COMPANY AUTOMATION - HOW TO SUCCESSFULLY IMPLEMENT ROBOTISATION AND INCREASE PRODUCTION EFFICIENCY

Estimated reading time: 8 minutes

TL;DR:

• Automation reduces costs and errors in the production process
• The key is to precisely define business objectives and select the right robots
• Implementation includes design, pilot testing and crew training
• Regular servicing and monitoring of KPIs ensures the effectiveness of robotisation
• A thoughtful approach to changing organisational culture increases employee acceptance

Table of contents

• Introduction
• Main content
  • Why is it crucial to automate your business?
  • Planning an automation strategy - where to start?
  • Choosing the right technology and selecting robots
  • Steps to implement robotisation - a proven workflow
  • Costs and return on investment (ROI) in company automation
  • Examples of robotisation applications in various industries
  • Staff training and change management
  • Monitoring, optimisation and service
  • Official distributor of SIASUN robots - a guarantee of quality
  • Practical conclusions - what is worth remembering?
  • Summary
• FAQ

Introduction

Company automation is an increasingly common theme in the manufacturing sector. Rising labour costs, difficulties in recruiting skilled employees and high customer expectations of quality are causing businesses to look for solutions to improve process efficiency. This is why there is so much interest in the robotisation of production. In this article, we show you what the entire automation implementation process looks like from the business and technical side. After reading, you will learn how to plan the investment step by step, avoid pitfalls and achieve a real increase in competitiveness.

Main content

Why is it crucial to automate your business?

The modern market requires companies to adapt quickly to changing conditions and quality requirements. Customers' expectations of timeliness and flexibility of orders are also increasing. The automation of a company therefore brings many benefits that affect the development and stability of the business:

Reduction in operating costs
With robots and automation systems, the cost of human labour can be reduced where it is repetitive and less efficient. It also reduces errors, resulting in less wastage of materials and energy.

Improving quality and repeatability
Automated processes ensure reproducible product quality, which eliminates rejects and complaints. This is particularly important in industries where absolute precision and compliance with strict standards are required (e.g. automotive or medical devices).

Production speed and efficiency
Industrial robots and cobots work without interruption and even 24/7. This can significantly reduce production cycle times, leading to faster order processing.

Flexibility and scalability
Many manufacturers are thinking about expanding production lines with increasing market demands. Automation makes it easier to scale processes and make changes to technology, especially if the company uses modular robotic solutions.

Planning an automation strategy - where to start?

The first step in the successful implementation of robotisation is planning, based on an in-depth analysis of the company's needs. At Michale Automatika, we always recommend that, prior to investment, processes are carefully traced and the areas where the company's automation will bring the greatest benefit are identified.

Process analysis and production audit

Start by mapping out all the basic operations - from material preparation to assembly to quality control. Worth considering:

• repetition of activities,
• time-consuming to implement,
• error-prone,
• costs associated with maintaining a particular part of the process (people, machinery, raw materials).

The post-audit report usually shows so-called bottlenecks (e.g. packaging or welding stages). This is very helpful for prioritising and calculating the expected return on investment (ROI).

Definition of business objectives

The next element is to determine what we actually want to achieve by automating the company. These could be goals such as:

• reducing labour costs by 20% over two years,
• reducing the production cycle time from 60 to 30 seconds,
• Increase quality and reduce shortfalls to 1% per month,
• eliminating occupational accidents on the job.

Accurate identification of business objectives will allow a precise timetable of activities to be developed and implemented, and will make it easier to later assess whether the investment has translated into the anticipated profits.

Choosing the right technology and selecting robots

Robot technology should be precisely matched to the type of process and the target performance of the line. There is a whole range of solutions available on the market - from collaborative robots (cobots) to highly specialised multi-axis machines for welding, painting or assembling large-scale components.

Key criteria for robot selection

1 Range of movement and lifting capacity. Check that the robot in question can carry the planned weight of material and that the reach of its arm is adequate for the line distribution.
2 Speed of operation. It is essential that the robot's duty cycle does not limit the speed of the overall production process.
3 Flexibility. Will the robot be reprogrammable or reconfigurable for other tasks in the future?
4. maintenance costs and availability of spare parts. This is important for the longer term life of the equipment.
5. integration with current systems in the company. New solutions should be able to work with existing control software and management systems (e.g. MES, ERP).

Selection of dedicated solutions

In addition to classic industrial robots, turnkey solutions are becoming increasingly popular. For many companies, robotic workstations for specific processes are an interesting choice. Examples include:

• Welding station - designed for the metal industry to achieve consistent weld quality.
• Packaging and stacking station - streamlining order handling in the FMCG industry.
• A workstation for repetitive activities such as assembling components or polishing products.

We encourage you to check the details of the various automation solutions in the section Robotisation.

Steps to implement robotisation - a proven workflow

Implementing robotisation is not just about buying a robot and putting it on the line. It is a whole, multi-stage process that must include design, integration and ongoing improvement.

Step 1 - Audit and conceptual design

- Establish the business objective and technical assumptions (e.g. type of robots, capacity, cubic capacity of the workstation).
- Identification of the necessary technical infrastructure, including power, control automation and safety systems.
- Create a conceptual model (e.g. using virtual 3D simulations) to plan how the machines will move.

Step 2 - Configuration and prototyping

- Selection of specific components, workpiece handling, grippers or vision systems.
- Building and testing a prototype of a station or line. This is where it is verified in practice that the design assumptions are viable for realisation.
- Checking the compatibility of robots with existing machines (PLC, intelligent sensors, IT systems).

Step 3 - Pilot tests and modifications

- Running the line on a limited production run in a test environment.
- Collection of data on process performance, quality and repeatability.
- Making necessary improvements based on analysis of the KPIs obtained (e.g. OEE, cycle time, number of defects).

Step 4 - Target implementation and integration

- Installing the full version of the workstation and plugging in all systems in a real production environment.
- Integration with current IT systems (ERP, MES). It is essential to be able to track the robot's performance in real time.
- Ensuring safe working conditions - both for people and the robots themselves (fencing, safety sensors, monitoring).

Step 5 - Staff training and change management

- Impart knowledge of robot operation and programming, as well as maintenance procedures and rapid error response.
- Consideration of occupational health and safety and hygiene requirements, especially with greater integration of people with machines.
- Conduct internal workshops and meetings so that the team understands the purpose of the implementation and does not fear losing their jobs.

Step 6 - Monitoring, optimisation and servicing

- Ongoing tracking of key indicators (e.g. productivity, quality, downtime).
- Regular inspection and servicing of robots - a service can help Service and maintenance stands.
- Systematic software updates to help maintain maximum production efficiency.

Costs and return on investment (ROI) in company automation

One of the most important issues that any company must consider before implementing robotisation is cost-effectiveness. Determining when and how the investment will pay off often has a key impact on its acceptance by the board.

Main cost components

- Purchase and installation of robots (sometimes a large part of the budget is the robot itself, but additional components such as grippers or sensors need to be considered).
- Integration with current production line and IT systems.
- Training of the crew and possible modifications to the existing infrastructure (power supply, ventilation, exhaust extraction for laser cutting, etc.).
- Maintenance and possible repairs during subsequent years of operation.

How do you calculate the ROI of robotisation?

The basis is to balance the total implementation costs (CAPEX: purchase of robots, integration, employee training) and operating costs (OPEX: energy, materials, maintenance) with the savings and additional revenue. The most popular methods include:

• Comparison of 'before' and 'after' status - e.g. a 30% reduction in staffing for selected positions, compensated only by a few new robot operators.
• Taking into account the reduction in quality deficiencies and complaints.
• Calculate the benefits of a faster production cycle and the ability to handle more orders.

Companies that want to accurately estimate the possible return on investment often turn to special ROI calculators, such as the following calculator-ROI-robotisation-welding, available on the Michale Automation website.

Examples of robotisation applications in various industries

The automation of a company can take different forms depending on the specific processes and industry. Below are some typical examples:

Robotisation of welding in the metal industry

In the metal industry, welding is one of the key yet most time-consuming processes. The implementation of a robotised workstation allows high repeatability of welds and reduces the risk of defects. More information in welding robotisation offers Michale Automation companies.

Robotisation of packaging in the FMCG sector

Scalability and speed in packaging are a huge competitive advantage. Thanks to robots, companies can produce and pack products 24/7, while complying with hygiene and safety requirements. The high level of automation also reduces the time it takes to deliver orders to retail chains.

Robotisation of repetitive production in the electronics industry

Electronics manufacturers are often faced with a huge number of small components and high repetitive assembly. Automating such processes reduces human factor errors. As a result, production lines become faster and less unreliable, and you will learn more about them in the Robotisation of repetitive production.

Staff training and change management

Automating a company is not only about implementing new machines, but also about transforming the organisational culture. Employees need to understand that robots are not a threat, but a support for them in their daily tasks.

Practical elements of training

1. Fundamentals of robot programming and configuration.
2. emergency operation (what to do in the event of an unforeseen machine stoppage).
3. safety procedures, especially at the robot-human interface.
4. data analysis (e.g. number of items produced, quality indicators) to improve the process on an ongoing basis.

Motivating and involving the team in the process

- Conduct workshops in which operators can put forward their ideas for improvements at the design stage.
- Promote internal change ambassadors who will enthusiastically show others how robotisation makes their work easier instead of taking away the meaning of it.
- Regularly communicate the benefits of implementation - e.g. improved quality, fewer onerous manual tasks and new opportunities for growth within the company.

Monitoring, optimisation and service

Once a robotic line is up and running, keeping it fully operational becomes the next important step. Ideally, you should design a reporting and regular maintenance system at the start of implementation.

Key performance indicators (KPIs)

- OEE (Overall Equipment Effectiveness) - measures how well a machine is used in practice.
- MTBF (Mean Time Between Failures) - the time between failures of a robot or component.
- MTTR (Mean Time to Repair) - average repair time.
- Number of deficiencies per 10000 units (or other, process-specific).

The importance of regular servicing

A well-organised service prevents unexpected downtime and loss of quality. At Michale Automation, we make it a point for companies to set up a maintenance schedule at least once a quarter, especially for intensive use. Regular maintenance extends the life of the equipment and maintains the high accuracy of robot movement.

Official distributor of SIASUN robots - a guarantee of quality

Michale Automatika is the official distributor of robots manufactured by SIASUN, one of the market leaders in robotic solutions. As a result, customers can count on:

• Modern designs and a wide range of models - e.g. SIASUN Robot SR25A-12-2-01 designed for tasks requiring greater lifting capacity and precision.
• Comprehensive technical support - from robot selection, installation and configuration to warranty and post-warranty service.
• Turnkey integration - projects implemented by experienced engineers who efficiently adapt solutions to the requirements of the production line.

For many companies in the medium and large enterprise sector, working with an official distributor offers the certainty of reliable implementation and access to professional training and service tools.

Practical conclusions - what is worth remembering?

- Thorough needs analysis: Before deciding on robotisation, clearly define the processes that most need it and the key business objectives (cost reduction, productivity increase, quality improvement).

- Appropriate choice of technology: You have a choice of collaborative robots or fully automated multi-axis workstations. Match them to the size and nature of your production.

- A comprehensive approach to implementation: Implementing the robotisation of a company requires analysis, concept development, prototyping and pilot testing. Do not overlook the aspect of integration with existing IT systems.

- Crew education and acceptance: Successful company automation is also about staff training and change management. Without staff understanding and acceptance, implementation may not be successful.

- Continuous optimisation: Even after a successful implementation, it is worth regularly checking performance indicators and making improvements.

Summary

The automation of a company using industrial robots and advanced automation is a multidimensional process, involving both technological and organisational aspects. Once all the steps have been followed - from a sound cost-effectiveness analysis, to the right choice of equipment, to implementation, training and optimisation - the company gains greater productivity, better product quality and a competitive advantage in the market.

It is also worth remembering that this is a long-term investment, the magnitude of the return of which largely depends on the thoughtful integration of all elements of the system and the involvement of people in the change process.

If you want to discover even more practical information, take a look at our robotisation of welding and other services in the section robotisation of repetitive production. At Michale Automation, we offer advice at every stage of the project and, thanks to our many years of experience and close cooperation with SIASUN, we guarantee a professional approach to robotic implementations.

We also encourage you to comment and ask questions - we are happy to share our knowledge and support you in tailoring the best robotic solutions for your business. If the topic interests you, please consider subscribing to our newsletter to receive regular updates on news from the world of automation and robotics. Good luck with your company's automation plans!

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.