How to prepare your company for the implementation of process automation and robotics - a practical guide

Estimated reading time: approx. 9 minutes

TL;DR:

• Define exactly what processes you want to automate to reduce errors and downtime.
• Set clear business objectives and plan costing with ROI in mind.
• Create a communication plan within the company so that the team understands the benefits and changes associated with robotisation.
• Choose the right machines and systems, keeping safety and integration into existing processes in mind.
• Conduct tests, optimisations and training to engage employees and avoid implementation errors.

Table of contents

• Introduction
• Process diagnosis and goal setting
• Team analysis and company communication plan
• Budget and ROI - key parameters for cost-effectiveness
• Preparation of technological infrastructure and security
• Selection of robots, machines and system integration
• Testing, optimisation and training of the team
• Practical conclusions and implementation steps
• Summary
• FAQ

Introduction

Automation and robotisation of technological processes is not just a temporary trend, but a long-term approach that supports the competitiveness of companies in almost every industry. Rising labour costs, ever-increasing customer demands for quality and speed of order fulfilment, as well as the global shortage of skilled workers confirm that minimising manual processes is a priority today. In this article, you will learn how to prepare your company step-by-step for the implementation of process automation and robotisation. You will learn about the main stages of process analysis, planning, as well as practical tips to ensure that the entire project runs smoothly and brings tangible benefits.

Process diagnosis and goal setting

In order to successfully embark on a process automation and robotics project, a solid analysis of your company's workflow is essential. At this stage, it is worth conducting a detailed review of all activities related to the production or service you provide and answering some key questions:

• What processes generate the most errors or downtime?
• Where in the company are costs highest and what causes them?
• Which operations are the most repetitive and taxing for staff?
• What results do you expect from implementing automation? (e.g. reduction in cycle time, reduction in scrap, increase in production volume)

The first step is to create a process map (so-called process mapping). Identifying all the activities on the production line or in the service chain will allow you to organise your knowledge and clarify your objectives. You can allocate a small project team for this purpose or use external consultancy to reliably measure the duration of each operation and determine the costs resulting from any errors.

The first, specific objective of the automation could be, for example:

• "Reduce outages by 20% by the end of next year."
• "Increase welding quality by 25% while maintaining current staffing levels."

Well-set goals will also be a benchmark for further action.

Criteria for selecting processes for automation

Repeatability
If certain activities are repeated at fixed intervals and require continuous employee involvement, it is a good candidate for automation.

Error rate
Processes with frequent faults or deficiencies expose the company to losses. Robotisation can significantly improve product quality and reduce complaints.

Security
Tasks carried out in harmful conditions (dust, high temperatures, working with chemical fumes) are particularly important from a safety point of view. Robots make it possible to eliminate risks to people.

Availability of resources
One of the key reasons for robot deployments in modern manufacturing is the shortage of skilled personnel. Automation minimises the risk of staff shortages while increasing product volume.

Team analysis and company communication plan

The second key pillar is the involvement of staff and clear communication of the goals of process automation and robotisation. Without a well-laid-out strategy for developing staff competence, a project can encounter a lot of resistance or misunderstanding of the benefits.

Proper preparation of organisational structures

• Appointment of a coordinator: Designate a person (or several persons) responsible for overseeing the implementation. The project coordinator will be responsible for communication between the production, IT and management departments.
• Team meetings: Introduce regular project meetings to discuss progress, challenges and next steps.
• Consultation with shop floor staff: In practice, it is the machine operators or line-level employees who have the most practical insights into optimisation needs and opportunities.

According to the experience of Michale Automation, developing a shared vision and involving staff in planning avoids conflicts and misunderstandings. In addition, involved employees become natural ambassadors for change.

Budget and ROI - key parameters for cost-effectiveness

Process automation and robotisation implementations require financial resources, but a well-planned investment pays off quickly. Calculating profitability and forecasting the so-called ROI (Return on Investment) is key here.

Calculating ROI from robot investments

• Equipment purchase costs: include both the price of the robots (including accessories) and the necessary modifications to the production line.
• Integration costs: These can sometimes be reduced if the company has a team to carry out the implementation internally. Otherwise, an experienced integrator or technology provider will be needed.
• Funding for staff training: operators and the maintenance team will need to be trained to operate and service the new equipment.
• Expected benefits: Increased productivity, reduced human labour costs, reduced waste and complaints or the ability to run machines 24/7.

For companies interested in robotic welding, for example, Michale Automation has prepared a free calculator to estimate the return on investment. Those interested are encouraged to use it here:
ROI calculator for welding robotisation.

Remember that accurate calculations increase the chance of a positive decision from the board and allow you to choose the right scale of automation.

Preparation of technological infrastructure and security

The next step in implementing automation is to adapt the technical facilities to the requirements of robots and automated lines. These include issues related to production space, power supply, communication systems and support equipment.

Technical issues - what do you need to check?

1. Shop floor space
   Robots and machines need sufficient space to work safely. Make sure there is sufficient area for manipulator movement and an area for servicing.
2. Safety systems
   In automation, one of the priorities is the protection of people's health. Fences, light curtains, safety readers or emergency stop buttons are just some of the solutions required by standards and regulations.
3. Integration with IT systems
   Planning the implementation of robots cannot overlook the aspect of communication with ERP or MES systems. In this way, real-time production status data can be received and material replenishment can be ordered automatically.
4. Stable power supply and service
   Automated production lines must run continuously, so power reliability and a qualified service team are prerequisites for robotisation to benefit.

Selection of robots, machines and system integration

When choosing specific robots or machines, it is important to pay attention not only to the price, but above all to the configuration possibilities, technical parameters and service support. Michale Automation, as an official distributor of SIASUN robots, offers tailored solutions for a variety of industries - but it is worth first determining whether you need robots dedicated to welding, packaging, grinding or other processes.

How do you choose an automation solution?

1. Product type and process parameters
   You will approach metal welding applications differently, and repetitive packaging or painting differently. Details such as weight, flexibility and product size are crucial.
2. Robot flexibility
   Look for solutions that can be integrated into an existing line or easily rearmed if production is varied. Examples include cobots, i.e. robots that collaborate with humans and require no (or fewer) additional safety barriers.
3. After-sales support
   Many companies calculate costs only at the purchase stage, forgetting about operation and service. Remember that good maintenance and professional support reduce potential downtime and extend the life of equipment. If you are interested in maintaining existing workstations, you may want to check out the option of service and maintenance of posts.
4. System integration and data exchange
   When you think about automation, you can benefit from different types of integration: with vision systems, with ERP/MES or even with tools based on artificial intelligence. In the context of full integration, it is also worth checking out the offer robotisation of repetitive productionso that routine tasks can be carried out in a stable and virtually maintenance-free manner.

Testing, optimisation and training of the team

After the installation and first trials of the robotic line, testing and optimisation are crucial. This stage often reveals additional challenges: unexpected conflicts between machines, a mismatch in the vision system or an error in IT integration. With carefully planned tests, it is easier to make adjustments.

Steps in the testing and training phase

• Real-life performance test: Check the performance of the machines during different shifts and with a variety of products.
• Data analysis: Collect data on the number of cycles performed, any downtime or the quality of the final product.
• Improvements: Make minor changes to the robot's software, welding, packaging or other process parameters to increase line stability.
• Team training: Train the operators in the use of the robot and the first maintenance operations. Take care to impart practical knowledge to them in an understandable way, avoiding excessive technological jargon.

A poorly trained workforce can effectively undermine the point of automation, generating errors and machine downtime. That is why investment in training is as important as in the robot itself.

Practical conclusions and implementation steps

Based on past market observations and conversations with customers, some universal advice can be identified for those planning future implementation:

• Pre-purchase internal audit: Before investing in robots, make sure your company has undergone a thorough audit of its processes, needs and technical resources.
• Test solutions on a smaller scale: if you are unsure about extensive applications, start with a professionally prepared pilot project (e.g. automation of one workstation).
• Talent analysis within the organisation: there may be people on your staff who can be trained to work with robots, reducing the integrator's costs.
• Measure the effects regularly: establish a schedule for reviewing and analysing key indicators such as OEE (Overall Equipment Effectiveness) or quality indicators.

In the implementation of automated production workstations, the technology partner plays an important role. Michale Automation builds turnkey machines and production lines and implements robotic solutions tailored to specific industry needs and conditions. By working with a company that has experience in integrating robots and control systems - you gain professional support from design to service.

Summary

Implementing process automation and robotisation is a multi-stage undertaking that requires a well-thought-out strategy. From a detailed diagnosis of the processes and setting specific goals, to planning communication with the team and preparing the budget, to selecting the right equipment and conducting tests - each stage has a direct impact on the final effectiveness of the investment.

Key points to remember:

• Set clear objectives and identify the processes most amenable to automation.
• Conduct a sound cost and potential return (ROI) analysis.
• Ensure proper technical infrastructure, security and systems diagnostics.
• Choose a trusted technology partner and focus on robust integration.
• Bet on training - an educated team is a guarantee of a quick return on investment.

Well-prepared and executed automation opens the door for a company to scale faster, streamline processes and build a competitive advantage in a demanding market. If you want to learn more about the possibilities of a robotic workstation (e.g. packaging), visit robotisation of packaging and see how Michale Automation can support your business in the process.

We also encourage you to take a look at our offer of robotisation of repetitive productionif you want to maximise the potential of your automated lines in your daily operations.

Do you have questions or concerns? Contact us for more information, to arrange a meeting with our expert or to request a customised analysis of your company's automation options.

Thank you for your time. If you find this article useful to your friends or colleagues, please share it and help us spread the word about effective robot implementations in modern manufacturing. Good luck with your 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.