Automation and robotisation: how to integrate robots into your production line - step by step

Estimated reading time: approx. 8-9 minutes

TL;DR

• Automation and robotisation is the key to competitiveness and scalable production.
• Implementation begins with needs analyses and selection of suitable robots and accessories.
• Design and simulation avoid costly errors during installation.
• Employee training and implementation tests are essential for proper operation.
• Monitoring of indicators such as OEE and regular modifications guarantee full business benefits.

Table of contents

The importance of integrating robots into the production line
Step 1: Analysis of needs and opportunities
Step 2: Selecting the right robot and components
Step 3: System design and simulation
Step 4: Assembly and configuration of the robot on the line
Step 5: Staff training and implementation tests
Step 6: Commissioning and monitoring the system
The most common challenges and mistakes made during integration
Return on investment (ROI) in robotisation
Summary - key recommendations

Introduction

In an era of rapid growth in automation and robotisation, more and more companies are facing the challenge of integrating robots into their existing production lines. For companies that want to increase productivity, improve quality and reduce costs, the introduction of robotic workstations is becoming a necessary step in many cases. However, it is worth knowing how such an implementation proceeds step by step and what to pay special attention to.

In this article, we will explain why robot integration is an important part of an industrial strategy, present the process of implementing such a solution and discuss examples of best practice. After reading, you will learn what else to consider at the planning stage and how to carry out the entire project smoothly. We will also refer to market data to show what trends are shaping today's robotics market.

We invite you to read on behalf of our company - Michale Automation. We deal with the construction of machines and production lines, industrial automation and the implementation of robotic workstations in companies, and we are the official distributor of SIASUN robots.

The importance of integrating robots into the production line

Integrating an industrial robot into an existing production line means combining machines, software and the working environment in such a way that the robot can work effectively with other components in the system. For many companies, automation and robotisation have become the way to gain a competitive advantage, protect against rising labour costs and ensure production scalability.

According to the latest International Federation of Robotics (IFR) report for 2023, Poland is still below the world average in terms of the number of robots per 10,000 employees, but the development of robotisation in our country is gaining momentum every year. Some industries are seeing double-digit growth rates in the number of new industrial robot installations. This confirms that the demand for automated production lines will continue to grow.

Changing market realities

The current market forces companies to continually optimise their processes - both in terms of cost and organisation. Replacing repetitive tasks with robots not only brings financial savings, but also increases work safety and allows better use of human resources in more creative or advanced areas. Some companies are also choosing to integrate robots into their ERP/MES systems. This gives them access to real-time production data, enabling faster decision-making and better management of the entire infrastructure.

Step 1: Analysis of needs and opportunities

The first step in implementing a robotic workstation is a sound assessment of the company's needs and an analysis of the production processes. At this stage, the following issues, among others, are identified:

• The type of tasks to be performed by the robot (e.g. welding, packaging, handling of components).
• Requirements for precision, speed or load.
• Safety aspects (e.g. use of safety curtains, fences or cobot collaboration).
• Availability of space and capacity to modify the existing production line.

Typically, companies hold meetings with management, production engineers and operational staff to collect all the necessary information together. At Michale Automatika, we place great emphasis on talking to customers at this stage, as a proper diagnosis of needs allows us to develop the optimal solution.

Step 2: Selecting the right robot and components

After the initial analysis, it comes time to select the specific type of robot and all the components that will be necessary for integration. The most important parameters to consider are:

• Capacity - the maximum mass that the robot must carry.
• Coverage - working radius, which should cover the area of operation in a given production slot.
• Speed of operation - robot performance important for mass production.
• Accuracy - crucial, for example, in precision welding processes or the packaging of delicate components.
• Type of working environment - e.g. dust, humidity or temperature conditions.

Michale Automatika is an official distributor of SIASUN robots, which gives us a wide range of solutions - from small, flexible cobots to heavy, specialised industrial robots. At this stage, it is also worth determining what accessories the application will require, such as grippers, tool heads, force sensors or vision-based quality control systems.

Cooperation with additional systems

It is not just the robot that is important. Often, vision systems that can accurately recognise the position and shape of products also prove to be a key element of integration. Producing large batches of a single item obviously makes the machines' job easier, but if there is variability in the process, the robot needs to be 'aware' of what it is moving and how. This is when artificial intelligence (AI)-based vision systems become increasingly important, as they help machines make real-time decisions.

Step 3: System design and simulation

Once all the assumptions have been gathered and the main parameters of the robot have been established, it is worth simulating the operation of the entire system. Designing in a virtual environment helps to verify that:

• The robot will not interfere with other parts of the line.
• The arrangement of safety sensors and guards is correct.
• The target work rate is achievable in practice.
• There will be no unforeseen delays in the various stages of production.

Professional computer tools, such as RobotStudio, Process Simulate or RoboGuide, allow engineers to carry out tests in a virtual environment without the risk of causing downtime or damage to real equipment. In this way, the robot's schedule can be optimised and costly corrections can be avoided during the implementation phase.

Positive results from the simulation tests give the green light to start working in real-world conditions. However, if inconsistencies arise (e.g. the robot exceeds the acceptable safety limits too often), design changes will have to be made.

Step 4: Assembly and configuration of the robot on the line

Once the design has been approved and simulated, it is time to install the robot at the target site. One of the challenges can be limited space and the need to adapt the various line segments to work with the new machine. Once all health and safety requirements are met, configuration can begin:

• Assembly of the robot and its accessories (e.g. grippers, welding heads).
• Connection of cabling and communication interfaces with host machines.
• Calibration of vision systems, if planned.
• Uploading and configuring the robot control software.

Depending on the complexity, the process can take from a few days to even a few weeks. If the production line is running 24/7, implementation is usually carried out in stages to reduce downtime.

Alignment with standards and regulations

The integration of an industrial robot brings with it the need to comply with safety standards such as ISO 10218 (concerning the safety of industrial robots) or EN ISO 13849 (related to machine safety). Appropriate certification and CE marking must also be ensured. At this stage, everything from safety sensors to the emergency stop system (E-Stop) is tested.

Step 5: Staff training and implementation tests

Even the best robot will not do its job if the staff do not know how to handle it. It is therefore crucial to train staff - not only the operators directly operating the station, but also the maintenance department, which will be responsible for the maintenance and eventual repair of the equipment.

• Operators learn the basics of programming the robot, changing tools and interpreting error messages.
• Maintenance department - learns about maintenance procedures, replacing components, diagnosing problems.
• Management - on the other hand - may need training in analysing data generated by vision systems or MES tools to better adapt production to changing market requirements.

Following training, a series of implementation tests are carried out, during which the behaviour of the system is observed under real production conditions. Only positive results from these tests allow the system to move to the next stage.

Step 6: Commissioning and monitoring the system

The full commissioning of a robotic station essentially means that it begins to operate as normal, carrying out the production tasks planned for the robot. However, it is worth remembering that implementation does not end with the start of the line. Continuous monitoring of key indicators is very important:

• OEE (Overall Equipment Effectiveness) - shows the efficiency of the equipment and the use of available working time.
• MTBF (Mean Time Between Failures) - average time between failures.
• Quality of manufactured products - whether the introduction of the robot has reduced the number of shortages.
• Security level - whether the number of incidents has increased and whether the security features are working properly.

If parameters turn out to be lower than expected, they can often be corrected by modifying the robot's motion sequence, improving the ergonomics of the workstation or introducing additional vision solutions. By continuously improving the integration of robots into the production line, it is possible to increase productivity and reduce cycle times.

The most common challenges and mistakes made during integration

While automation and robotisation bring many benefits to companies, it is worth bearing in mind the typical pitfalls that can arise during implementation:

• Underestimation of design costs - The expense of the robot itself is only part of the investment. You also have to factor in the cost of accessories, safety systems, line modifications or employee training.
• Lack of precise diagnosis of needs - if implementation takes place without a sound process analysis, there is a risk of poor exploitation of the robot's potential.
• Insufficient staff training - Failure to understand the capabilities and limitations of the robot leads to downtime and reduced productivity.
• Too little flexibility in the solution - designing a stand to serve only one product variant can make future expansion or change of product range more difficult.

At Michale Automatika, we assume that the key to success is proper preparation - both at the conceptual level and during the later stages of implementation.

Return on investment (ROI) in robotisation

One of the key factors in deciding whether to implement robotic workstations is, of course, the potential return on investment (ROI). Often entrepreneurs are concerned about the high cost of purchasing a robot and integrating it into an existing production line. However, in practice - especially with continuous operation (24/7) - industrial robots are able to start 'earning' for themselves very quickly.

How do you calculate ROI in robotisation?

1. Investment costs:
   • Robot price.
   • Costs of accessories, sensors, safety components.
   • Expenditure on design and integration.
   • Training and implementation costs.
2. Savings:
   • Reducing human labour costs on repetitive jobs.
   • Fewer failures due to improved quality.
   • Lower risk of accidents at work (from the point of view of possible compensation).
   • Shorter downtime.
3. Payback period:
   • Calculated most often in months or years (e.g. 12-24 months).

We encourage you to make use of our ROI calculator, where it is possible to make an initial estimate of how long an investment in welding robotisation can take to pay off. Although the example relates to a specific welding operation, the same principles can be transferred to many other processes.

Summary - key recommendations

Implementing robots and integrating them into a production line is a complex process that requires a considered approach, technical expertise and design experience. However, when done well, automation and robotisation bring a range of benefits: from cost reductions to significant improvements in quality and occupational safety.

• Always start with a sound analysis and identification of exact needs.
• Choose a robot and additional tools in line with the nature of the process - there are no one-size-fits-all solutions for every industry.
• Design and test in a simulation environment to avoid surprises during installation.
• Provide adequate training and service support - the competence of the team is as important as modern equipment.
• Monitor performance indicators and carry out regular health checks.

Want to find out more about other forms of manufacturing robotisation? Take a look at our side of robotisation services. If you need to automate your welding process, discover our solutions for Robotisation of welding. In order to maintain the highest efficiency of a newly deployed robot, proper servicing and Service and maintenance stands.

Integrating robots into a production line is a process that, although requiring specialist knowledge, can bring tangible benefits to a company in the long term. In today's business reality, there is increasing pressure to reduce costs, improve quality and respond quickly to changes in demand. Well-designed robotic solutions make it possible to meet these challenges while improving working conditions for people.

At Michale Automation, we make sure that throughout the entire process - from design to simulation to final testing - the investment is tailored as much as possible to the needs of the specific industry. In this way, the integration of robots provides a solid support for the development of the company, instead of just a one-off solution.

If you have questions, are planning to robotise a selected process or would like to consult on your needs, please feel free to get in touch. And if you found the article helpful, we also encourage you to read the rest of the material in our knowledge area, comment and share it on social media.

FAQ

How long does it take to implement a robotic workstation?
The implementation time mainly depends on the complexity of the process, the degree of line modifications required and the resources available. It usually ranges from a few weeks to several months.

Is the cost of robotisation very high?
Although the investment may initially seem large, the savings from higher productivity, fewer shortages and reduced labour costs must be taken into account. In many cases, the return on investment is quicker than initially assumed.

Does operating the robot require specialised skills?
Operators and maintenance staff usually receive adequate training to enable them to operate and maintain the robot efficiently. Today's solutions are designed to be as intuitive as possible to operate.

Are there industries where robotisation does not make sense?
In practice, most industrial sectors can benefit from robotisation. Even for low-volume or specialised production, suitable solutions can be found, especially with increasing technology capabilities and falling implementation costs.