Automation service - how to keep systems reliable and reduce production downtime

Estimated reading time: approx. 10 minutes

TL;DR:

• Regular servicing of automation minimises costs and downtime.
• Inspection surveys allow faults to be detected in advance.
• An adequate service schedule ensures production continuity.
• Upgrading systems extends the life of machines.
• The specialists have the necessary knowledge and tool facilities.

Table of contents

• Introduction
• Automation service - what exactly is it?
• Importance of automation service in industry
• Automation service in practice: step-by-step stages
• How do you effectively plan your automation service schedule?
• What factors influence the cost of automation service?
• Automation service in the context of the robotisation of workplaces
• We link to related services
• The most common challenges and problems in automation service
• Retrofitting and servicing as a way of extending the life of machinery
• Benefits of entrusting the service to specialists
• Practical tips for managers and business owners
• Summary: Key findings
• Incentive to act

Introduction

Automation service is a key element in maintaining process continuity in industrial plants. Modern companies increasingly rely on highly automated production lines, machines and industrial robots. Without regular inspection, diagnosis and maintenance of automation systems, even a seemingly minor fault can cause long-term downtime, generating huge financial losses.

In this article, we will discuss how to organise an effective automation service step by step. We will also point out why these services should be a priority for every manufacturing company - regardless of the scale of the business. From the reading you will learn, among other things:

• What the automation service process looks like from diagnostics to upgrades.
• How to plan the review schedule accordingly.
• What to look out for to minimise the risk of failure.
• How Michale Automation (Michale Automation) can help your business.

For years, our company, Michale Automatika, has been providing services in the area of design and construction of machines, production lines and implementation of robots from the world's leading manufacturers (including SIASUN). This experience allows us to comprehensively support our customers in servicing automation equipment and systems. Regular maintenance and fast service are one of the foundations of stable production, without the need for sudden and costly downtimes.

Automation service - what exactly is it?

The automation service is not only about emergency repairs, but also about a wide range of preventive measures to ensure failure-free control systems and individual devices. This includes, among other things:

• Hardware and control software diagnostics.
• Carry out periodic inspections and maintenance.
• Repair and replacement of faulty components.
• Control tests, calibration and adjustment of equipment.
• Upgrades to existing systems to improve their performance.

Thanks to these measures, the company is able to operate continuously and any faults can be nipped in the bud or at least identified in advance.

Importance of automation service in industry

One of the most significant challenges in production plants is unexpected downtime. According to industry estimates, each hour of line downtime can cost a company from several to even tens of thousands of zlotys - it all depends on the specifics and scale of production.

Planned and reliably carried out automation service:

• Reduces the risk of failure to a minimum.
• It allows potential faults to be predicted through diagnostics.
• It facilitates smooth production and maintains product quality.
• Reduces overall line maintenance costs - it is cheaper to maintain than to repair after a critical fault has occurred.

From the point of view of managers and business owners in the manufacturing sector, regular maintenance means not only stability, but also predictability of expenditure. They appear in proportion to the planned maintenance activities, rather than in the form of sudden and usually very expensive emergency investments.

Automation service in practice: step-by-step stages

The following is a general service routine that greatly improves the work of our teams at Michale Automatics.

Demand declaration and initial documentation

The first step is usually to contact the service provider - this can be by phone, email or a dedicated reporting platform. It is then necessary to provide detailed information on:

• Type of device (e.g. PLCs, converters, industrial robots).
• Type of failure, errors displayed by the system.
• Previous service history.
• Dates of last inspection and upgrade.

At this stage, specialists are able to make an initial determination as to whether the problem is due to a hardware or software fault or perhaps a misconfiguration. Sometimes telephone advice is sufficient, but in most cases it is necessary for an engineer to intervene at the production site itself.

Diagnosis and root cause analysis

Once the service technician arrives on site or the component is delivered to the service centre, a thorough diagnosis of the cause of the fault is made. This involves:

• Analyse entries in error logs and system logs.
• Control of operating parameters (voltage, temperature, current).
• Assessing the visual and mechanical condition of components (circuit boards, bearings, contactors).
• Verification of correct network communication (e.g. EtherNet/IP, Profinet protocols).

Often, specialists compare the current performance of the device with the manufacturer's factory values. This step requires not only specialist knowledge, but also professional test tools.

Repair, reconditioning and replacement of components

Once the cause of the failure has been identified, the actual repair is undertaken. This may include:

• Replacement of faulty electronic components (capacitors, transistors, integrated circuits).
• Repair or reconditioning of mechanical components (bearings, guides, drive belts).
• Update or reload the control software.
• Calibration of equipment to restore operating parameters to factory standards.

Sometimes the automation service requires unusual activities, such as reworking the machine design, consulting the original parts manufacturer or integrating new systems into old lines. At Michal Automatik, we often encounter situations where modules are already end-of-life and customers need to fit replacements with as similar parameters as possible.

Testing, calibration and quality control

Once the repair or replacement of components has been completed, it is crucial to check that the equipment is operating correctly under near-real conditions. To this end, diagnostic and control tests are used and verification of set parameters is carried out.

If a simulation system can be involved in the process, it is worth doing so, as the simulator avoids dismantling the machines again if another anomaly occurs. The tests take into account:

• Stability of operation (checking that errors do not reappear in the logs).
• Correct temperatures and correct power supply to equipment.
• Compatibility with other production line components and control systems (e.g. SIASUN robots).
• Safety processes, including system responses to emergency conditions.

Documentation and recommendations for the customer

The final stage is to provide the client with a detailed report of the work carried out. This contains the results of the tests, a description of the anomalies diagnosed, a summary of the spare parts used and recommendations for the future (e.g. inspection in a few months, safety system upgrade).

It is also important to adequately secure and archive the configuration so that the status of the unit can be quickly compared at any subsequent service. Regularity of maintenance helps to reduce downtime - all it takes is a planned schedule.

How do you effectively plan your automation service schedule?

For most companies, the priority is to keep production running, which often means keeping interruptions to an absolute minimum. However, even state-of-the-art machinery has to undergo inspection and maintenance.

Preventive versus reactive approach

• Preventive approach is based on a predetermined schedule and regular health checks of the equipment. This allows potential faults to be pre-empted, which usually results in a short planned shutdown instead of a long line stoppage due to a sudden breakdown.
• Reactive approach implies intervention only after a fault has occurred. It may be tempting for companies that rely on high equipment turnover or have machines with low failure rates. However, for most manufacturing companies, especially those using advanced robots, controllers or actuators, such a solution carries an increased risk of costly and unpredictable downtime.

Elements of an effective schedule

• Maintenance intervals: in most cases, maintenance every 3-6 months is recommended, but in heavily used lines this may be more frequent.
• Principles of equipment performance monitoring: real-time recording of parameters such as temperature, vibration, as well as analysis of programming logs.
• Ensuring the availability of key spare parts: this is particularly important with older systems and less popular models.
• Regular staff training: production staff should be able to recognise early signs of failure and provide basic assistance.

What factors influence the cost of automation service?

Estimating the cost of an automation service is not straightforward, as it depends on many elements:

• The extent of the failure itself - replacing a small module is usually much cheaper than repairing a complex control board.
• Availability of spare parts - with rare or obsolete components, prices can be higher than for popular solutions.
• Rates for professional services - more specialised and fast action often costs more, but minimises downtime.
• Additional upgrade work - software updates, safety upgrades, replacement of cables or sensors also affect the total price.

The key to cutting costs can be signing a long-term service contract with an experienced supplier. In such a contract, cyclical maintenance, priority response times and attractive service rates can be agreed, giving financial predictability and production stability.

Automation service in the context of the robotisation of workplaces

In the age of modern automation, more and more companies are opting for robotisation of various production processes. However, purchasing and installing the robots themselves (e.g. from SIASUN) is only the beginning of the journey. Equally important is ensuring their subsequent operation and maintenance.

Cobots or industrial robots require:

• Regular lubrication and replacement of mechanical parts (e.g. bearings, seals).
• Update of control software and safety controllers.
• Verification of the calibration of vision systems or force sensors.
• Checking network connections and input/output signals.

For robotic workstations, it makes sense to work with a service company experienced in integrating robots and vision systems into existing production lines. We at Michale Automatika support our customers in both daily operation and comprehensive maintenance.

We link to related services

If you would like to learn more about the full range of our services, we encourage you to visit the website:

• Our services ⇒ Automation Services Michale

At the same time, we offer specialised service and maintenance work for workstations and production lines:

• Service and maintenance ⇒ Service and maintenance stands

As part of the implementation of new solutions, you can also check out our robotisation offering, which will reduce labour costs and make your plant more resilient to staff fluctuations:

• Comprehensive robotisation ⇒ Robotics - service offering

The most common challenges and problems in automation service

Even a well-thought-out service process can encounter various difficulties. Here are the most common ones:

No technical documentation or service history

It is not uncommon for companies to collect documents in a disorganised manner, which delays diagnosis and repair. It is worth keeping a consistent, up-to-date archive of all service interventions, along with a description of changes to machine configurations.

Unqualified staff

Operating machines and robots requires training. Employees should regularly attend training in the basics of PLC programming or HMI operation to be able to correctly interpret the first signs of failure.

Complexity and diversity of systems

In large companies, different departments may use equipment from multiple manufacturers. Their integration and service requires comprehensive knowledge and testing tools. Working with a single experienced service provider is sometimes the best solution and saves valuable time.

Time pressure on production

Many managers fear planned downtime for periodic maintenance. However, planned downtime is definitely cheaper in the long run than a sudden, uncontrolled breakdown in the middle of the peak production season.

Retrofitting and servicing as a way of extending the life of machinery

The lifespan of equipment can be dramatically increased by combining regular servicing with periodic modernisation. While some components are subject to natural wear and tear, upgrading the control system or implementing new functionalities can breathe 'second life' into an older production line.

• Software update - introduces new operating algorithms, optimises energy consumption, improves security.
• Hardware upgrade - replacing drives with energy-efficient ones, adding vision sensors for quality control.
• Integration with IT systems (ERP/MES) - allows ongoing control of production indicators and faster response to deviations.

In an era of rising production costs and skills shortages, modernisation can sometimes be more cost-effective than completely replacing machinery.

Benefits of entrusting the service to specialists

Is it worth outsourcing automation maintenance to an external company instead of relying solely on the in-house maintenance department? Many companies rely on a mixed model: in-house staff are responsible for basic maintenance, while tasks requiring advanced knowledge or expensive measurement equipment are delegated to specialists.

Key benefits:

• Access to advanced diagnostic facilities.
• Faster path to support from component manufacturers and suppliers.
• Guaranteed knowledge of current technology and safety standards.
• Flexibility - an external service company can more easily organise additional technicians in the event of a major breakdown.

At Michale Automatics, we have our own team of engineers and parts warehouse, which allows us to respond rapidly - especially in the region where we operate on a daily basis.

Practical tips for managers and business owners

• Create clear procedures for reporting faults - every employee should know who to report to and how.
• Invest in training - employees' knowledge of machines directly affects the speed of response.
• Keep an archive of your data - both in the form of physical documentation and digital backup.
• Plan downtime for maintenance - preventively to avoid the need to interrupt production at peak times.
• Consult your service company regularly - frequent contact and reports allow you to anticipate upgrade needs.

Summary: Key findings

• Automation service is not just about ad hoc repairs, but a comprehensive process to prevent major failures.
• A rational maintenance schedule and attention to detail (diagnostics, calibration, upgrades) ensure production continuity.
• The state-of-the-art service also includes industrial robots and advanced control systems.
• Failure costs always exceed maintenance expenses, so it is worth betting on preventive measures.
• Entrusting an automation service to a specialised company (such as Michale Automatics) gives you access to expert knowledge and unique resources.

Incentive to act

Your production line deserves reliability and full support. At Michale Automation, we have an experienced team of engineers and extensive technical facilities. This enables us to carry out comprehensive servicing, maintenance, as well as upgrading of your machines and production stations.

If you would like to find out more about service solutions and consultancy services, please do not hesitate to contact us:
Service and maintenance stands,
Automation Services Michale

You can also use the other materials on our blog to gain a better understanding of modern robotisation and process automation methods. We will be happy to answer any questions you may have and help you choose the optimal solution for your industry.

Thank you for reading. If you would like to share your opinion or your own automation service experience, please feel free to comment and contact our team. Together we can make your production even more efficient and reliable.

FAQ

How often should automation equipment be inspected?
The recommended interval is usually 3-6 months, but more frequent checks also work well in heavily used lines.

Is it worth signing a long-term maintenance contract?
Yes, because this solution ensures priority response times, fixed rates and no surprising downtime.

How quickly can you respond to an emergency?
Much depends on the service contract and the availability of technicians. At Michale Automatics, we strive to ensure the shortest possible intervention time.

Does an upgrade always come out cheaper than replacing a machine?
Most often, yes, especially when the mechanical base and design of the equipment are in good condition. Upgrades allow machines to be upgraded at less expense.