Plant design - the key to modern and efficient production lines

Estimated reading time: 8 minutes

TL;DR

• Solid foundations: By precisely defining the machine's objectives and operating conditions, it is possible to create an optimal production line.
• Design stages: from needs analysis and prototyping to implementation and integration with IT systems.
• Technologies of the future: Automation and robotisation streamline processes, increase productivity and reduce costs.
• Safety and ergonomics: key elements affecting the comfort of workers and the long life of machinery.
• Design challenges: include schedule, budget and the need to ensure continuity of production, but proper planning minimises risk.

Table of contents

• Why is equipment design so important?
• Main stages of equipment design
• Equipment design versus automation and robotics
• New trends in the design of machines and production lines
• Safety and ergonomics
• Integration of equipment throughout the plant
• Challenges in equipment design and how to meet them
• Examples of applications of modern equipment
• Costs and return on investment (ROI)
• Summary of practical conclusions
• Encouragement for further action
• Summary

Introduction

Plant design is the cornerstone of efficiently functioning factories and manufacturing companies. In an era of intensive technological change and increasing customer expectations, properly designed machines and production lines have a huge impact on the efficiency, safety and profitability of manufacturing processes. Why is plant design so important right now? Because the modern market requires companies to respond quickly to changing needs, to be flexible and to provide robust solutions.

In this article, we will look at the key stages of equipment design, showing you how to create functional yet future-proof machines and production lines. You will also learn what role modern technologies, including industrial robots and automated systems, play in this process. After reading, you will gain a working knowledge of how to plan and implement projects from concept to implementation.

Why is equipment design so important?

Plant design is not just about developing innovative designs or selecting materials with the right parameters. It is also a holistic view of the needs of the production facility, including:

• Optimising workflow on the production floor.
• Minimising failures and downtime.
• Increased worker safety.
• Reducing the operating costs of equipment.

A well-designed machine must be durable, easy to operate and service and safe for daily use. The challenge is to take all of the above factors into account right from the design stage, as well as to plan for the possibility of further development and modernisation of the machines. In particular, advanced technologies from robotics or vision systems are playing an increasingly important role in this process.

Main stages of equipment design

Equipment design can be broken down into a number of key steps that help to structure the work and ensure the quality of the final solution.

Analysis of needs and definition of objectives

The first stage is a thorough analysis of the project. Designers need to understand the business objectives, industry requirements and environmental conditions (e.g. humidity, dust, vibration). It is important to familiarise themselves with the applicable standards and regulations in the sector - this may include, for example, food safety, metalworking or specific internal transport conditions.

Examples of questions to be answered at this stage:

• How large do you want the capacity of the machine or production line to be?
• Will the unit operate continuously or intermittently?
• What materials will be processed?
• What space or logistical constraints exist at the plant?

Defining business objectives at the outset allows designers and developers to agree on priorities - some companies will focus on maximum efficiency, while others will choose to focus more on comprehensive flexibility and modularity.

Concept development and technology selection

Based on the defined needs, initial concepts are created. This includes:

• Choice of drive types (pneumatic, electric, hydraulic).
• Consider the control system (PLCs, industrial computers, vision systems).
• Thinking about integration with existing production and IT infrastructure.

Nowadays, projects involving the use of industrial robots or cobots are becoming increasingly common, especially in monotonous or dangerous tasks. This is a stage at which it is worth considering the robotisation of selected processes. Michale Automatyka - the official distributor of SIASUN robots in Poland - advises on the selection of optimal robots and supports the preparation of the project in terms of integration into the production line.

Detailed design

Once the concept takes shape, it moves on to detailed mechanical, electrical and automation design. CAD modelling (3D) allows an initial assessment of the machine's appearance and the fit of its components.

• Accurate drawings, diagrams and 3D models are created.
• A set of components is defined.
• Engineering calculations are used to ascertain the strength and stability of the structure.

This stage also allows simulation of the device's operation under near-real conditions. This allows errors to be corrected quickly and changes to be made before prototype production takes place.

Prototyping and testing

The prototype is a key tool in device design - with it you can:

• Verify design assumptions in practice.
• Check ergonomics of use.
• Test the operation of key components and control software.

An important element is to include the employees who will be operating the device in the tests. Their suggestions will help to improve and facilitate daily operation.

Implementation into production and commissioning of the line

The final step is to take the device from the design and prototype phase to actual production. This can mean:

• Assembly and installation of all components on the production floor.
• Integration with existing production line and IT systems (e.g. MES or ERP).
• Final testing and calibration of machines and equipment.
• Training of employees in the operation and maintenance of the unit.

Once the implementation is complete, the production line should operate at its intended capacity and meet safety standards. Service and maintenance play a key role in the early detection of faults and the maintenance of continuous operation.

Equipment design versus automation and robotics

More and more companies - both large and smaller plants - are choosing to implement automated solutions. Robotising processes helps to increase productivity, reduce quality deficiencies and reduce production costs in the long run. In plant design, this means a must:

• Designing suitable grippers and feeders for the robots.
• Consideration of space limits needed for traffic and safety zones.
• Integration of the robot control system with the other machines in the line.

For example, if a production line is to operate a robot to package finished products, thought needs to be given to the early stages of the process so that the material arrives at the robot station in a properly ordered manner. Michale Automation, as a company that builds machines and production lines and implements robotic workstations, provides both complete turnkey solutions and retrofit services for existing installations.

If you're looking for more information on automation options and potential implementations, it's worth taking a look at the Production line construction and modernisation services.

New trends in the design of machines and production lines

The industrial world is in the midst of another technological revolution. Industry 4.0, a combination of automation, robotics and digital production management systems, is also influencing the approach to equipment design.

• IoT (Internet of Things) - intelligent sensors transmit data in real time, which helps to keep track of the machines' status.
• Vision systems - allow quality control and fault detection without operator intervention.
• Cobots - collaborative robots (collaborative robots) that can work side-by-side with humans, increasing the versatility of the line.
• Advanced data analytics - allows potential problems to be anticipated and machine maintenance to be planned.

This approach to equipment design ensures high efficiency and flexibility. As a result, production lines are able to adapt more quickly to changing market requirements and companies gain a competitive advantage in the form of stable, scalable production.

Safety and ergonomics

Safety in use is an equally important aspect. Regulations require all industrial machinery to be properly protected and brought up to standard. On the other hand - the designed equipment must be operator-friendly, so that it does not cause injuries and excessive strain on the body.

• Light curtains, safety curtains and fences protect against the risk of collisions or injuries.
• Ergonomic operating areas avoid awkward working positions and repetitive strain injury (RSI).
• The simple and intuitive operation of the HMI (Human Machine Interface) panels reduces the risk of human error.

Michale Automation combines advanced technology with attention to ergonomics in its designs. Comprehensive risk assessment and safety testing are carried out as early as the design and prototyping stage. Regular maintenance and servicing and maintenance of stations - is the key to the longevity of the equipment and to maintaining optimum process safety.

Integration of equipment throughout the plant

Modern factories are often complex ecosystems of machines, robots and IT systems. Integration therefore plays an increasingly important role in equipment design:

• With existing production lines and machinery.
• With ERP/MES systems that oversee production and logistics processes.
• With robotic workstations such as robotisation of packaging.

The integrated system allows real-time monitoring of machine status, production planning based on actual production rates and optimisation of raw material or semi-finished product flows. As a result, unused resources are minimised and the company can manage customer delivery times more effectively.

Challenges in equipment design and how to meet them

Every project, regardless of scale, comes with challenges that can involve:

1. Schedule - tight deadlines often require multiple engineering teams to work in parallel.
2. Costs - Not all investments have an immediate return. Accurate ROI forecasts are sometimes necessary to convince management of the right purchasing decisions.
3. Maintaining production continuity - In continuous operations, any modernisation requires a well-planned shutdown and downtime period.
4. Staff shortages - The operation and maintenance of new machinery requires skilled staff, so it is worth ensuring that staff are trained and supported.

The solution is proper planning, the use of effective project management methods and close cooperation between departments. Michale Automation supports its customers with a comprehensive approach to machine design and construction, offering technical advice, team training and service support.

Examples of applications of modern equipment

Thanks to advances in robotics and automation, many areas of production are being radically transformed. Here are some examples:

• Robotic welding stations - enable precise and reproducible welding of metal parts with minimal human intervention.
• Automatic packaging lines - robots equipped with vision systems recognise the shape and position of the product and then deposit it in cartons or on pallets in a space-optimised manner.
• Mounting systems - In the electronics or automotive sector, without automation and precision machinery, it is difficult to speak of a fast and stable component production process.
• Machining and grinding machines - allow a high-quality surface finish to be achieved on metals or plastics.

In each case, it is crucial to adapt the design of the equipment to the specific requirements of the manufacturer and the characteristics of the process.

Costs and return on investment (ROI)

Plant design is an investment that, depending on the scale of the project, can be significant. However, the long-term benefits - in terms of higher quality, less waste, shorter downtime and reduced labour costs - usually compensate for the outlay within just 1-3 years of line operation.

When calculating ROI, we take into account:

• Purchase, installation and implementation costs.
• Operating costs (energy, spare parts, service support).
• Reducing production cycle times.
• Reduction of quality errors and complaints.
• Logistical improvements and reduced material losses.

If in doubt, it is worth using ROI calculators to estimate the payback period before making a final decision.

Summary of practical conclusions

Device design is a complex process, where a holistic view of the company's needs, the market and future growth prospects is important. Below are the most important recommendations to remember:

• Carefully define requirements and objectives - A good needs analysis facilitates the development of appropriate solutions.
• Opt for flexibility - modularised and scalable equipment is easier to adapt to changing demand.
• Consider robotisation selected processes - industrial robots or cobots are increasingly becoming an efficient alternative to traditional methods.
• Ensure safety and ergonomics - The well-thought-out design protects workers and allows machines to last longer.
• Use simulation tools - They allow modifications to be made more quickly without risking losses in real production.
• Plan integration with IT systems - The gain from automation is much greater when machines work together with production management software.
• Calculate costs and benefits - This makes it easier to justify the investment and get the project budget under control.

Finally, it is worth remembering to regularly monitor the condition of the equipment. Reliable servicing and partial upgrades can significantly extend the life cycle of machines and guarantee continuous and trouble-free operation.

Encouragement for further action

Wondering what the process of designing a new machine for your company looks like in practice? Or are you planning to modernise an already functioning production line? If so, we invite you to contact the Michale Automation team - we will be happy to advise and present comprehensive solutions for the design and implementation of machines and robotisation of production processes.

Benefit from our experience and support - whether it's designing completely new machines or improving existing workstations. Working closely with manufacturer SIASUN, we can offer a variety of robots and robotic workstations tailored to your specific industry.

Also learn more about our offer and sample implementations in the field of industrial automation - visit our website and see how modern equipment will translate into increased productivity in your company.

Summary

Equipment design is at the heart of any efficient production line and is the starting point for modern industry. Properly planned stages - from needs analysis, conception and detailed engineering to testing and integration - ensure that the equipment will meet its business objectives for many years to come. Thanks to the increasing availability of robots, advanced sensors and vision systems, designers today have tremendous opportunities to create bespoke solutions.

After reading the article you already know:

• How the device design process works - from idea to implementation.
• What to look out for when selecting technology and how robotisation supports day-to-day production.
• Why safety and ergonomics are the pillars of modern production lines.

We encourage you to read other publications on our blog and to contact us to discuss your individual needs. Do you want to implement a robotic workstation, modernise your machine park or design a new production line? Contact us - Michale Automation specialists will be happy to help you plan and implement the most effective solution.

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.