IMPLEMENTING NEW TECHNOLOGIES IN A MANUFACTURING COMPANY - HOW TO LEAD CHANGE AND INCREASE COMPETITIVENESS

Estimated reading time: approx. 8 minutes

TL;DR

• Implementing new technologies is the key to increasing a company's competitiveness and productivity.
• Needs analysis and employee engagement are essential before the transformation begins.
• The implementation process includes auditing, planning, pilot testing and continuous improvement.
• The main challenges are cost, integration with existing systems and staff concerns.
• Consistent monitoring of results helps to maintain efficiency and optimise processes.

Table of contents

- Introduction
- Why implement new technologies in a manufacturing company?
- How to prepare a company for the implementation of new technologies?
- Step by step - the process of implementing new technologies
- The most common challenges in implementing new technologies and how to solve them
- Examples of modern technological solutions in production
- Example of application scenario in a production facility
- Summary of benefits and key findings
- Completion

Introduction

Implementing new technologies in a manufacturing company today is one of the key ways to increase operational efficiency, improve product quality and reduce costs. Technological innovations can range from robotised workstations, automated quality control, implementation of ERP/MES systems to integration of intelligent sensors or solutions based on artificial intelligence. Companies that decide to take such a step gain the opportunity for faster growth and better adaptation to changing market requirements.

In this article, we present the pillars of successful implementation of modern technology in production. You will learn how to prepare the company and employees for the transition to a new operating model, how to implement the digitisation or robotisation process step by step and what challenges may arise during implementation. Finally, we provide tips to help you evaluate the effects of all changes.

We encourage you to stay with us until the end of the article. With the knowledge you have gained, you will find it easier to carry out an effective transformation in your company that will not only streamline your production processes, but also improve the competitiveness of your business in an increasingly demanding market.

WHY IMPLEMENT NEW TECHNOLOGIES IN A MANUFACTURING COMPANY?

Increased competitiveness and productivity
The primary objective of implementing new technologies in a production facility is to increase competitiveness. Through automation, robotisation or intelligent management systems, it is possible to increase production while reducing unit costs. Robots and machines perform repetitive tasks reliably and quickly, thus reducing the risk of errors.

Improved quality control and reduced downtime
Innovative solutions, such as vision systems integrated into the production line, allow detailed quality control in real time. An automated testing station can detect any irregularities at an early stage, before the product reaches the next stage of the process. This reduces the number of complaints and downtimes that often result from having to recall and correct defective batches.

Scalability and flexibility
The implementation of modern technology makes it easier for companies to rapidly scale their operations. If the number of orders increases, a flexible production line equipped with robots or cobots (collaborative robots) can instantly adapt to new production volumes, semi-finished product configurations or schedule changes.

Motivation and team development
Although, at first glance, new technologies may generate anxiety among employees, in the long term they increase job satisfaction and improve working conditions. People who previously performed monotonous or potentially dangerous tasks can be redeployed to more creative and developmental tasks.

HOW TO PREPARE A COMPANY FOR THE IMPLEMENTATION OF NEW TECHNOLOGIES?

Analysis of needs and resources

The first step is to define the most important areas of production where modernisation will bring the greatest benefit. To do this, conduct an audit of processes and resources. Analyse:

• Which production stages are most prone to error
• What part of daily work can be automated or robotised
• Where downtime and bottlenecks occur

It is also worth investigating whether the departments concerned have sufficient technical expertise and access to training. In some cases, it will be necessary to engage external specialists to help evaluate processes and develop an implementation strategy.

Employee involvement

Before work can properly take off, agreement with employees is key. People are often worried about losing their positions or having to learn how to work with new software. It is worth allaying these fears, for example by organising technical presentations or workshop meetings with the team.

At this stage, it is also worth identifying specific change leaders (e.g. a production manager or process engineer) who will be responsible for communicating with colleagues and providing substantive support during the transition.

Implementation plan and schedules

After the audit and consultation with the team, an outline implementation plan can already be created. Such a document should include, among other things:

• List of technologies to be implemented
• Scope of upgrading production lines or workstations
• Sequence of tasks and expected duration of each stage
• Assumed success rates (e.g. reduction in product cycle time by 15%, reduction in defectiveness by 20%)

Then you can start looking for reliable solution providers who will not only provide sales of the chosen technology, but also guarantee advice and after-sales service.

STEP BY STEP - THE PROCESS OF IMPLEMENTING NEW TECHNOLOGIES

Identification of the problem and technology specifications

The first step is to identify precisely what problem the technology is intended to solve. If your business often experiences downtime due to manual handling, robotics and automation of transport or raw material handling processes may be the solution. If, on the other hand, inconsistent welding quality is the main concern, a welding robot with a vision sensor to inspect the weld face would be appropriate.

Selection of a technology partner

Once the needs have been defined, it is time to look for a supplier. Michale Automation Company (also known as Michale Automation) specialises in machine building and the integration of robots into production lines. As an official distributor of SIASUN industrial robots, the company provides expert advice on the selection and implementation of robotic solutions.

It is also worth checking the other services that accompany robotisation, such as technical consulting or service availability. It is good practice to trace the supplier's past implementations and to talk to companies that have already had similar implementations.

Testing and design development

Many companies first opt for pilot projects and prototype tests to see how the technology will behave under specific production conditions. These tests make it possible to detect possible inconsistencies with specifications or obstacles to system integration (this is especially true when combining robotisation with ERP/MES systems).

• If you are considering implementing a welding robot, you may want to first test its performance on a limited basis to measure the quality and repeatability of the welds.
• When you plan to integrate a new solution into your production management system, check how smoothly the data exchange runs and whether it remains compatible with the rest of your IT infrastructure.

Full implementation and integration

Once the tests are successful, the actual installation in the production environment can proceed. This stage includes:

• Transport and installation of new robotic line or equipment on site
• Integration with existing IT infrastructure and machinery
• Trial run and training for machine operators

At this point, it is worth remembering to maintain health and safety standards. Operators should be thoroughly familiar with emergency procedures, and workstations should meet the requirements of Polish and EU regulations (e.g. the Machinery Directive).

Evaluation and continuous improvement

After a few weeks or months of stable operation of the system, it should be assessed whether the success indicators defined at the beginning have been achieved. By analysing the effectiveness of the modified line, further improvements can be made. The process of implementing modern technology never ends on the day the equipment is installed. It is only through continuous monitoring, analysis of production reports and gradual adjustment of functionality that you can be sure that your company is making full use of the installed potential.

THE MOST COMMON CHALLENGES IN IMPLEMENTING NEW TECHNOLOGIES AND HOW TO SOLVE THEM

Employees' fear of losing their jobs
A common challenge in the process of automation and robotisation is the fear of downsizing. However, in practice, it is repeatedly found that the implementation of new technologies in a manufacturing company leads to staff redeployment rather than the forced elimination of some positions. Previously repetitive and error-prone tasks are taken over by machines, while employees have the opportunity to develop in new areas (e.g. quality control, production planning or maintenance).

High initial cost
As a rule, initiating a digital transformation requires financial investment in terms of hardware, software and infrastructure. However, it is worth bearing in mind the long-term return on investment. To make it easier to estimate the expected benefits, you can use the ROI calculator for welding robotisation. It helps to pre-calculate whether improving welding with a robot or integrating new technologies in the packaging department will result in sufficiently high savings in the short term.

Integration into existing systems
Many entrepreneurs are concerned that the implementation of the new technology will interfere with legacy systems. Indeed, integrating different tools takes some time, but it offers tremendous opportunities - such as real-time production monitoring and automatic transfer of inventory data to an ERP system. If you are considering a comprehensive process, check out robotisation offered by Michale Automatics.

Problems in maintenance and servicing
Remember that even the most advanced production line requires periodic servicing. It is worth scheduling inspection and maintenance flexibly so that production continuity is not disrupted. The availability of qualified service technicians (both externally and internally) can be crucial to the proper operation of machinery, especially in the initial phase of use. For more information on servicing and maintenance, see. Service and maintenance stands.

EXAMPLES OF MODERN TECHNOLOGICAL SOLUTIONS IN PRODUCTION

Robotisation of key processes
One of the most popular solutions is the robotisation of repetitive tasks such as welding, bolting parts together or packaging. Industrial robots allow these tasks to be performed with extreme precision and in longer cycles. As a result, the line can operate for up to 24 hours a day, without the risk of human error or a drop in productivity during night-time hours. If you would like to see our wide range of proposals for the industrial sector, visit Automation services Michale.

Integrated vision systems
Thanks to intelligent vision systems, the devices are able to verify in real time the correct positioning of the product, check the quality and dimensions of the product. When combined with a robot that has a built-in trajectory correction function, highly precise results can be achieved, especially in industries with high quality requirements.

Internet of Things (IoT) and data analytics
Sensors that monitor parameters such as temperature, humidity or machine vibration can send data to the cloud. Special algorithms then process this information and generate conclusions, such as warnings of potential failure. In this way, the company minimises the risk of machine downtime and prevents damage to the equipment.

Artificial intelligence and machine learning
AI algorithms can support, among other things, production planning and forecasting of market trends, enabling increased flexibility and reduced material wastage. The use of machine learning techniques also makes it possible to further analyse the performance of robots and equipment in real time, identifying areas for optimisation.

EXAMPLE APPLICATION SCENARIO IN A PRODUCTION PLANT

Suppose that a medium-sized manufacturing company (e.g. producing metal parts for the automotive industry) experiences frequent downtime in the packaging process, as operators manually sort and stack parts in bulk packaging. The company decides to implement a collaborative robot (cobot) equipped with a vacuum gripper and an integrated vision system.

1. Audit
- It has been investigated that manual packaging generates up to 15% of losses due to errors or damage to finished products.
- For large orders, operators work overtime, which further increases costs.

2. Choice of technology and supplier
- A cobot with a payload capacity of up to several kilograms and a reach suitable for picking up workpieces from the line was chosen.
- The equipment was purchased through an experienced integrator, such as a company Michale Automationwhich additionally offered to assist with the installation and training of the robot's operators.

3. testing and integration
- A test area was launched to see how the new system recognises the shape of parts and how it handles different product variants.
- After minor modifications to the software, errors in the recognition of non-standard edges have been eliminated.

4 Full implementation
- The Cobot was set up next to the existing production line and the packaging process itself was integrated into the production management system.
- After two weeks of normal operation, the layout of the bench was improved and new grips were introduced, increasing productivity by 12%.

5. Effects and further improvements
- The number of incorrectly packaged items has halved.
- Operators who were previously in charge of packaging were redeployed to supervise product quality, improving overall process control.

SUMMARY OF BENEFITS AND KEY FINDINGS

The following is a summary of the most important tips and advantages associated with implementing new technologies in a manufacturing company:

• Thorough needs analysis. Before investing in robots, vision systems or software, check which areas of production will be best affected.
• Engaging and training employees. Let the team be involved in the innovation implementation strategy process from the beginning.
• Well-planned schedule. All stages (from analysis to implementation and training) should have a clear sequence and deadlines.
• Measuring key indicators. Verify the effects, e.g. by measuring the level of cost reduction, reduction in cycle time or decrease in batch rejections.
• Continuous improvement and service. Modern production lines require constant monitoring and maintenance (see Service and maintenance stands).

END OF

Implementing new technology in a manufacturing company is not just about installing a machine or launching software. It is a complex process that includes a thorough needs analysis, preparing the team for change, selecting a reliable supplier, conducting pilot projects and continuously monitoring the actual effects.

If you are looking to upgrade your production line and gain a competitive edge in the market, the key is to plan the whole project properly. When in doubt, you can benefit from professional advice and integrator services. It is worth visiting the Michale Automation website and learn about complex solutions in the area of robotisation of various processes.

We also encourage you to familiarise yourself with our ROI calculator for welding robotisationwhich allows an initial estimate to be made of the profitability of investing in modern robotic workstations.

We wish you the best of luck as you modernise your business. If you have any additional questions regarding the implementation of technological innovations, please do not hesitate to contact the Michale Automation team, who will help you find the best solution for your industry and your specific production process.

With a properly executed transformation, you can count on lasting benefits in the form of higher productivity, stable quality and lower operating costs - as well as happy employees who will gain the opportunity to develop in new, often more attractive areas. Good luck in reaching for the future of the industry.

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.