What does custom machine building look like step by step? A practical guide for manufacturing companies

Estimated reading time: 8 minutes

TL;DR

• Bespoke machine construction allows the functions of the machine to be tailored precisely to the needs of production
• Key stages include: needs analysis, design, prototype, implementation and service
• Robotisation can further increase the efficiency and flexibility of operations
• Regular maintenance and the ability to upgrade machines as the company grows are important
• Implementing bespoke machinery involves an investment that brings a rapid return through cost reduction and increased quality

Table of contents

• Introduction
• Why is custom mechanical engineering so important to industry?
• Stage 1 - Analysis of needs and requirements
• Stage 2 - Conceptual and detailed design
• Stage 3 - Prototype construction and initial testing
• Stage 4 - Production of the actual machine and full implementation
• Stage 5 - Service, maintenance and upgrades
• What role does robotisation play in custom machine building?
• Examples of business benefits of customised machine building
• Most common fears and challenges - how to overcome them?
• How do you prepare your company to implement a bespoke machine?
• Summary - key benefits and recommendations
• What's next? Next steps and materials to explore

Introduction

Custom machine building is one of the key areas where specialists such as the Michale Automation team can help companies achieve higher levels of productivity. In an era of increasing market demands and pressure to optimise costs, customised machine solutions are gaining popularity. They enable companies to automate their processes, introduce new technologies and increase competitiveness in the industry.

If you are wondering how bespoke mechanical engineering works in practice and why it is worth investing in it, this article is for you. We will show you the most important steps, highlight the key formal and technical aspects and show you what benefits you can gain by opting for this solution.

Why is custom mechanical engineering so important to industry?

Customised machine building is becoming increasingly important in the manufacturing world. This is due to several factors: increasing market pressures, the need to increase productivity while maintaining quality and the dynamic development of new technologies.

Personalisation as the key to efficiency

Off-the-shelf solutions are sometimes limited, as they are often designed for typical, almost universal applications. Tailor-made machine building, on the other hand, makes it possible:

• Fine-tuning of the machine functions to the selected production processes.
• Modular expansion at successive stages of company development.
• Streamlining and automating specific, often unique processes.

Responding to market developments and legal requirements

In many sectors (e.g. food, cosmetics or automotive), new standards and quality and safety requirements are increasingly emerging. Custom-built machines can be optimised for updated standards or specific industry guidelines. As a result, companies are able to react more quickly to changes and avoid costly downtime associated with equipment upgrades.

Stage 1 - Analysis of needs and requirements

The first step in the process of custom machine building is a thorough needs analysis. Companies such as Michale Automation begin their project work with customer interviews and a process audit.

Client interview and project specification

Automation specialists and engineers consult with the client to determine:

• Precise business objectives (e.g. increasing productivity by a certain percentage, improving quality, reducing labour costs).
• Technical parameters (type of product, speed and precision of operation, dimensional constraints).
• Regulatory requirements (certification, safety standards).

At this stage, it is already worth indicating whether the process will include elements of full automation or robotisation (e.g. the use of industrial robots). If you are interested in development using robotic technology, take a look at the full range of automation Michaleto find out what opportunities exist in this area.

Process audit and workflow analysis

The audit identifies bottlenecks in production and determines where new machinery can bring the most benefit. Engineers check:

• Production line load.
• Duration of the various stages of the process.
• Frequency of errors or failures.
• Integration possibilities with other systems (e.g. ERP, MES systems).

Based on these observations, an initial vision of the solution is being developed, as well as a quote and timetable for the potential work, which will be detailed in subsequent stages.

Stage 2 - Conceptual and detailed design

Once you know the general idea and functions of the machine, it is time to move on to the design stage. Very often there are two types of design: conceptual and detailed.

Conceptual design - visualisation and simulations

At this stage, the engineering team prepares preliminary 3D models, technical drawings and simulations of the machine's operation. Simulations may include performance tests, studies of how individual components behave under different conditions or predicting potential mechanical failures.

Why are simulations so important?

• They help detect collisions of moving parts early.
• They make it possible to anticipate bottlenecks in the process.
• They make it easier to fit the machine into the existing infrastructure.

Executive design - detailed plan and selection of components

Once the concept is approved, the engineers proceed to work out all the details. They work out, among other things:

• Detailed technical drawings of each module.
• Material specification and list of components (motors, actuators, PLCs).
• Control algorithms (if software is required).
• Safety solutions (sensors, emergency stops).

Automation and the possible robotisation of workstations are also very often discussed during this stage. If you want to see how this might affect your production, take a look at the our industrial automation services.

Stage 3 - Prototype construction and initial testing

Once the design work is complete, the team begins the actual construction of the machine. Often the first stage is to create a prototype or test version of the machine, especially when dealing with very complex components.

Assembly and commissioning of the prototype

At this stage, engineers and technicians assemble the individual components according to the detailed design. It is crucial that all assembly takes place under strict quality control.

• Compliance with the technical documentation is checked.
• Safety parameters (e.g. tightness, insulation of cables) are verified.
• On an ongoing basis, the prototype is being tested - both mechanically and controllably.

Sometimes minor adjustments are necessary, such as replacing a handle, changing the material of a component or redesigning a sensory part.

Functional and safety tests

Once the prototype is assembled, tests are carried out:

• Functional: that the machine performs all foreseen operations, e.g. cutting, transport, assembly.
• Loads: checking resistance to overloading, higher production speeds and emergency situations.
• Security: handling risk assessment (whether safety systems respond to malfunctioning).

Tests with the customer's staff can also be carried out at this stage. Pre-implementation of operators provides information on the ergonomics and intuitiveness of the device.

Stage 4 - Production of the actual machine and full implementation

If the prototype phase has been successful, the company moves on to the production of the target machine. When an order involves a larger number of identical machines or a complex production line, engineers duplicate the configuration, taking into account any modifications made after the prototype tests.

Final assembly and integration into the production line

In the integration process, the assembling company must consider, among other things:

• Communication links with other machines and IT systems in the company (e.g. MES, ERP).
• Intralogistics, i.e. the flow of materials and products (e.g. conveyor belts, conveyors).
• Site-specific health and safety procedures in place.

A full implementation often includes a stage called FAT (Factory Acceptance Test) and SAT (Site Acceptance Test).

• FAT are acceptance tests carried out at the contractor's factory - this is where it is verified that the equipment works as agreed.
• SAT and are on-site tests of the target installation at the customer's company, taking into account the operation of the machine under target production conditions.

Operator training and documentation

The construction of bespoke machines is inextricably linked to the transfer of knowledge about their operation. The specialists at Michale Automation place great emphasis on:

• Training in the use of operator panels and control systems.
• Maintenance and inspection basics.
• Health, safety and security in working with new equipment.

An important part of the acceptance stage is also the handing over of the complete technical documentation in the form of: drawings, electrical diagrams, safety instructions and any certificates of conformity.

Stage 5 - Service, maintenance and upgrades

The investment in a bespoke machine includes not only the production itself, but also after-sales support. Regular maintenance and possible upgrades are required to keep the machine running reliably for many years.

Regular inspection and servicing

It is worth including in the contract with the contractor (e.g. at Automation Michale):

• Planned periodic reviews.
• Constant service contact and access to spare parts.
• Possibility of remote support (e.g. for rapid fault diagnosis).

This reduces the risk of major breakdowns, which could result in financial and image damage. If you are looking for help with maintenance or servicing, check out the offer servicing and maintenance of stations.

Modernisations and improvements

The market is constantly changing and with it production technologies. Custom-designed machines can be expanded with new functions relatively easily or certain components (e.g. mechanical components, controllers, robots) can be replaced. In this way, a one-off investment can serve a company for a long time, and upgrading the system will allow it to remain competitive in a constantly changing environment.

What role does robotisation play in custom machine building?

While not every bespoke machine needs to be robotic straight away, current market trends show the increasing importance of industrial robots. This is particularly the case in those industries where precision and repeatability are key success factors.

When to consider robotisation?

• For operations requiring high repeatability (welding, packaging, sorting).
• In processes where scalability and the ability to change configurations quickly are important (e.g. small production runs, lack of manpower for manual handling).
• Where there are stressful tasks for employees (e.g. working in hot conditions).

Michale Automatics is the official distributor of SIASUN robots, making it easy to integrate and select robots for individual applications. Due to their advanced solutions and technical support, SIASUN robots are well suited to a wide range of industries.

Examples of business benefits of customised machine building

Custom machine building brings with it a number of tangible benefits, both short-term and long-term. Below are the most important ones that may convince companies considering such an investment.

Improving productivity and quality

• Higher productivity through process optimisation and elimination of redundant activities.
• Reducing the risk of human error, resulting in stable product quality.
• Ability to work 24/7 when connected to robotisation.

Cost reduction and rapid return on investment

• A personalised solution can dramatically reduce labour costs.
• Faster lead times translate into better use of resources and increased revenues.
• Increased price competitiveness due to shorter production cycles.

Scalability and flexibility

• Bespoke machines can be modified and expanded as the company grows.
• They enable quick changeovers, which is particularly important with frequent product range changes.
• Integrate with existing IT solutions (production planning, reporting systems).

Most common fears and challenges - how to overcome them?

Although custom machine building sounds like the perfect solution, in practice many companies are concerned about costs, potential downtime or the risk of a failed investment. Here are some of the most common concerns and ways to address them.

High cost barrier

Indeed, the creation of a new machine represents a significant expense. In practice, however, this cost often pays for itself in a relatively short time - e.g. within 1.5-2 years, depending on the industry and the specifics of the process. The tangible gain in terms of higher productivity and lower operating costs is also valuable.

Integration problems in the existing line

Specialised companies, such as Michale Automation, have their own design departments to ensure that the machine is correctly matched to existing plant conditions. It is good practice to create a detailed 3D model of the entire line even before the machine is manufactured. This significantly reduces the risk of incompatibility.

Lack of adequate staff to handle

Modern bespoke machines are increasingly equipped with intuitive operator panels and support systems. In addition, the manufacturer undertakes to provide training. It is essential that the company regularly ensures the competence of the team and schedules periodic workshops.

How do you prepare your company to implement a bespoke machine?

The implementation of even the best-designed machine requires the company to prepare properly. Key activities include:

1. Analysis of potential - Are machines really necessary? Can the problem not be solved by simpler methods?
2. Acquisition of funding - Many businesses benefit from EU or national grants. It is worth checking the available programmes to support innovation in your industry.
3. Project team - It is important to appoint people responsible for liaising with the machine supplier (e.g. maintenance engineer, production representative).
4. Reorganisation of the process - The implementation of a new machine is a great opportunity to analyse the entire value chain. It is worth considering changes to work sequences or schedules.

Summary - key benefits and recommendations

Custom machine building is a strategic decision that can make a significant difference to the operation of your business. With custom-designed equipment, you will automate production processes, eliminate errors and increase adaptability in the face of changing trends.

Key benefits:

• Higher productivity and process repeatability.
• Ability to flexibly develop the production line.
• Significant reduction in labour and material costs.
• Access to robotics and automation solutions (you can find an offer at the official website of Automata Michale).

Recommendations for companies considering this solution:

• Start with a comprehensive process analysis and, even before signing the contract, clearly establish business objectives.
• Carefully define the technical specifications. Well-prepared documentation speeds up subsequent engineering work.
• Ensure that staff are trained. Even the best machine will not be fully effective if it is not operated in the right way.
• Choose suppliers that provide service and the possibility of future expansion - then you will be assured that your investment will stand the test of time.

What's next? Next steps and materials to explore

If you are considering building a bespoke machine, a good start would be to speak to experts who can assess your needs and suggest how best to implement this type of solution. Teams of experienced engineers will help you through all stages - from audit and design to actual production.

Additional materials:

• Check out robotisation in various production processes and assess whether, in your industry, machines with attached robots could be of benefit.
• Familiarise yourself with service possibilities for new and existing equipment to avoid unplanned downtime.

Remember, too, that it is sometimes worthwhile to develop automation gradually, starting with less complex solutions and gradually gaining confidence that the investment is delivering the desired results.

Summary
Custom machine building is a process that requires a thorough needs analysis, professional design and careful implementation. Even at the initial stage, defining business objectives and understanding existing processes is crucial. Subsequently, the design and prototype testing stages play an important role in minimising the risk of errors.

In the long term, tailor-made machines give a company a competitive advantage through higher productivity, more stable quality and the ability to adapt quickly to changing market conditions. If you are trying on such an investment, we encourage you to contact the specialists and find out more about the services of Michale Automation.

Do you have questions? Leave them in the comments, contact us directly or subscribe to our news to keep up to date with trends in automation and robotics. Share this article if you think it might help other companies in their decision to build bespoke machines. Good luck with your plans and process optimisation!

FAQ

How long does it take to prepare a bespoke machine design?
This time depends on the complexity of the project and the scope of work. Simple equipment can be designed in as little as a dozen weeks, while extensive production lines may require several months of conceptual and engineering work.

Does robotisation always mean big costs?
Not always. Costs depend on the type of robots and the degree of integration into the production line. At the same time, the rapid return on investment resulting from more efficient and repeatable processes must be taken into account.

Is it possible to upgrade an existing machine instead of building a new one?
Yes. Upgrades are often a beneficial solution as long as the basic design of the machine is in good condition. New control systems can be included, robots added or key components replaced to restore or increase efficiency.