How to prepare your company for the implementation of robotic workstations - a practical guide

Estimated reading time: approx. 8 minutes

TL;DR

• Carefully analyse your processes to find the areas with the greatest potential for robotisation.
• Use an experienced supplier with comprehensive implementation support.
• Calculate the real return on investment (ROI) - include costs and potential savings.
• Ensure employee safety, training and servicing posts.
• Develop systems: start with one robot and gradually expand production lines.

Table of contents

• Understanding the company's needs and process analysis
• Selection of appropriate technologies and robots
• Investment planning and ROI
• Integration of robotic workstations into the current production line
• Safety aspects and staff training
• Service, maintenance and further development
• Summary and recommendations
• FAQ

Introduction

Robotic workstations are increasingly appearing in various types of production facilities, regardless of their size and industry. The dynamic development of modern technologies, the shortage of skilled workers, as well as growing expectations regarding quality and speed of order fulfilment, make robotisation a real opportunity for many companies to increase their competitiveness. In this article, we will show you how to prepare your company step by step for the implementation of robotic workstations. You will learn why proper planning and a preceding process audit are so important, what steps to take to successfully integrate industrial robots into an existing production line, and how to calculate the return on investment (ROI) of automation.

Understanding the company's needs and process analysis

The first step is to understand in which areas of production robotic workstations can bring the most benefit to the company. Without this, reliable investment planning is virtually impossible. In practice, this means carrying out a detailed review of current processes - from the receipt of raw materials, through the subsequent manufacturing stages, to packaging and storage.

Most often, robotisation is considered where:

• Activities are repetitive and monotonous.
• There is a high proportion of manual work, the quality of which is difficult to standardise.
• The risk of errors due to the human factor is high.
• The working conditions are particularly difficult (e.g. high temperatures, dust).

At this stage, it is also crucial to identify the quality and productivity indicators that we want to improve - for example, reducing the number of defects from 5% to 2% or reducing the production cycle time by 20%.

Selection of appropriate technologies and robots

Once the existing processes have been thoroughly analysed, it is possible to move on to selecting the technologies and robots that best meet specific needs. The industrial robotics industry today offers a wide range of possibilities - from classic six-axis robots, to cobots (robots that collaborate with humans), to complex systems integrated with vision systems or artificial intelligence.

Criteria for robot selection

During the selection process, it is worth paying attention to:

• Range of movement and lifting capacity of the robot (whether it will be able to handle heavy parts).
• Repeatability of movement and precision (important in processes requiring high accuracy).
• Suitable for demanding environments (e.g. dusty or high humidity conditions).
• Ability to quickly reconfigure the workstation (especially in companies with frequent product range changes).
• Ease of integration with other equipment and systems, such as production line, conveyors, sensors, vision systems.

Importance of working with the right supplier

Crucial in this process is cooperation with a proven integrator or supplier that is able to provide not only specific equipment, but also full support during implementation and subsequent service. Michale Automatyka - the official distributor of SIASUN robots in Poland - specialises in the comprehensive construction of machines, production lines and the implementation of robotic workstations. This approach allows for fully personalised solutions and the certainty that every element of the system will be compatible with each other.

Investment planning and ROI

The cost of purchasing the robot, the necessary hardware and the integration itself can be significant. Therefore, one of the most pertinent questions is: "Is it really going to be worth it?" To answer this, it is worth conducting a detailed financial analysis - considering not only the price of the equipment, but also the savings that process automation will bring.

Analysis of costs and potential savings

Cost factors include:

• Purchase and installation of a robot (hardware + integration).
• Additional site equipment (e.g. safety systems, sensors).
• Possible modification of the production line.

Gains or savings from robotisation can result from:

• Reducing the number of shortages and complaints by eliminating human error.
• Lower labour costs (robots can work 24/7).
• Reducing production cycle times.
• Opportunities to increase production volumes without recruiting new staff.

Examples of ROI calculations

According to studies published in industry reports (e.g. by the International Federation of Robotics - IFR), the payback time for an industrial robot in mass production is often between 1.5 and 3 years. To be able to estimate this accurately, it is worth using available tools - e.g. online ROI calculators.

If you want to estimate the first return on investment associated with robotic welding processes, you can use the free calculator: ROI calculator - welding robotisation.

Integration of robotic workstations into the current production line

Simply purchasing a robot is only the beginning. The next step is to fit it into the existing production environment so that it works with the other hardware, software and people. A well-prepared implementation schedule, taking into account testing and necessary downtime, helps reduce the risk of unplanned delays.

Collaborative working with vision and ERP/MES systems

Today's robotic workstations increasingly interact with sophisticated vision systems, which allow automatic shape recognition, defect detection or precise positioning of the workpiece in front of the robot gripper. Integration with ERP or MES systems is equally important - this makes it possible, for example, to track production progress in real time, maintain continuity of component deliveries or automatically generate productivity reports.

Key implementation steps

• Design stage: creation of a concept and visualisation of the robot workstation (appropriate number of robots, selection of sensors).
• Infrastructure preparation: provision of the required space, power supply, industrial network.
• Assembly and integration: connecting the robot to the production line and control systems.
• Tests: checking all functions and running in test mode (dry and then in real conditions).
• Project acceptance: final commissioning and assessment of whether the stated objectives (e.g. productivity, quality) have been achieved.

If you would like to learn more about company wide robotisation, please read the information on the website: Find out more about robotisation.

Safety aspects and staff training

The introduction of robotic workstations also requires that safety is taken care of - both for the operators and the plant as a whole. Relevant standards and directives apply (e.g. the Machinery Directive in the European Union). In practice, this means that:

• Adequate cordoning off of the robot's working area (if it is a high-powered industrial robot).
• The use of light curtains or safety sensors.
• Ensure correct emergency shutdown procedures.

Equally important is the training of the personnel who will work with the robotic systems - both from the perspective of operation and possible maintenance repairs. Many companies choose to work with a supplier of robotic workstations precisely because of the possibility of comprehensive support, also in terms of staff training.

Service, maintenance and further development

Keeping a robotic workstation running at all times requires regular maintenance and a quick response to faults. It is therefore crucial to choose a partner that can guarantee efficient service and access to spare parts.

Amongst other things, we offer the service and maintenance services you will find on offer: Service and maintenance stands.

Let us also remember that modern industrial robots offer a wide range of expansion possibilities. Companies often start with a single workstation and then - as production grows - expand robotic systems with further modules, combine robots with new technologies or introduce artificial intelligence systems.

For companies looking for a solution with a higher payload or precision, another robot from the SIASUN series could be an excellent choice. For example: SIASUN SR25A robot.

Summary and recommendations

Implementing robotic workstations is an investment that can significantly improve the efficiency of production processes, ensure higher product quality and allow the company to make better use of human resources. However, if it is to bring the expected return, it requires carefully planned measures beforehand - from auditing the processes, to selecting the right type of robot, to integrating and training the workforce.

Key findings and recommendations:

• Carefully analyse your company's current processes and identify those where robotisation will bring the greatest benefit.
• Choose an experienced supplier and integrator who will provide not only the hardware, but also support with system design and commissioning.
• Conduct an ROI analysis as early as the investment planning stage, taking into account both purchase and integration costs, as well as the potential reduction in shortages and savings from eliminating multi-shift working.
• Ensure staff safety and training. Robotic workstations require the right infrastructure and an informed workforce.
• Don't forget service and maintenance. Reliable operation is key to production continuity.
• Remember that developing and modernising industrial processes is an ongoing process. You can start with one station and expand the system with more robots and modules as required.

If you would like to learn more about specific application examples, verify the cost-effectiveness of robotisation in your company or simply learn about new technologies available on the market, please contact us. At Michale Automation, we develop and implement solutions fully tailored to your production needs - from small plants to large enterprises.

We also encourage you to further explore our blog articles and use the ROI calculator. You can also write to us to receive a dedicated quote for the implementation of robotic workstations.

Summary
Robotic workstations in a company do not have to be an expensive fad. With increasing competition and quality requirements, more and more companies are choosing robotisation as a strategic tool to optimise costs and increase productivity. Well-planned implementation, the right choice of technology and reliable staff training ensure a rapid return on investment.

• If you are considering robotisation, start by analysing your processes and potential savings.
• Plan the key stages of the project, including testing and training.
• Find an experienced partner who will offer comprehensive support - from design to robot servicing.
• Continue to develop, monitor the effects and, if necessary, expand the systems with further modules to realise the full potential of automation.

We hope that this guide will help you prepare for the implementation of robotic workstations in your plant. If you need additional information, please feel free to contact us at Michale Automation. We will be happy to answer any questions and help you choose the solutions best suited to your business. Good luck on your way to more efficient, modern and safer production!

FAQ

How long does it take to implement robotisation in a company?
The implementation time depends on the complexity of the processes and available resources. For simple solutions it can be a few weeks, and for extensive projects even a few months.

Does automation involve redundancies?
Usually no. With robotisation, employees can be delegated to more creative or demanding tasks. This is often accompanied by a process of retraining and upskilling the team.

Is robotisation only viable for large manufacturing plants?
No. Current technology allows robotic workstations to be flexibly adapted to the needs of both small and medium-sized companies, with a rapid return on investment.