Building a machine step by step: how to integrate new solutions effectively in a company's production line

Estimated reading time: approx. 10 minutes

TL;DR

• Designing a new machine requires a sound analysis of needs and future expansion possibilities.
• Integration with ERP and MES systems provides real-time data insights that significantly improve production management.
• Automation and robotisation speed up processes and ensure higher product quality.
• Aspects of safety and ergonomics are key in the development of new machines, especially involving robots.
• Regular servicing and operator training minimises downtime and increases line efficiency.

Table of contents

• Introduction
• Why is machine building so important in today's manufacturing realities?
• Machine building stages and their importance in systems integration
• Integration of machines with ERP and MES systems
• Automation and robotic workstations - when is it worth including them in a project?
• Key technical aspects: safety, standards and ergonomics
• Implementation example from practice: automatic assembly line integrated with ERP
• Internal linking and additional resources
• Challenges and possible problems during machine implementation
• Practical lessons for CEOs and production managers
• Summary
• FAQ

Introduction

The construction of a machine is one of the key stages in the development of manufacturing companies in the Polish and global markets. An effectively designed machine, fully integrated with the existing infrastructure, can quickly improve productivity, cost efficiency and the quality of the production process. In this article, we will look at how the machine is built in today's industrial reality. We will also discuss its integration with both internal and external systems, such as ERP or MES. After reading, you will learn the practical benefits of a professionally executed machine building project and what mistakes to avoid so that your investment pays off quickly.

This article is primarily aimed at those who are considering expanding their machine park or want to create a new automated or robotic station from scratch. The solutions and tips discussed will work well for medium and large plants and for companies facing integration challenges. At Michale Automatika, we design, build machines and production lines, as well as implement robotic workstations in various types of industries. As an official distributor of SIASUN robots, we offer a professional approach to automation.

Below, we outline the step-by-step process of building the machine and how it can be optimally integrated into existing production systems to fully exploit the potential of the new solution.

Why is machine building so important in today's manufacturing realities?

The construction of a new machine or the modernisation of an existing one is a process that can determine the competitiveness of a company for many years. In an era of rising labour costs, constant pressure for high quality and speed of delivery, and ever-increasing customer demands, it is difficult to imagine efficient production without a suitably automated and integrated machine park.

Companies often wonder whether the implementation of a new machine will actually translate into a marked improvement in operational indicators. In Michale Automatyka's experience, a well-considered investment in a machine created from scratch or purchased in modular form, combined with advanced management systems, can increase productivity by up to several tens of per cent in a short period of time.

Furthermore, the design of the machine is closely linked to future production scalability. The new machine - appropriately designed and customised - allows for easy expansion of the line with further modules, which is an invaluable asset in a rapidly growing market.

Machine building stages and their importance in systems integration

The construction of a machine is a multi-stage process that requires consideration not only of strictly engineering aspects, but also of the proper adaptation of the machine to work with the rest of the production line. Let's look at the most key points of such an undertaking.

Analysis of needs and specifications

The first step is a thorough analysis of the company's needs. This includes identifying the production processes and understanding the expectations of the planned machine. It examines:

• What is the main purpose of implementing the new device?
• What functions do operators, production managers and other departments expect?
• What systems do we plan to incorporate in the future (AI, vision systems, cobots)?

On the basis of these questions, a specification is established: technical parameters, requirements for speed, accuracy, operational safety and integration with ERP, MES or quality monitoring systems.

Device design

The next stage is to design the machine to meet the specified requirements. During the design, all additional control systems are taken into account, for example sensors, vision cameras or industrial robots. At Michale Automatika, we attach great importance to the flexibility of the design so that it is expandable in the future.

Construction and pre-testing

The construction phase of the unit includes mechanical assembly, installation of control systems and preliminary testing under laboratory conditions. At this stage, compliance with the design is verified and any adjustments are made. This is also the right time to test communication protocols if the machine needs to interact with external systems.

Integration into the production line

Once the initial testing is complete, the crucial phase of integration into the existing plant infrastructure follows. The machine is connected to the production line and it is checked that it interacts correctly with other equipment, robots or vision systems. Communication with ERP and MES is tested so that real-time data on productivity, quality and breakdowns are transmitted to central databases.

Commissioning and staff training

Once the new machine is operating at the target location, proper training of the operators and maintenance department is crucial. This ensures smooth operation and minimising downtime.

Service and continuous improvement

Once it is up and running, it is worth ensuring that regular servicing and periodic maintenance is carried out to ensure that the machine maintains its high performance and is ready to accept new developments, such as integration with new robots or software.

Integration of machines with ERP and MES systems

Another extremely important part of building and implementing a new machine is its integration with higher-level systems such as ERP or MES. In the era of Industry 4.0, the intercommunication of devices, robots, vision systems and control applications is becoming a key factor in ensuring market advantage.

Benefits of integration

• Access to real-time data: Thanks to the integration, the machine can automatically send data on productivity, material consumption or downtime to the ERP system. This allows managers to react quickly in the event of problems in the production line.
• Automatic quality control: Connection to the MES enables detailed tracking of process parameters to reduce quality deficiencies and limit material wastage.
• Easier production planning: The ERP system, seeing the current capacity of the machine, can adjust the production schedule to the actual availability of the machine and crew.

Challenges and good practices

• Standardisation of interfaces: Integration can be difficult when devices use different communication protocols. It is worth betting on solutions that comply with popular standards, such as OPC UA.
• Data security: A key aspect is the security of data transfer between the machine and the company's IT systems.
• Maintaining flexibility: Design the machine in such a way that it can be easily extended in the future with new functionalities (e.g. AI, collaborative robots).

Automation and robotic workstations - when is it worth including them in a project?

When considering the construction of new machinery, many companies wonder whether it is worthwhile to go straight for robotics solutions. In most cases, the answer is: yesas long as the production process is largely repeatable and can be automated.

Examples of applications

• Robotic welding stations: Welding processes require precision and repeatability, which is why robots are very popular here. If you would like to see specific examples from this area, see our offer in the area of welding robotisation.
• Assembly works: The tasks of assembling small parts, packaging or labelling can significantly improve daily production in the food or cosmetics industry.
• Collaborative robots (cobots): They work well in processes where operators share the workspace with the robot. This reduces the risk of human error while improving productivity.

Selection of robots for production tasks

The choice of the type of robot (e.g. welding or handling) depends primarily on the specifics of the production. We are an official distributor of Siasun robots, which guarantees access to modern and highly configurable equipment. Sometimes the process starts with an ROI analysis - if you are wondering how long it will take to recoup the purchase and implementation of a robot, you may find our ROI calculator for welding robotisation.

Use of robots in new machine construction

Sometimes a machine designed from the ground up can have an integrated robot as an integral module, so that the station operates fully autonomously. An example is a packaging machine with an industrial arm for sorting products and stacking them.

Key technical aspects: safety, standards and ergonomics

Building a machine is not just about achieving maximum performance and integration with IT systems. Equally important is the aspect of operator safety and maintaining quality standards and industry norms.

Certifications and standards

The majority of machinery installed in Polish production facilities must comply with the Machinery Directive (2006/42/EC) standards and carry the CE marking. If robots are involved in the project, additional guidelines for human-machine interaction and risk assessment must be taken into account.

Ergonomics at work

In the age of the worker's market, there are increasing expectations of convenience and job security. When building a fully automated machine, extra emphasis must be placed on:

• Minimising the burden on operators,
• Facilitate access to essential components (e.g. control panels, service points),
• Use of barriers, safety sensors or operator confirmation systems if the nature of the work requires them.

Maintenance and upkeep

In companies that make intensive use of new equipment, a common problem is the lack of service facilities or the limited possibility to maintain machines while the line is in operation. For this reason, procedures for inspection and replacement of spare parts, as well as the possibility of online diagnosis, should be planned as early as the design stage.

Implementation example from practice: automatic assembly line integrated with ERP

To illustrate the topic, let's look at an example of an implementation that is typical in medium and large plants.

Project objectives

• Start-up of an automated assembly line in the metal industry,
• Integration with the ERP system to send real-time performance and quality data,
• Reduce installation time by 30% while maintaining high safety standards.

Implementation

1. Machine design: An assembly module integrated into the handling robot was designed. A state-of-the-art PLC with data exchange via the OPC UA protocol was responsible for the control.
2. Construction and testing: Once the build was complete, testing was carried out under simulated conditions. Software was developed to streamline the data flow to the ERP.
3. Integration in the hall: The machine was installed at the target location, network connections to the ERP were set up and production data was checked to ensure that it was being recorded correctly. The results confirmed the translation of automation into reduced assembly errors.
4. Training and service: Operators and the maintenance department were trained. Constant monitoring of the line status through the MES system was provided.

Effects

• Increasing production capacity by 35%,
• Reduced downtime by 40% with rapid fault diagnostics visible in ERP,
• Significant reduction in assembly errors.

Internal linking and additional resources

For those looking for detailed information on services related to machine building, production lines and robotisation, we recommend taking a look at the our services and design capabilities of Michale Automatics. You can also to see an example of the Siasun SR25A robotwhich can be incorporated into the design of a new machine as an automated module.

We also encourage you to contact our advisory service for a personal consultation.

Challenges and possible problems during machine implementation

Even the best designed construction process can encounter difficulties. It is worth being aware of the most common challenges and being prepared to deal with them.

• Inaccurate specification: If the most important needs of all departments (production, IT, warehouse) are not taken into account at the design stage, the final result may differ from expectations.
• Miscommunication with external suppliers: This is especially true for subcontractors responsible for a specific line module. A clear project management plan is key here.
• Integration with outdated ERP/MES systems: Not all plants have the latest software. It is sometimes necessary to combine protocols, which increases implementation time.
• Competence gaps in the area of maintenance: If staff are not trained, frequent breakdowns or incorrectly operated machines will generate downtime and costs.

Practical lessons for CEOs and production managers

When planning to invest in the construction of a machine, it is worth paying particular attention to:

• Setting measurable goals: Specify the expected increase in productivity, specify whether it is to improve quality, speed or reduce labour costs.
• Flexibility: The machine should be designed to allow for line expansion.
• Staff training: Failure to provide adequate training to operators could negate the benefits of the new solution.
• Safety and ergonomics: These aspects influence the high acceptance of the new technology among the staff and increase staff motivation.
• ROI calculation: Even at the initial stage, it is worth analysing the costs and expected revenues to make sure that the investment will be profitable.

Summary

The professional construction of a machine that will ultimately be included in an integrated production line brings significant benefits to the company. With a properly planned and executed process of design, assembly, testing and integration with ERP and MES systems, productivity can be quickly increased, quality errors reduced and labour costs reduced. Proper implementation of the new solution also gives the company the flexibility to adapt to future market requirements - both technological and business.

We invite you to continue your search for information and consult with Michale Automation experts. We regularly publish material on robotisation, implementation of innovative production solutions and cost optimisation. If you are interested in issues such as automated machining, welding, packaging or painting, you will find them in our dedicated offers and articles.

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Thanks for reading and good luck with your engineering projects!

FAQ

How long does it take to implement a new machine in a production line?
The implementation time depends on the scale of the project and the technological sophistication of the machine. For simpler machines it can be a few weeks, while for large integrations it can reach several months.

Is integration with ERP and MES systems necessary?
It is not mandatory, but in the era of Industry 4.0 it is the key to effectively monitoring and optimising production processes. It allows you to react quickly to potential downtimes and gain real-time data insights.

What are the business benefits of robotising the welding process?
Robotisation of welding improves the repeatability and quality of welds, reduces production time and reduces the risk of human error. As a result, the company gains higher productivity and can more easily adapt the process to changing needs.