Designing automation systems - how to create an efficient and future-proof industrial infrastructure

Estimated reading time: approx. 7 minutes

TL;DR

• Analysing needs and selecting the right technologies is the basis for successful automation.
• Proper safety planning protects workers and reduces downtime.
• Integration with ERP/MES systems allows processes to be monitored and optimised.
• Regular service and maintenance ensure stable, long-term performance.
• The investment in robotisation usually pays for itself quickly through higher efficiency.

Table of contents

• Why is thoughtful automation system design so important?
• Stages in the design of automation systems
• Examples of application areas for automation system design
• Safety aspects in automation design
• Costs and return on investment
• The most common challenges and mistakes made in automation design
• Working with an experienced integrator
• Practical step-by-step recommendations
• Summary

Introduction

Automation system design is the cornerstone of modern industry. Whether you are just getting started with automation or want to expand an existing production line with modern robotic solutions, well thought-out design is the key to success. In this article, I will explain what the design of automation systems is in practice, what to consider when planning and what mistakes to avoid so that the final result not only increases productivity, but also brings a significant return on investment. You will learn why the analysis and concept stage can be just as important as the implementation itself, and you will see examples of how Michale Automatyka (sometimes also referred to as Michale Automation) implements complete design processes, combining advanced technology with market needs.

Why is thoughtful automation system design so important?

The design of automation systems is not just about selecting a PLC or programming robots. It is a complex process that includes:

• Analysis of the company's production needs.
• Identify the objectives and scope of automation (e.g. cost reduction, increased productivity, quality improvement).
• Selection of appropriate technologies (e.g. industrial robots, sensor systems, HMIs).
• Integration with existing solutions (e.g. ERP, MES, vision systems).
• Development of project documentation (electrical and pneumatic diagrams, component lists).
• Commissioning and testing under production conditions.

A poorly designed automation system is associated with significantly higher operating costs. Continuous software patches, replacements of ill-suited sensors or controllers, and costly downtime due to unforeseen failures are required.

Increased productivity and reduced costs

From the point of view of company boards or production managers, the key outcome of any automation project is cost reduction and productivity improvement. By analysing processes and developing an automation model, it is possible to identify bottlenecks, high human labour costs or inconsistent product quality. Robotised workstations, controlled by precise algorithms and using proven programming methods, eliminate typical manual errors and the plant can operate 24/7 at a stable quality level.

Building a competitive advantage

In a competitive industrial market, advantages are gained through innovative solutions and stable processes. Thoughtful design of automation systems allows companies to keep up with the growing demands of the market and adapt quickly to changes. The integration of AI (artificial intelligence), vision systems or collaborative robots (so-called cobots) with classic automation is an increasingly common way to increase flexibility, efficiency and safety in production facilities.

Stages in the design of automation systems

A complex industrial automation project usually follows a specific sequence of stages. Each differs slightly depending on the industry and company specifics, but the goal remains the same: to create a well thought-out, safe and profitable infrastructure.

Analysis of needs, objectives and environment

The first step is to analyse manufacturing and other types of processes (e.g. packaging, welding). The project team, together with engineering and management staff, collects data on:

• The company's current process flow.
• Bottlenecks occurring (e.g. long machine changeover times, frequent downtimes).
• Costs and productivity of individual production lines.
• Potential opportunities for new systems to work with existing software (ERP, MES, vision systems).

At this stage, the experts at Michale Automatics get to know the nature of the plant's work and clarify the objectives: whether it is to reduce labour costs, optimise quality, improve production flow or perhaps increase line flexibility.

Concept development and technology selection

Once the needs have been identified, concept development begins. The choice of technology is a key moment. Depending on the processes, the following are used:

• Industrial robots for welding, painting or packaging tasks.
• Cobots (collaborative robots) where there is a need for direct human-machine interaction.
• Specialised vision systems for quality control and measurement.
• Systems that record real-time data from the production line and send it to ERP/MES systems.

The aim is to select a set of equipment and software that work together in a coherent way. Many companies opt for SIASUN robots, which Michale Automation is authorised to distribute. This is equipment that has been proven in various industrial applications, offering high repeatability and easy integration.

Control system design and documentation

Once the concept is established, detailed technical documents are prepared. Engineers design electrical diagrams, control systems, select sensors and actuators (e.g. actuators). Documentation describing the operation of the control logic, safety parameters and alarm codes is also produced. This has a beneficial effect on later stages:

• Allows for efficient installation and verification of corrections.
• Accelerates commissioning and testing of the entire system.
• Facilitates future expansion or upgrading of the line.

System implementation and testing

On the basis of the prepared plans, the selected components and software are physically implemented. In parallel, factory tests (FAT - Factory Acceptance Test) and site tests (SAT - Site Acceptance Test) are carried out. During this time, engineers check whether the entire system is working as intended, whether performance is as expected, and whether the PLC and robot software requires additional adjustments.

Training and commissioning

Once the tests have been completed, training of the company's operators and technical staff is crucial. Even the most advanced production line will not be effective if staff do not know how to operate it. Michale Automation provides comprehensive training in programming, servicing and safe operation of automated workstations.

Examples of application areas for automation system design

Although the design of automation systems is a universal process, different sectors of the economy may have completely different priorities and technical requirements. Explore examples of the most typical areas where new solutions are being implemented.

Robotisation of welding and painting

Welding or painting workpieces in an automated manner not only increases quality, but also improves ergonomics. The operator does not have to manually weld large structures, which reduces the risk of injury. In automated systems, precision and parameter stability are key.

• Example implementation: SIASUN industrial robot with high payload and repeatability.
• Benefits: Faster pace of work, consistent quality, less risk of errors or corrections.

See also the welding robotisation offer available from Michale Automation: robotisation of welding.

Robotisation of packaging and palletising

In the food, pharmaceutical or e-commerce industry, it is important to have a high packaging speed while maintaining precision. Designing a system to automate this process requires not only selecting the right robot, but also developing workstations that work with conveyor belts, labelling machines or vision systems that recognise the position of products.

• Example implementation: Vision systems for goods stacking detection and high-speed delta robots.
• Benefits: Reduced staffing requirements, less material waste, increased packaging efficiency by several tens of per cent.

Internal transport systems and integration with ERP

By automating the transport of workpieces or semi-finished products between workstations, it is possible to reduce downtime and improve material flow in the plant. Industry 4.0 also sees the growing importance of integrating robots with ERP/MES systems to help manage orders and track the status of orders in real time.

Safety aspects in automation design

Modern automation systems, especially those involving heavy-duty robots, must be designed with strict safety standards in mind. Engineers are responsible for:

• Risk assessments (such as those related to collisions, operator entrapment between machines or electrical hazards).
• Selection and installation of safety components (light curtains, laser scanners, emergency control systems).
• Application of safety functions in PLCs and robot controllers.
• Designation of safety zones and training for staff in handling.

Safety issues are crucial from both a legal and ethical point of view. A well-designed system minimises the risk of accidents, protects the health of employees and ensures compliance with applicable legislation (e.g. EU directives or ISO standards).

Costs and return on investment

Many customers wonder whether the investment in designing automation systems pays off in the short term. Indeed, the cost of buying a robot or a specialised PLC may seem high. In practice, however, a properly designed production line often brings a rapid return on investment (ROI).

Case study - reducing labour costs and increasing productivity

An example is a medium-sized company in the furniture industry. By modernising production and implementing packaging automation, labour costs were reduced by 25% and the company was able to accept more orders due to a 35% increase in speed. This resulted in an increase in revenue and profitability for the entire plant.

ROI calculator

A good tool to help assess cost-effectiveness is an ROI calculator. Michale Automation has developed a special calculator that takes into account the hourly cost of an employee, the number of shifts per day, the efficiency of the processes and the price of implementing a robot. Checking how long it will take to recoup the investment makes the decision to implement easier. If you are interested in this topic, go to ROI calculator for welding robotisation.

The most common challenges and mistakes made in automation design

Even the most promising implementation idea can fail if key factors and potential risks are not considered. Here are some of the most common challenges faced by companies:

Insufficient pre-implementation analysis

A too cursory approach to the needs and process analysis stage often leads to a situation where the new system does not deliver the expected results. Unrealistic expectations regarding implementation time, lack of a plan for integration with other systems or omission of technological details result in the need for rework.

Mismatch between technology and real needs

It sometimes happens that a company invests in an advanced robot or controller, the functionality of which it does not use in practice. Meanwhile, investing in an over-engineered system generates considerable costs at the outset, and also requires advanced maintenance and expensive servicing.

Lack of flexibility in future plans

Today's production is changing rapidly. For this reason, it makes sense to plan the design of automation systems in such a way that growth and modification are possible. Closed solutions limit flexibility and the introduction of new products or packaging formats requires line rebuilding from scratch.

Working with an experienced integrator

Designing automation can sometimes be a challenge for companies that do not have their own engineering background or experience in selecting equipment. In this situation, an external integrator - a team of specialists who will plan, implement and test the entire system - plays a key role.

Benefits of working with Michale Automation

• A comprehensive approach: From needs and concept analysis, to technology selection, to service and training.
• A broad portfolio of robotic solutions: Michale Automatika is the official distributor of SIASUN robots, which stand out for their reliability and flexibility in adapting to different tasks.
• Experience in integration with MES/ERP systems: This allows ongoing monitoring of key production indicators (KPIs).
• Continuous after-sales support: The company offers servicing and maintenance of robotic workstations, which minimises the risk of downtime (see: servicing and maintenance of stations).

Practical step-by-step recommendations

Based on the experience of many companies implementing advanced automation systems, some good practices can be identified:

1. Start with a sound process analysis.
   
   Collect data on production time, cost and quality and identify the biggest challenges (downtime, errors, material losses).
2. Engage key stakeholders at an early stage.
   
   Include operators, department managers and the quality department in the discussion to take all opinions and needs into account.
3. Bet on safety and compliance with standards.
   Use experienced safety engineers and remember to assess the risks. Never cut back on resources for safety components.
4. Ensure that the integration of IT systems is as smooth as possible.
   Determine which data will be sent to the ERP systems and how, so that everything works together from the start.
5. Plan service and maintenance.
   Develop a maintenance and support schedule. Regular maintenance prevents costly breakdowns in the future.

Summary

Designing automation systems in a modern factory is a complex process that requires in-depth analysis, selection of appropriate technologies and reliable implementation. A well-thought-out design is the key to scalable and profitable business growth in the face of increasing competition and growing market demands.

Key findings and recommendations:

• Prepare for the project by performing sound analyses of production processes and resources.
• Select technological solutions (robots, controllers, vision systems) in line with the actual needs of the company.
• Take care of the safety aspect right from the design stage of the control system.
• Don't forget proper staff training and service support.
• Control the effectiveness of the implemented system through data from ERP/MES systems to quickly catch bottlenecks and improve processes.

If you would like to learn more about implementing robotisation in your facility, read the robotisation offerings in Michale Automation services or consult our engineers for detailed solutions tailored to your needs.

With thoughtful automation system design, your company will gain:

• Stable market position.
• Safe, comfortable working conditions for operators.
• Greater flexibility when introducing new products or processes.
• Higher productivity and a measurable return on investment.

I also invite you to check out other articles on our blog and to get in touch if you need support in planning and implementing new solutions. Michale Automation has specialised in the construction of machines and production lines, industrial automation and the design of robotic workstations for companies for many years - our knowledge and experience could prove crucial to the success of your business.

I encourage you to explore the topic further, subscribe to the Newsletter or comment - every comment or question brings us closer to a more efficient and safer future in industry. Good luck with your automation projects!

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.