Introduction

Automating a company's processes is increasingly the key to remaining competitive in a rapidly changing market. Reducing costs, optimising work, increasing productivity and enhancing employee safety are just some of the benefits of implementing automation systems in manufacturing and service companies. According to the latest market analyses and reports (e.g. by the International Federation of Robotics, IFR), the trend of implementing industrial robot solutions and control systems will continue to strengthen in the coming years.

So if you are wondering how to carry out step-by-step automation and whether it is the right time to invest in modern technology, this article is for you. In this text, we show you why - and how - to plan the implementation of process automation in your company.

Why has the automation of company processes become a priority?

Automation is entering more and more boldly into industries where only a few years ago only manual work dominated. For example, the IFR 2023 report showed that the number of industrial robots installed each year is increasing not only in Asian countries, but also in Europe. An important factor here is the dynamically changing labour market and employment costs.

Costs and staff shortages

The economy is facing staffing challenges and wages in the manufacturing and service sectors are steadily increasing. For many companies, process automation is the answer to the problem of labour shortages and declining motivation for hard, repetitive manual work. By reducing the cost of human labour while increasing productivity, companies are beginning to treat investment in robots or automated lines almost as a necessity.

Quality growth and stable production

Another important factor is the need to maintain quality and repeatability of processes. Machines and robots do not get tired, thus ensuring stable production parameters and drastically reducing errors. This is a huge benefit at a time when customers expect mass-produced products, but with the highest standards.

Employee safety

Automation relieves people of dangerous and non-ergonomic tasks. High temperatures, risk of burns, contact with chemicals - such hazards can be eliminated by transferring machining to a robotic workstation. As a result, the number of accidents in the workplace decreases and companies reduce costs related to sickness absence or compensation.

Step by step - how to prepare your company for automation

Wondering where to start with the automation process? Ideally with a solid plan, team preparation and financial analysis. Here are the key steps you should go through before you start implementing robots or control systems.

1. Audit of processes and identification of objectives

The first step should be a meticulous analysis of all business and production processes. The audit will highlight tasks that are particularly stressful for employees, sensitive points in the material flow and potential places where repetitive activities are high.

• Find out where employees perform the most monotonous, repetitive and time-consuming tasks.
• Pay attention to the cost of labour, raw materials and the failure rate of machinery and production lines.
• Assess which jobs generate the most downtime or hazards.

As a result of the audit, you will establish the scope of the investment and be able to determine what goal you want to achieve - such as increasing productivity by 30% or increasing the quality of the final products.

2. Budget planning and ROI analysis

Once the objectives have been defined, it is time for the financial analysis. It is worth taking into account here:

• Initial costs (purchase of equipment, integration, training, maintenance).
• Potential savings (e.g. reduction in scrap, reduced number of production staff employed, shorter downtimes).
• Return on investment (ROI) time.

Tools to estimate the profitability of a project can also be considered at the budget planning stage. For example, it is worth exploring the functionality of the ROI calculator, which makes it easy to calculate the return on costs associated with the purchase or leasing of robots and upgraded machinery. See an example of the online tool:
ROI calculator - welding robotisation

3. Choice of supplier and technology

Once you know the key processes to automate and the budget, it is time to find the right partner. It is worth betting on integrators with experience in handling projects of similar scale. Michale Automatika implements machine concepts and production lines for a wide range of industries, from metal to food to plastics. As an official distributor of SIASUN robots we provide solutions that successfully combine the functionality of industrial robots with vision capabilities and quality control systems.

It is important that the technology meets the real needs of your business:

• Are you planning just one robotic station or a full production line?
• Will the integration also extend to vision systems, e.g. for precision part recognition?
• Do you want to incorporate an MES/ERP system into the process in 2-3 years' time to keep track of production?

All of these factors are worth taking into account when discussing the scope of cooperation with a potential supplier.

4. Crew preparation and work schedule

A key aspect of automation is proper training of the team. Employees need to know basic safety rules, the basics of operating robots or automated lines and how to respond to unforeseen events.

• Consider running short in-house courses.
• Invest in the training offered by the robot and machine supplier.

And don't forget to create an implementation schedule. It is worth including:

• Test run stage (pilot).
• Time to make any adjustments to software and machine configurations.
• Deadline for getting the line fully operational (known as commissioning).

Areas where process automation is most effective

Sometimes companies start to innovate in one area (e.g. packaging) and then develop further stages of automation. It is therefore worth looking at where the benefits are particularly apparent.

Robotisation of welding, packaging and processing processes

The metal, automotive or steel construction industries have relied on welding robots for years. Thanks to this:

• They reduce costs and speed up the execution of orders.
• They increase weld precision and eliminate process bottlenecks.

Explore the offerings for the robotisation of these areas, such as:
Robotisation of welding,
Robotisation of packaging.

Welding and packaging are among the most commonly automated operations. Robotisation of machining processes (e.g. grinding, painting, stacking of parts) is no less important for companies. These types of work are extremely monotonous and their repetitive nature places a heavy burden on workers. A robot, on the other hand, can ensure consistent quality and greater safety.

Integration of storage systems

Another area with high optimisation potential is internal logistics. A warehouse in which some of the activities are carried out by mobile robots or autonomous AGVs (Automated Guided Vehicles) makes it possible to significantly speed up order picking and loading. At the same time, the risk of collisions and human error is reduced.

Service and maintenance of automated workstations

Remember that with the implementation of automation, you are entering equipment that requires regular inspection and maintenance. What does this mean in practice?

• Ensure continuity of operation with rapid service support.
• Regular health checks of machines and robots - most manufacturers recommend checking key components at least quarterly.

For more information on robot maintenance and servicing, click here:
Service and maintenance stands.

Examples of market implementations and trends (based on industry reports and observations)

According to data published by the International Federation of Robotics (IFR), China, Japan, the US and Germany remain the leaders in terms of the number of newly installed robots. However, greater growth is also being recorded by Central and Eastern European countries, including Poland. Although we fell in the global ranking of robot purchases last season, forecasts for 2025 and 2026 suggest a clear upturn in automation investment.

Interestingly, it is not always just about machines for the assembly and handling of parts. The greatest growth has been in so-called 'non-standard' applications, among others. Innovative workstations based on collaborative robots (cobots) and workstations integrating artificial intelligence fall into this category.

Why are entrepreneurs more likely to opt for non-standard implementations?

• Market demands for product personalisation are increasing.
• Many factories operate in a confined space, which favours the installation of small-scale collaborative robots.
• AI integration facilitates the detection of irregularly shaped parts or real-time quality control.

Challenges and most common objections to implementing automation

Although the automation of company processes is mainly associated with progress and investment in the future, entrepreneurs still have some doubts.

Initial costs

The most common objection is the purchase price of robots, machines and software. In Poland, where some companies still operate with a manual work model, the investment barrier may seem high. However, leasing technology or taking advantage of EU and government subsidies can help.

Fear of stoppages

Companies fear that implementation takes too long to take them out of their normal production rhythm. Planning for automation therefore requires an appropriate timetable so that tests and migrations to new systems are as painless as possible.

Lack of specialised staff

Some companies do not have engineers or technicians familiar with automation system integration. A turnkey approach (design, delivery, commissioning and service from a single source) helps reduce these problems. Training of existing employees is also important.

How to build a business growth strategy based on automation?

The automation strategy should fit into the long-term growth objectives of the company. For example:

• Increasing production capacity by 50% over three years.
• Entering new export markets by maintaining stable quality.
• A response to staff shortages, especially in heavy lifting jobs.

Building such a strategy can also be supported by tools that integrate different technologies. Software such as MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning) allows the monitoring of key indicators such as line performance or downtime. The automation system then communicates directly with these platforms, allowing a faster response to anomalies.

Key findings and recommendations

• Start with an audit and definition of objectives: without clear data and priorities, it is difficult to assess whether automation will deliver the expected efficiency gains.
• Prepare a realistic budget and calculate the ROI: remember to take into account the full costs (equipment, implementation, maintenance) and potential savings (e.g. less shortages, less downtime).
• Choose an integrator partner: an experienced implementation team will help save time and avoid mistakes.
• Remember to train your employees: employees are the key to a smooth launch of new technologies.
• Bet on stable service and maintenance: an efficient maintenance department is crucial for production continuity.

Summary

The automation of company processes is not just a modern buzzword or a passing trend. It is a strategic direction for development, supported by rapid technological advances and the rising costs of traditional manual labour. For the head of a medium to large production, it can be an opportunity to scale the company, improve quality and flexibility of operations. For the owner of a smaller plant, a lifeline against labour shortages and increasing customer demands.

If you are interested in the robotisation of specific processes, check out more information under:
Robotisation.

At Michale Automation, we provide comprehensive support for companies deciding to automate their processes. We help from the vision and audit stage, through the project, to operator training and warranty service. As an official distributor of SIASUN robots we offer state-of-the-art solutions tailored to your needs and production specifications.

We encourage you to continue reading and exploring further articles on trends and tools in robotics. You can also contact us directly if more specific questions arise. Together, we will develop solutions that will realistically translate into business results, work optimisation and satisfaction for your team.

Thank you for reading the article. If you want to keep up to date with news in the world of automation, please subscribe to our newsletter or check out our other posts on robotisation and modern production management methods. Also, share this text with colleagues and friends - especially those who are wondering whether investing in process automation is really a good choice.

Good luck with optimising and growing your business!

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.

What to look for when choosing a technology provider?
First and foremost on the experience of the integrator and the adaptation of the technology to the specific needs of your plant. After-sales service and the ability to expand the system in the future are also important.

Does robotisation work for small businesses?
Yes, more and more smaller companies are seeing the benefits of robotisation. The market offers modular and flexible solutions that can be adapted to limited spaces and smaller budgets.