Machine technology in practice: how to integrate robots and ERP/MES systems to optimise the production line

Estimated reading time: 8 minutes

TL;DR:

• The integration of robots and ERP/MES systems is the foundation for effective management of modern production.
• Proper planning and pre-implementation analysis minimise the risk of a failed project.
• The lack of competence in the team can sometimes be a challenge, but it can be overcome by training and working with an experienced integrator.
• Robotisation of repetitive processes provides a rapid return on investment and a measurable reduction in costs.
• A trusted technology partner supports the company at every stage of its operations, from design to service.

Table of contents

• Introduction
• The importance of integrating robots with modern systems
• Step by step: from analysis to implementation
  • Stage 1 - Pre-implementation analysis
  • Stage 2 - Solution design
  • Stage 3 - Implementation and configuration
  • Stage 4 - Testing and optimisation
• Challenges in integration and how to solve them
  • Lack of competence within the team
  • Limited software compatibility
  • Costs and risks of uncertain ROI
  • Integration of machine and robot safety
• Examples of practical applications
• The role of the trusted partner in the integration process
• Conclusions and recommendations
• Summary
• FAQ

Introduction

Machine technology is becoming a mainstay of modern manufacturing as companies around the world seek to reduce costs and increase efficiency. The increasing availability of advanced robotic solutions or digital management systems (for example, ERP or MES) allows not only the automation of processes, but also the coupling of robots and machines into a cohesive ecosystem. In this article, we will look at how businesses can effectively integrate manufacturing robots with existing systems to achieve noticeable improvements in quality and productivity. We will also discuss the key challenges that can arise when implementing such projects and present tips to make the adaptation process much simpler.

If you are wondering what the integration of robots with ERP or MES looks like in practice, read the following chapters. You will learn why a holistic approach to information management is so important in the era of Industry 4.0, what mistakes to avoid and what to pay attention to right from the solution design stage.

The importance of integrating robots with modern systems

The integration of robots into ERP/MES systems is much more than just the next stage of automation. It provides the foundation for the effective management of data flowing directly from machines, production lines and warehouses. Instead of leaving robots in isolation, companies can take advantage of the real-time flow of information and gain insights into productivity and operating costs.

- Elimination of errors and increased safety - When all equipment communicates with each other and exchanges data in management systems, operators can react more quickly to downtime. This minimises the risk of failure of key machines and makes condition management more transparent.

- Quality tracking and efficient problem identification - A modern MES enables the ongoing monitoring of key production indicators, which helps to spot irregularities at the individual station level. If a robot encounters an inconsistent sequence of movements, or the vision system signals poorer workmanship, this data is immediately visible in the operator panel - and can be cross-referenced with data from the ERP system.

- Scaling up processes - A common machine and software language makes it easier to expand the plant with further stations. If the integration is carried out consistently and a defined standard for data exchange is implemented, connecting further robots is quicker.

Instead of carrying out modernisation in a point-by-point fashion - a robot in one area, a new IT module in another - it is worth looking at the entire product development cycle and considering how to reduce unnecessary costs, eliminate bottlenecks and, at the same time, make optimal use of human resources.

Step by step: from analysis to implementation

The integration of robots and machines with ERP or MES systems largely depends on the conscious planning of the next steps. The following is a general procedure that can be adapted to the specifics of different companies - from smaller production facilities to large multi-departmental factories.

Stage 1 - Pre-implementation analysis

The first step is to define the problems we want to solve and the goals we plan to achieve with robotisation and its integration into production software. This should include:

• Outline of the company's process structure (from order to dispatch of the product).
• Main operations performed by workers, machines and robots (if any).
• Available resources: budget, competence of the team, time for implementation, current state of the IT infrastructure.

It is good to carry out test trials and estimate the potential benefits. The calculation of the return on investment (ROI) should be based on reliable data. For this purpose, for example, the following can be used. Dedicated ROI calculator created for the robotisation of selective processes - even if it is not typically welding, this tool allows a better understanding of cost and profit dynamics.

Stage 2 - Solution design

Based on the information gathered, it is time to develop the technical concept. In this step, companies answer the question of how many robots they want to implement, which workstations to automate first and how to integrate the software. At this stage, it is extremely important to plan the communication between the robot and the ERP/MES system.

It is important to take into account:

• Data exchange protocol - A properly defined standard avoids information 'confusion'.
• Network architecture - It may be necessary to prepare a separate VLAN for machine communication.
• Monitoring and safety - Defining the robot's working zones and implementing safeguards to avoid collisions or situations that endanger personnel.

Stage 3 - Implementation and configuration

Once the final design has been developed, it is time for practical implementation. This involves, among other things:

• Robot installations (such as models from SIASUN, of which Michale Automatika is an authorised distributor).
• Configure and test PLCs and integrate machine signals.
• Programming of work paths and adaptation of production parameters to specific tasks (e.g. conveying speed or gripper pressure).
• Launch ERP/MES software modules that will collect, process and visualise data in real time.

During this phase, care should also be taken to integrate the safety system. Each robot should have defined procedures for emergency situations and safety zones. This will allow the operator to stop the machine instantly and avoid collisions with cooperating equipment.

Stage 4 - Testing and optimisation

The next step is testing in the target environment. It is necessary to check that all the integration 'links' - from the ERP system to the robots to the line controllers - communicate correctly with each other. It is also important to identify key indicators (KPIs), such as:

• Line throughput per hour (or day).
• An indicator of the quality of the products produced.
• Percentage of deficiencies resulting from errors that are only discovered later in the process.
• Employee utilisation rates and the impact of automation on employee productivity.

Analysis of this data makes it easier to make modifications. It may be that the robot's speed needs to be reduced at a certain stage of assembly to increase precision, and at another point in time, movements need to be accelerated to improve efficiency.

Challenges in integration and how to solve them

Any project of this type, regardless of the size of the plant, is likely to encounter obstacles. The most common include:

Lack of competence within the team

Even the most modern equipment will not help if the team does not have the right knowledge of robotics and IT/OT (Information Technology/Operational Technology) integration. The solution is comprehensive training support and working closely with an experienced integrator. It is good practice to involve employees in the conception process - then the operation of hardware and IT systems becomes intuitive for them.

Limited software compatibility

Sometimes a company uses custom modules that are difficult to integrate with robots or sensors. In such a situation, it is worth considering:

• upgrading the current system to a newer version,
• changing some modules to be more versatile,
• the use of so-called communication gateways or middleware, which enable the translation of data from different protocols.

Costs and risks of uncertain ROI

Many companies fear that implementation costs will prove too high and the return on investment uncertain. The key to success is to start integration with well-defined, repeatable processes (e.g. handling, packaging or quality control). In this way, the risks are reduced and the results are seen more quickly. A good example of such a department in a company could be robotisation of repetitive productionwhich allows you to focus on the aspects that bring the greatest savings in the short term.

Integration of machine and robot safety

When choosing a specific robot model, compliance with the safety standards in force in a given country should be taken into account (in Poland, the PN-EN standards for machine safety are key). Safety barriers, light curtains and the designation of zones of possible human-machine interaction should be kept in mind.

Examples of practical applications

In addition to large-scale production, robots and ERP/MES systems are also gaining ground in smaller plants. Tasks such as transferring components to individual production stages or sorting components have now become the domain of robotisation. Among others, we can specify:

• Integration of the packaging robot into an ERP system - This allows the automatic generation of stock documents while the robot packs the parcels leaving the production line. There are also solutions that monitor in the system how many pieces of product have left the belt and inform the logistics department automatically of the volume ready for dispatch.
• Robotisation of welding - implementation robotisation of welding gives high repeatability and higher quality, especially in the production of metal components. If you integrate such a module with an ERP, you can not only track parameters (welding speed, temperature), but also analyse the work on a daily or weekly basis in terms of welding material and energy costs.
• Robotisation of control processes - In the food manufacturing or pharmaceutical industries, machines and robots are used to take measurements and quickly segregate defective products. The integrated MES system can continuously report on the degree to which quality standards are met and archive data for audits.

The role of the trusted partner in the integration process

The design and implementation of robotic workstations, and their subsequent integration with ERP/MES systems, can often be complex and requires not only technological expertise but also project management experience.

• Working with a trusted integrator - Michale Automatika, which operates in the machinery and industrial automation market, acts as an all-round partner. As an official distributor of SIASUN robots, it provides support from the consultation and design phase, through purchase and installation, to service and maintenance of the workstations. Check out the details of the offer servicing and maintenance of stations - It is always a good idea to be sure of a full after-sales service.
• A comprehensive approach - The specialists at Michale Automation understand the importance of a holistic approach: from matching the robot's parameters to the requirements of a specific line, to integrating the software to enable advanced analysis. This makes the implementation process shorter and, above all, less prone to misguided decisions.
• Employee training - In the final stage, the company can also ensure that employees and engineering staff are properly trained so that they do not feel overwhelmed by the new technology. Operators will then be able to react quickly to line or configuration changes and take advantage of available capabilities without unnecessary downtime.

Conclusions and recommendations

The integration of robots into ERP/MES systems in the area of machine technology is not just a catchy marketing slogan, but first and foremost real improvements for companies of all sizes. Below are the most important findings:

• Start with a precise process analysis - Without understanding their essence, it is difficult to choose the optimal robotisation or integration strategy.
• Focus on repetitive high-volume tasks - you will ensure a quick return on investment and better control over quality.
• Define standards for data exchange in IT/OT systems - you will avoid messy communications and reduce problems caused by incompatible protocols.
• Divide the project into small stages - test solutions, draw conclusions and only then scale the project to further areas within the company.
• Count on a trusted partner - expert support helps to reduce integration time and gives confidence that any problems will be resolved quickly.

Summary

A key aspect in planning the integration of robots and machines into existing systems is understanding that each component - both hardware and software - must work together within a coherent data architecture. Michale Automatics has been working on such projects for years, combining experience in building production lines and knowledge of advanced IT systems.

However, even the best machine technology and software are not enough if the right people preparation and adequate concept are missing - hence the importance of creating a solid pre-implementation plan, carrying out step-by-step testing and providing comprehensive support throughout the project lifecycle.

If your company is planning to enter the area of robotisation or you would like to modernise your existing solutions to make full use of ERP/MES data, please also take a look at our range of robotisation available from Michal Automation. There you will find example implementations and expand your knowledge of the possibility of improving processes through automation.

I encourage you to share your insights in the comments and to contact the specialists at Michal Automation if additional questions arise. Also consider subscribing to industry newsletters to keep up to date with trends in cutting-edge machine technology that are revolutionising more areas of industry.

By integrating robots and production management systems, you gain a competitive advantage, reduce risk and create the conditions for rapid growth of your business. And all this is based on the consistent use of machine technology, ERP/MES data and team knowledge.

Good luck with the implementation!

FAQ

How long does it take to integrate robots into an ERP/MES system?
The duration depends mainly on the size of the plant and the complexity of the processes. In smaller companies it can be a few weeks, while in large companies it can even be several months.

Does integration mean job cuts?
This does not have to be the case. Often, the integration of robots into ERP/MES systems allows workers to be relieved of monotonous and hazardous tasks, and they can be trained for more demanding tasks.

What should I pay particular attention to when planning implementation?
First and foremost, pre-implementation analysis, definition of objectives, selection of appropriate technology and data exchange standards. It is also important to consider security issues and train the team accordingly.