Automation project - how to plan and implement effective automation in a manufacturing company

Estimated reading time: approx. 12 minutes

TL;DR:

• You will learn the benefits of thoughtful process automation.
• You will learn the key stages of an automation project in a manufacturing company.
• You will receive guidance on the selection of equipment, robots and control systems.
• You will understand the importance of service-based aftercare and long-term development.
• You will discover how to calculate the projected return on investment (ROI) of robotising selected processes.

Table of contents

• Introduction
• Automation project - why now?
• Step 1 - Analysis of business needs and objectives
• Step 2 - Selecting an experienced technology partner
• Step 3 - System design and integration
• Step 4 - Implementation and testing under production conditions
• Step 5 - Maintenance and development of the new system
• The most common challenges and obstacles
• Practical examples of the application of automation
• How to increase the effectiveness of an automation project?
• Useful resources - where to find further information?
• Summary and recommendations
• Completion

Introduction

In today's industrial reality, competition is becoming increasingly fierce and increasing customer demands are driving the need for continuous modernisation of manufacturing processes. One of the most important elements of this transformation is project automation, a comprehensive approach to implementing and optimising enterprise automation solutions. The article you are reading will help you better understand what such an investment looks like - from the initial plan to the maintenance and development of the implemented system. You will learn what to look for when choosing a technology partner, what are the most important stages of engineering and design work and how to assess the cost of such a solution.

The main benefit of reading this article is the structured and practical knowledge that will enable you to plan your own 'automation project' in your company. With proven tips, you will reduce the risk of mistakes and avoid underestimating costs and time. Find out how, with the help of modern equipment and the right solutions - including industrial robots - you can optimise your production line, improve the quality of your manufactured products and increase your profits.

Automation project - why now?

Automated solutions have been improving the competitiveness of companies for many years, but today the demand for them is growing even faster. Customers expect short delivery times, flexible orders and excellent product quality. With such requirements, manual production, even with a solid team of employees, is often not enough.

More and more companies are relying on robots and intelligent assembly lines to dramatically reduce the proportion of human labour in the most repetitive processes. This translates into:

• reducing production costs,
• maintaining and improving quality (less human error),
• higher productivity (24/7 production),
• elimination of downtime (rapid diagnosis of possible faults).

At Michale Automatika (also often referred to as Michale Automatika), we deal with the complete construction of machines and production lines, the implementation of robotic workstations and offer a wide range of industrial automation services. As an official distributor of SIASUN robots, we rely on the latest technologies, and our experience shows that companies that opt for an automation project gain a competitive advantage - especially when larger contracts or the need to significantly increase production capacity are on the horizon.

Step 1 - Analysis of business needs and objectives

The first stage of any engineering venture should be a thorough analysis of the company's needs. Whether you are dealing with a long-standing factory or just starting out in the market, it is crucial to identify:

• production tasks (e.g. packaging, sanding or painting),
• level of current performance,
• target quality parameters,
• expected savings (labour costs, energy costs),
• line load (number of shifts, production volume).

It is also worth thinking about long-term developments at this stage. If you intend to expand the line or implement new processes in the future, it is essential to consider this now. The automation project is not meant to be a one-off solution, but a foundation on which you can continue to build.

Definition of target ROI

Right from the needs analysis stage, you should consider what financial benefits you want to achieve. The return on investment in automation varies depending on the industry and the technology used. The food sector often has different requirements than the metal industry or the furniture industry. To get precise values for the possible ROI, first identify the operational costs that automation can reduce. Then estimate the value of the potential human errors and downtime avoided by robots and automated control systems.

It is already worthwhile using tools to help pre-calculate the cost of the investment and its potential benefits. A good starting point might be the example of ROI calculator - Welding Robotics available on our website.

Step 2 - Selecting an experienced technology partner

A successful automation project is based not only on high-quality equipment, but above all on the knowledge and practical experience of the engineering team. At Automatika Michale, we know that the mere selection of specific equipment - such as the type of SIASUN robot or vision system - is only part of the success. After all, the key is to design the entire system so that it is integrated into the company without making cumbersome changes and downtime.

Automation equipment and components

When you work with a technology partner, you choose the solutions that best meet your needs. This could be welding, sorting or painting robots, as well as PLCs (Programmable Logic Controller) and the entire sensory infrastructure. Much depends on the industry and the specific processes to be optimised.

If you can find a contractor who can provide design, parts supply, installation, system integration and follow-up care all at the same time - you can expect significant savings. This is not just about costs, but about a lower risk of delays and higher technical security for your investment.

Project coordination and management

A good partner supports the customer every step of the way: from the initial concept, through detailed arrangements and design work to post-warranty support. The coordination of these stages is particularly important in medium and large plants, where the implementation of automation involves several departments or even multiple production halls.

Step 3 - System design and integration

Once we have clarified expectations and selected suppliers for key components, it is time for detailed design work. This stage is sometimes considered the most difficult, as it requires consideration of both hardware issues (such as the placement of robots or sensors) and programming issues (software configuration, means of communication between controllers and the production management system).

3D model creation and simulation

Before anything is installed on the shop floor, it is a good idea to create a virtual model of the production line. By doing so:

• check that the layout of the equipment fits into the intended space,
• assess the ergonomics for the operators (if the work is still partly manual),
• you will test scenarios of possible failures,
• you will plan the robot's movement sequences and sensor parameters precisely.

Three-dimensional simulations avoid the situation where it is only at the assembly stage that we discover that certain components interfere with existing machinery or that access to the bench is difficult.

Interfaces and integration with ERP/MES systems

For an increasing number of companies, it is crucial that production lines are integrated into the IT environment. Companies are increasingly using ERP and MES (Manufacturing Execution System) systems for process management, inventory control and production planning.

The automation design should therefore take this combination into account - in practice, this can mean that a PLC or industrial robot will provide real-time data on production progress, material consumption or potential bottlenecks. This enables management to make accurate decisions more quickly.

Step 4 - Implementation and testing under production conditions

After the design phase comes the time for practical implementation. Assembling the equipment, bringing in the cabling, integrating it with old machines - all this requires precision and good organisation. The peace and quiet of the plan is important at this stage: attention to detail minimises the risk of downtime.

Commissioning stage

Deployment begins with what is known as the commissioning phase, in which engineers check that the equipment and software are working as intended. This is followed by a series of tests to detect possible inconsistencies, such as incorrect cycle times or insufficient safety parameters.

It is best practice to carry out a pilot run at a lower line load to then move to full capacity in a controlled manner. Well-planned testing is a guarantee that the automation project functions exactly as designed.

Staff training

New technologies often involve the need to train staff, especially operators or maintenance services. Today's systems can be highly advanced - it is no longer just about operating traditional machinery, but also about working with computer interfaces, process control and diagnostic panels.

The role of the contractor (e.g. Michale Automation) is then to conduct a series of practical training sessions. Employees can learn how to operate the new equipment in real conditions on their shop floor and learn the safety rules. This is particularly important when collaborative robots (cobots) that work right next to humans are being implemented.

Step 5 - Maintenance and development of the new system

Automation is not a one-off activity. Once you have completed implementation, you will probably start thinking about further optimisation, increasing production capacity or introducing robots into further processes (e.g. grinding, painting or packaging). To make this possible, however, you first need to take care of the service and maintenance of the system already in operation - including regular inspections.

Service, maintenance and safety

Servicing the machines and robots plays an important role in the long-term maintenance of the system. Without the right support, even the best automation design can lose its effectiveness after a while - all it takes is a few minor faults, neglect of periodic maintenance or a lack of software updates.

Some companies rely on their own maintenance department, but many prefer to work with a specialised service provider. In this option, key maintenance, replacement of wear parts and possible repairs are outsourced to a partner who is most familiar with the system in question and has spare parts available.

If you want to take care of a professional service, you can find out more about service and maintenance of posts offered by our team.

Line extensions and new functionalities

Companies that see the positive effects of implementing automation often extend the project to include more machines or robots. This could be the robotisation of painting or packaging processes, or the extension of an existing line with AI modules (e.g. vision systems to precisely check the quality of workpieces).

Integration with new IT solutions, such as quality management systems or advanced production data analytics, is also one way forward. The result is an increasingly 'intelligent' plant that reacts in real time to changes in demand and is able to quickly adapt line operating parameters to current market challenges.

The most common challenges and obstacles

Even the best-prepared automation project can run into difficulties. In companies that are new to robotics, fears of employees losing their jobs are common. In reality, automation mainly replaces the repetitive and most difficult physical tasks, while opening the way for the development of engineering competence and process supervision.

Another challenge is sometimes the technological barrier - if the production line is outdated or insufficiently equipped with the right sensors, additional upgrade costs must be anticipated. Finally, a common problem is to over-optimistically assume installation and integration deadlines. This is why careful planning of the work and consultation with departmental staff is so important.

Practical examples of the application of automation

Automation is excelling in a variety of industrial sectors, not just in the powerhouse of the automotive or white goods industries. Examples?

• Robotisation of welding - The robot can weld around the clock, in consistent quality, reducing scrap and increasing the rate of production. If you want to find out more, see also the offer related to robotisation.
• Robotisation of packaging - ideal for highly variable batch sizes. The robot can stack products in cartons, foil pallets or transfer finished packages to further production phases.
• Robotisation of painting - minimisation of material losses and uniform surface coverage.
• Optimisation of assembly - robots are able to carry out assembly tasks even with small product sizes, with complete repeatability and safety.

In all of these processes, it is crucial to think about the future and potential development opportunities. If you take this into account when designing, you will avoid costly upgrades in the coming years. A well-planned automation project should grow with your business.

How to increase the effectiveness of an automation project?

Automation is much more than just buying a robot. To make the whole thing work effectively and for the long term, it is worth remembering a few key principles:

• Ensure internal communication within the company - explain the advantages of the new approach to staff, organise workshops and training to minimise resistance to change.
• Set a realistic timetable - do not prevent the normal operation of other company departments. Try to implement the various stages so as not to block production.
• Think ahead - if you want to expand the line in six months' time with more modules, let the designers know at the start.
• Provide continuous supervision and service - Routine inspection and maintenance of equipment is a simple way to maintain high production efficiency.

It is also important that the entire digital infrastructure supporting production remains secure. Remember that control systems can be vulnerable to hacking attacks or viruses. Good cyber security practices therefore become part of a proper automation maintenance strategy.

Useful resources - where to find further information?

1. automation services
As part of the activities carried out, our company, Michale Automation, offers a wide range of support, from technical audits to staff implementation and training. If you would like to learn more about the full range of possibilities, visit our offer of automation services.

2. service and maintenance of posts
In order for an automated production system to work reliably for years, regular maintenance and repairs are essential. In doing so, it is worth relying on a proven supplier. See service offering.

3. ROI calculator for robotisation
If you are concerned about the cost of your investment, check the initial calculations or consult our experts using the ROI Calculator - Welding Robotics.

Summary and recommendations

The decision to start investing in an 'automation project' can sometimes be a significant step in the development of a company - especially if you want to increase production efficiency and compete in a demanding market. The action plan can be put into five main steps:

1. Analysis of the company's needs and objectives: Precise definition of the processes to be automated.
2. Selection of an experienced technology partner: Finding a company that is able to comprehensively plan a turnkey solution.
3. Design and integration: Creation of detailed plans, simulations and configuration of the control system and peripherals.
4. Implementation and production testing: Assembly, commissioning, staff training and testing of the line under target conditions.
5. Maintenance and development: Providing service, maintenance and further extensions to continuously improve the production process.

Once automation has been implemented, it is possible to see a clear increase in productivity, minimisation of shortages or greater flexibility in responding to orders. Industrial automation solutions also bring tangible financial benefits, such as energy savings or reduced risk of breakdowns (resulting in lower line maintenance costs).

Completion

With this article, we hope you have sorted out your knowledge of implementing an 'automation project' in a manufacturing company. Remember, automation is an opportunity to grow and gain a competitive edge - especially at a time when reliability and fast production are key to success.

If you would like to explore the topic further, get back to our team at Michal Automation and see how we can help you. You can also browse other articles on our blog or visit offer section.

We encourage you to comment, ask questions and share this article with your industry friends. The more companies in Poland decide to thoughtfully implement automation solutions, the faster our economy will meet the global challenges of the industrial market. Good luck with your own automation project!

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.