Machine design and construction - how to create efficient and modern industrial solutions

Estimated reading time: approx. 8 minutes

TL;DR

• Key stages include needs analysis, 3D modelling, prototyping and safe construction.
• Automation and robotics increase productivity, reduce costs and minimise the risk of failure.
• Personalisation machines allows solutions to be tailored to specific industry needs.
• Integration with digital systems (ERP, MES) improves supervision, production planning and warehouse management.
• ROI under favourable conditions can be as much as 1.5-2 years due to savings and higher quality.

Table of contents

• Introduction
• Key stages of machine design
• Mechanical engineering in practice - what to look out for?
• Why implement automation elements?
• Personalised workstations
• Modern trends in machine design and construction
• Robotisation as a key element of modern machinery
• Integration of machines and production lines with digital systems
• Why is systems integration so important?
• Maintenance and service
• Costs and return on investment (ROI)
• How to estimate the return on investment?
• Examples of return ratios
• Summary
• FAQ

Introduction

Machine design and construction is the cornerstone of the development of many industries. In the age of digitalisation and increasing competition in the market, companies are increasingly relying on modern and automated solutions to increase productivity and production quality while reducing costs. In this article, we will explain what the process of designing and building machines from scratch entails and the importance of optimising company operations in this context. We will also reveal some practical tips to facilitate decisions regarding the implementation of complex automation and robotisation solutions.

Key stages of machine design

Definition of technical and performance requirements: The first stage involves defining the customer's needs - establishing the objectives, the scope of the machine and the technical requirements. Together with the customer, expectations, the materials to be used and the required safety standards are clarified.

Modelling and verification: A 3D model is then created and strength analyses and ergonomic assessments are carried out. This allows early detection of potential design flaws and ensures the compatibility of all parts and components.

Prototyping: Making a first version of the machine allows the actual functionality to be assessed and any necessary adjustments to be made before final production.

Mechanical engineering in practice - what to look out for?

Once the design phase is complete, it is time for construction. Components are assembled, drives and control systems are installed. It is extremely important to ensure that the components are of high quality and that safety is maintained during installation and subsequent operation.

• Selection of technology and components: Relying on reliable suppliers and certified materials ensures a longer machine life.
• Ensuring safety: Installation of safety systems such as light curtains, safety sensors or fences to protect operators.
• Optimisation of control systems: The selection of PLCs, HMI panels and additional sensors (e.g. vision) allows full control over machine operation.

Why implement automation elements?

Automation components speed up and streamline the company's processes, allowing irregularities to be detected and eliminated quickly. It also becomes possible to integrate production with ERP systems, facilitating resource management and flexible process modification.

Personalised workstations

Not all companies can benefit from off-the-shelf, serialised automation solutions. In such a situation, it makes sense to opt for customised machine and robot designs. At Michale Automatika, we specialise in the creation of turnkey automated workstations - both for new production lines and for integration into existing machinery.

Modern trends in machine design and construction

The advent of so-called Industry 4.0 means the increasing importance of technologies such as Big Data, the Internet of Things (IoT) and Artificial Intelligence (AI). Machines can communicate with each other, self-diagnose faults and dynamically adjust operating parameters to meet current needs.

• Vision systems and AI: They enable advanced quality control and a rapid response to any irregularities.
• Internet of Things (IoT) and the cloud: It allows real-time analysis of production data, which influences faster decision-making.
• Implementing cobots: Robots that cooperate with humans (so-called cobots) can be successfully used even in smaller companies.

Robotisation as a key element of modern machinery

Many experts believe that robotisation is the future of many industrial sectors. With robots, we gain greater precision, repeatability and job safety. In addition, frequent staff shortages mean that robotic workstations often prove to be the only way to maintain a high production rate. If you are considering implementing robotisation in your company, find out about our solutions and gain a competitive advantage.

Integration of machines and production lines with digital systems

Many companies are now implementing ERP or MES systems that integrate data from different stages of production. Designing machines according to the requirements of these systems makes it easier to collect information about product quality, line efficiency or production costs. This is a step towards reacting quickly and planning work on the basis of reliable analyses.

Why is systems integration so important?

• Full control over KPIs at every stage of production.
• Better use of resources by analysing stock levels and material flows.
• Reduction in downtime and faster planning of maintenance work based on real-time data.

Maintenance and service

In order to maximise the life of machines and minimise the risk of breakdowns, it is important to take care of regular inspections, maintenance and software updates. Our team at Michale Automation also provides services servicing and maintenance of stationswhich avoids unplanned downtime and keeps processes at peak efficiency.

Costs and return on investment (ROI)

Although the purchase of a new machine or the modernisation of an existing one requires a financial outlay, well-designed solutions very often pay for themselves in a short time through increased productivity, reduced material waste and reduced staff costs.

How to estimate the return on investment?

• Cost analysis: Comparison of current production expenditure with projections after implementation of new solutions.
• Inclusion of training costs: It is necessary to assess the time and effort required to prepare staff for working with the new technology.
• Special calculation tools: For robotic welding, you can use our ROI calculator.

Examples of return ratios

Depending on the volume and nature of production, the return on investment can be achieved after just around 1.5-2 years. High repetition and high production volumes promote faster paybacks and make better use of the potential of automation and robotisation.

Summary

Machine design and construction is a strategic element of development in industry. Modern automation, robotics and integration with digital systems make it possible to increase productivity, improve product quality and better adapt to market requirements. Although initial costs may be a cause for concern, in the long term these investments pay off in the form of increased competitiveness and savings in many areas of production.

Feel free to contact the Michale Automation team to discuss your individual needs. Find out more about robotisation and check out other articles on our blog to keep up to date with the latest industry trends. Leave a comment or subscribe to our newsletter to benefit from the knowledge and experience of professionals in creating bespoke solutions.

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.