identify business objectives and conduct a process audit before implementation.
• The right choice of robots and control systems determines the success of the entire implementation.
• Budget planning and staff training are the cornerstones of effective integration.
• Rethink scaling and further development based on the first pilot results.

Table of contents

• Introduction
• Why is machine automation becoming a priority?
• Preparing a company to implement machine automation - step by step
• Key benefits of machine automation
• The most common challenges in implementing machine automation
• Examples of areas in the company that can be automated
• Implementing machine automation with the help of Michale Automation
• Key findings and recommendations
• Summary
• FAQ

Introduction

Machine automation is becoming one of the key factors determining the competitiveness of industrial enterprises. It makes it possible to significantly reduce costs, shorten the execution time of tasks and limit the risk of errors resulting from the human factor. According to data from the International Federation for Robotics (IFR) cited by PARP, in 2020, there were 52 machines per 10,000 people working in industry in Poland, while in world leaders in automation, such as South Korea, it was as many as 931. In the coming years, the situation may change, as entrepreneurs increasingly recognise the need to invest in integrated production systems.

In this article, you will learn why machine automation has become so important for industrial companies, how to prepare for it step by step, and the effects of introducing automated solutions. You will learn about the necessary elements of plant modernisation, methods for effective integration of machines and systems, as well as key workforce competencies in the automation era.

Why is machine automation becoming a priority?

Machine automation is the answer to the challenges of today's market, where speed, efficiency and high quality production play a key role. These are the main factors that make companies all over the world - also in Poland - invest in automated production lines:

• Increasing cost pressures and labour shortages - Rising labour costs and difficulties in recruiting skilled professionals are prompting companies to purchase modern equipment to support repetitive tasks.
• Need to improve quality and repeatability - automated machines minimise errors due to the human factor, ensuring higher precision.
• Reducing lead times - robots and vision systems allow a rapid transition between different tasks, so that you can react flexibly to changes in demand.
• Increased security - relieving people of hazardous activities leads to fewer accidents and lower sickness absence costs.
• Positive image and innovation - companies that focus on modernity attract the attention of consumers and contractors, building a leading position in the market.

Preparing a company to implement machine automation - step by step

Implementing machine automation is not just about buying equipment. It requires developing a strategy, carrying out analyses and creating a solid foundation to facilitate the integration of new solutions.

Definition of business needs and objectives

The first step is to clearly define the expectations of automation. Is the priority to improve quality, reduce costs or increase production flexibility? Only once specific objectives have been established can the appropriate technologies be selected and the scope of investment planned.

Sample questions to ask yourself:

• Do you need full automation of the entire production line or just support for selected workstations?
• Which area to start with in order to quickly see critical benefits?
• What tasks in the company are most amenable to automation?

Audit of production processes

The next step is an in-depth analysis of current production stages: cycle times, complaint rates, scrap levels. It is also worth identifying potential barriers, such as insufficient space on the shop floor or a shortage of skilled workers.

Surveying operators, observing production lines and checking the causes of delays in the supply chain are effective tools to help gather valuable information and adapt technology to real needs.

Selection of appropriate technological solutions

There are many automation options on the market: from simple manipulators and vision systems to advanced collaborative robots (cobots) and industrial robots. The choice of a specific solution depends on priorities, budget and industry characteristics.

It is worth considering working with specialists - for example Automation Michalewhich, as an official distributor of SIASUN robots can offer comprehensive advice and adapt equipment to specific production conditions.

Definition of budget and timetable

Plan not only the cost of the hardware itself, but also training, production line adaptations or integration with IT systems. Develop a detailed schedule covering conceptual phases, prototype testing, implementation in the target environment, employee training and stabilisation of the entire system.

Tools such as Example ROI calculatorwhich allows the cost-effectiveness of an implementation to be quickly assessed, e.g. for robotic welding.

System integration, testing and training

After the planning phase comes the actual integration: adapting existing production lines and connecting new machines to central systems (MES, ERP).

• Pilot tests - It is best to start with a small section of the production line in order to verify the effects and make any adjustments.
• Staff training - preparing staff to operate, program and maintain the new equipment is crucial.
• Performance and quality assessment - In the first phase of machine operation, it is worthwhile to intensively monitor the results achieved and draw conclusions for further optimisation.

Scaling and development

After the success of the pilot phase, automated solutions can be extended to other departments or the entire plant. Many companies then introduce advanced options such as vision systems, cobots for palletisation or integration with Big Data and artificial intelligence algorithms.

Key benefits of machine automation

Improving production processes through automation has a number of tangible effects that allow the company to increase its profitability.

Increased productivity and flexibility

The robotic workstations are able to operate continuously, significantly reducing downtime. In addition, reprogramming the machines allows processes to be flexibly adapted to changing order needs.

Reduction in operating costs

The initial expenditure on robots or automation can be high, but it translates into fewer errors, shorter production cycles and increased productivity, allowing you to quickly recoup your investment.

Improved quality and repeatability

The machines eliminate the impact of operator fatigue, distraction or interruptions. This is particularly important in sectors where precision and maintaining a consistent level of quality is crucial.

Improving staff safety

By eliminating unsafe processes, employees can focus on supervision or project tasks. As a result, the risk of accidents is reduced and the work itself becomes more attractive.

The most common challenges in implementing machine automation

While automation is a dynamic growth opportunity for many companies, it is worth being aware of the difficulties that arise and preparing accordingly.

Initial costs and return on investment

For small and medium-sized companies, the expense of industrial robots or supporting infrastructure can be significant. However, it is worth starting with smaller projects to assess the effects and build a case for further investment.

Lack of qualified staff

Modern technology requires advanced skills, such as robot programming or production data analysis. This is why it is important to include training plans for the team in the budget and schedule.

Integration into existing infrastructure

Old machines, lack of compatible interfaces or the need to upgrade production facilities are common roadblocks that increase implementation time and costs. It is important to carefully verify your existing resources before starting a project.

Human resistance and organisational culture change

Employees may fear losing their jobs. In practice, automation often leads to changes in job structure and competency promotion. Proper internal communication helps to alleviate fears and involve the whole team in the transition process.

Examples of areas in the company that can be automated

It is a good idea to start line modernisation with the processes where errors, downtime or quality problems are most common. Here are some of the most common applications of robots and automation systems:

• Robotisation of packaging - Many companies are investing in robotisation of packaging and palletisation to speed up the shipment of goods to the customer.
• Robotisation of welding - key in the metal and automotive industries. You should get to know our offer of welding robotisationwhich significantly speeds up and standardises the process.
• Robotisation of stacking and palletising - if a company packs hundreds of products a day, automatic product stacking saves time and reduces the risk of errors. Examples of implementations can be seen in the robotisation of paving.
• Robotisation of repetitive production - ideal for series production. For more information, please see the offer automation of repetitive tasks.

Implementing machine automation with the help of Michale Automation

For years, Michale Automation has specialised in the construction and modernisation of production lines and the implementation of robotic workstations. As an official distributor of SIASUN robots, the company offers access to innovative solutions and advanced control systems. With many years of experience in the integration of vision systems, cobots or welding equipment, the expert team effectively supports customers at every stage:

• Pre-consultation - detailed analysis of needs, budget and industry specifics.
• Designing turnkey solutions - covering hardware, software and full integration into the customer's infrastructure.
• Staff training - so that the company can independently maintain and develop the implemented systems.
• Service and maintenance - technical support and minimising the risk of downtime.

This approach allows your company to focus on business development, leaving technology issues to experienced engineers.

Key findings and recommendations

• Define objectives and needs - determine which indicators you want to improve, e.g. cycle time, labour costs or scrap rates.
• Conduct a process audit - check where the biggest problems occur in order to choose the most effective solutions.
• Choose the right technology - consult experienced partners and bear in mind the specifics of the industry.
• Invest in staff competence - Training in machine operation and robot programming is the key to fully exploiting the potential of automation.
• Implement gradually - start with a pilot project to minimise risks and learn lessons.
• Monitor the effects - regularly analyse indicators in order to continuously improve processes and optimise production.

Summary

Machine automation is a strategic step for manufacturing companies wishing to remain competitive in a demanding market. Modern control and robotics solutions translate into higher productivity, cost savings and greater employee safety. Although the number of robots per 10,000 industrial workers in Poland is still lower than in global leaders, the automation trend will accelerate, especially in the context of rising labour costs and a shortage of qualified staff.

Automation Michale offers comprehensive support: from analysis and design, through installation and training, to service and maintenance of modern machines. The decision to invest in automation not only streamlines production processes, but also creates space for the development of employees - instead of performing monotonous tasks, they can undertake tasks with higher added value.

We encourage you to follow our blog to keep up to date with the latest trends in robotics and automation. Share your own experiences of machine automation implementations in your company in the comments - the discussion will clear up doubts and provide inspiration for other readers.

FAQ

How long does it take to implement automation in a company?
Time depends on the complexity of the processes, the resources available and the degree of integration with the existing infrastructure. It can range from a few weeks for simpler projects to several months for more extensive implementations.

Does automation mean redundancies?
Most often they don't. Automated machines take over repetitive and tedious tasks, while people can focus on quality control, supervision or robot programming. As a result, there is a growing demand for employees with higher skills.

Does automation only pay off for large companies?
Current solutions are increasingly flexible and affordable, so that small and medium-sized companies can also benefit from robotisation. It is best to start by automating a key process and gradually develop the use of new technologies.