Bespoke machinery - how to prepare your business for implementation and increase production efficiency

Estimated reading time: 10 minutes

TL;DR:

• Bespoke machines are designed to meet individual company needs
• They give greater efficiency and can bring up to 30-40% increase in production
• Allows flexible expansion and upgrading
• Reduce long-term operating and maintenance costs
• Proper planning of the process and selection of an experienced supplier is key

Table of contents

• Introduction
• What does 'Bespoke machinery' mean?
  • Differences from standard equipment
  • What industries use bespoke machinery?
• Why invest in bespoke machinery?
  • Precise adjustment to processes
  • Increased productivity and quality
  • Reducing long-term costs
  • Scalability and flexibility
• What to look out for before ordering a machine?
  • Analysis of needs and requirements
  • Choosing the right supplier
  • Design and simulations
  • Quality of materials and components
  • Costs and deadlines
• Implementation and integration - key aspects
  • Assembly and commissioning
  • Training for employees
  • Integration into existing production lines
  • Servicing and maintenance
• Benefits of an in-house bespoke machine
  • Competitive advantage
  • Less dependence on suppliers
  • Possibility of robotisation and further automation
  • Improved service support and advice
• Examples of implementation and good practice
  • Integration with video systems
  • Connection to ERP/MES systems
  • Support in the area of robotisation of welding processes
• Additional conditions and formalities
  • Certifications and standards
  • Technical documentation and DTR
  • Funding
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Customised machinery plays a key role for companies looking to increase productivity, reduce costs and gain a competitive edge in a demanding market. In an era of increasing automation and robotisation, there are more and more opportunities to improve production processes, so the topic of ordering customised machinery is timely and extremely important. In this article, we explain what you should consider before deciding to order a customised machine, what benefits you can count on in the short and long term and how to prepare for the implementation process. After reading, you will gain knowledge that will help you make an informed decision regarding the development of your business.

What does 'Bespoke machinery' mean?

Bespoke machines are those that are designed and built to meet the specific needs of a particular company or unusual requirements of a production line. They are designed to precisely match the functionality and parameters to the company's processes. In practice, this means that unique solutions are obtained that take into account both current and future production needs.

Differences from standard equipment

• Standard machines often have a specific set of functions that cannot be adapted to more complex or non-standard processes.
• Tailor-made solutions allow every stage of the machine to be planned - from the selection of components and drives to the integrated control system or the configuration of vision systems.
• Buyers receive design, consultancy and service support, and the implementation of such a machine can be staggered so as not to disrupt existing production processes.

What industries use bespoke machinery?

• Food and beverage industry: automation of packaging, packaging and labelling processes.
• Automotive: custom assembly lines, part strength testing equipment, inspection machines.
• Furniture and woodworking industry: specialised machining centres with functionalities tailored to series and prototype production.
• Pharmaceutical and cosmetics industry: automated filling, closing or labelling lines for packaging of various shapes and sizes.
• Other sectors requiring unusual integration of several processes in a single machine.

Why invest in bespoke machinery?

Precise adjustment to processes

The main advantage of investing in customised equipment is that it can be precisely tailored to meet production needs. In practice, this means that the company does not have to change its existing production system to meet the requirements of the new machine. Instead, a machine is created that fits completely into the existing business model.

Increased productivity and quality

Industry reports show that well-designed custom machines can translate into up to a 30-40% increase in productivity compared to using standard machinery. Custom design also allows for better control of the quality of the products produced and reduced downtime by tailoring equipment to specific work cycles and materials.

Reducing long-term costs

Implementing a dedicated machine may require a larger investment at the outset. However, in the long term, it often leads to a reduction in operating, service and potential production line downtime costs. Dedicated equipment operates more efficiently and requires fewer technical interventions, resulting in significant financial savings.

Scalability and flexibility

Bespoke machines are generally designed with expandability and modification in mind. When a company expands rapidly or introduces new products, these machines can often be rebuilt or extended with further modules quite easily. This flexible approach avoids the need to buy more machines at short intervals.

What to look out for before ordering a machine?

Analysis of needs and requirements

The first step in the process of ordering a dedicated machine should be to precisely define your needs:

• What are the key functions of the machine?
• What materials does the machine need to work with?
• What performance is required?
• Are there plans to expand the functionality in the future?

A detailed analysis will produce design assumptions that will be the foundation for the development of the device concept.

Choosing the right supplier

Choosing a supplier is one of the most important parts of the whole process. A good partner will not only fulfil your order, but will also advise and present the best technological solutions. At Michale Automation, we specialise in customised machine building, production lines and the implementation of robotic workstations. As an official distributor of SIASUN robots, we have access to high-end industrial robots, which can further help to optimise production steps.

Design and simulations

Once the company supplying the machines has received precise guidelines, the design phase begins. Modern engineering solutions make it possible to perform accurate simulations of the machine's operation even before we move into the production phase. This allows potential difficulties to be identified in advance and the necessary improvements to the design to be implemented.

Quality of materials and components

When it comes to industrial machinery that is expected to last for many years, the quality of the materials and components used is of paramount importance. It is worth asking the supplier whether the components and control systems used are from reputable manufacturers. The better the quality, the lower the risk of breakdowns and the longer the failure-free life of the machine.

Costs and deadlines

• Costs: Pricing for bespoke machines usually includes the design stage, prototype manufacture and final production. In addition, there may be costs for service, employee training or optional modifications.
• Deadlines: The construction of an advanced machine can take several months to a year, sometimes even longer. Therefore, possible delays in the supply of parts or the need for tests and revisions must be factored into the schedule.

Implementation and integration - key aspects

Assembly and commissioning

Once the production process is complete, assembly follows. In the case of complex machines, investors often opt for a test run of the machine while it is still at the supplier's premises to confirm that it functions as intended. In the next stage, the machine is transported to the customer's plant for final testing.

Training for employees

New technology in a company usually means that training on operation and maintenance is required. Particularly when implementing robotic solutions, it is worth ensuring that staff are familiar with all safety modes and basic maintenance procedures.
Often, the level of competence of the crew translates directly into the efficiency of the unit, so well-planned training can increase the return on investment.

Integration into existing production lines

For companies that already have some level of automation or robotic workstations, it is crucial to properly integrate the newly ordered machine into the production line layout. Additional integration activities may be necessary, such as:

• Agree communication protocols with other equipment (PLC, vision systems).
• Configuration of ERP/MES systems so that the machine reports production progress in real time.
• Possible modifications to transport routes or workstations.

Servicing and maintenance

Once implemented, it is a good idea to establish a schedule for regular maintenance and servicing. Both standard and bespoke machines may have wear parts, so it is essential to keep an eye on timely replacements and inspections. At Automation Michale, we also offer service and maintenance services, which are detailed at servicing and maintenance of stations.

Benefits of an in-house bespoke machine

Competitive advantage

Companies using bespoke solutions can significantly optimise production cycles compared to companies that still rely on universal but less integrated machines. Implementing a customised solution makes processes more efficient and quality control faster and more streamlined.

Less dependence on suppliers

Having equipment specifically designed for the business means less susceptibility to changes in prices or conditions from external production suppliers. It gives a sense of security and independence - the company can decide for itself how it carries out production.

Possibility of robotisation and further automation

When a company is considering implementing automation and robotics at the same time, it is worth considering looking at which tasks can be taken over by industrial robots. The aforementioned flexibility of bespoke machines makes them a great base for implementing robots for welding, packaging or CNC machine operation. If you would like to learn more about how to automate repetitive tasks in your facility, see the offer robotisation of repetitive production.

Improved service support and advice

The bespoke machinery supplier often steps into the role of technology partner, offering:

• Advice on process optimisation.
• Assistance with possible upgrades to the unit.
• Advice on occupational safety and health certification.

Such support can be extremely useful for those who decide to purchase a machine with unique characteristics for the first time.

Examples of implementation and good practice

Integration with video systems

In many industries (e.g. pharmaceuticals or electronics), bespoke machines are equipped with sophisticated vision systems. Their task can be to automatically check the quality of products, to check that components are in the correct position, and to identify defects. In this way, production waste can be significantly reduced and defects can be detected at an early stage in the process.

Connection to ERP/MES systems

If the company has ERP or MES systems, it is worth ensuring that the new machine fully communicates with these platforms. This gives you the ability to monitor OEE (Overall Equipment Effectiveness) indicators and react quickly when line performance drops. Integration at this level also allows for accurate production planning and real-time scheduling of tasks.

Support in the area of robotisation of welding processes

In plants where there is a need for repeated welding tasks, a robotic workstation can be fully integrated with a machine designed for the given shape and form of the components to be welded. To find out whether such an investment is viable, it is worth using the ROI calculator welding robotisation.

Additional conditions and formalities

Certifications and standards

Many industries, especially food and medical, operate to strict quality and safety standards (e.g. HACCP, GMP). Designing machinery to meet exacting standards can be time-consuming and costly, but is necessary for companies that need to maintain compliance with current regulations.

Technical documentation and DTR

Each bespoke machine should be accompanied by full documentation:

• Operating instructions in Polish.
• Technical and Operational Documentation (DTR), containing information on the construction and maintenance of the equipment.
• Quality and conformity certificates, e.g. CE.

It is worth ensuring that the documentation is prepared carefully and covers any potential contingencies or operating configurations.

Funding

The purchase of highly specialised equipment is often a major financial challenge. Depending on the profile of the company and the planned investment, different forms of support can be considered:

• Machinery and equipment leasing.
• Investment loans.
• EU grants and funding for SME businesses.

Suppliers of bespoke machinery often work with financial institutions and help prepare documentation, making the whole process much easier.

Practical conclusions and recommendations

- Define key needs: Before ordering a device, prepare a precise list of requirements. This will help you avoid surprises and design modifications later on.
- Choose an experienced partner: Custom machine building requires specialist knowledge. Look for manufacturers and suppliers who have a strong portfolio and experience in your industry.
- Plan ahead: The design and manufacture of bespoke machinery is ongoing. Make sure lead times do not derail your production plans.
- Ensure team training: The efficiency of a new machine depends largely on the competence of the employees. By investing in their knowledge, you will speed up adaptation and avoid costly mistakes.

If you are interested in additional automation solutions for various processes, such as packaging, have a look at our website robotisation of packaging.

Summary

Bespoke machinery is the perfect solution for companies that focus on efficiency and competitiveness in a rapidly changing market reality. With this approach, you can not only increase productivity and production quality, but also control costs over the long term. However, implementing a fully customised solution requires proper planning and cooperation with an experienced supplier - at all stages, from needs analysis and design to service and integration with other systems.

With the knowledge from this article, you have a solid basis for conducting a cost-effectiveness analysis and a better understanding of the process of configuring and implementing machines tailored to your needs. If you have additional questions related to machine building, robotic workstations or other topics in the field of industrial automation, please feel free to contact us at Michal Automation. We will be happy to share our experience and help you achieve success in production.

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Thank you for reading and we wish you a successful implementation of bespoke machines in your company!

FAQ

How long does it take to design and manufacture a bespoke machine?
This depends on the level of complexity of the project and the availability of components. It can take from a few months to even over a year for very complex solutions.

Are bespoke machines more expensive than standard machines?
Their initial cost can sometimes be higher, but they can bring long-term savings in operation and servicing through customisation and improved performance.

Does the implementation of such a machine heavily disrupt plant operations?
A properly planned implementation process, often in stages, minimises downtime. A good supplier is able to stagger all stages so as to accommodate the current production schedule.

What are the benefits of choosing an experienced bespoke machinery supplier?
Specialised knowledge and extensive experience allow the project to be optimised, errors to be avoided at an early stage and the entire implementation to be carried out smoothly - from design to after-sales service.