Industrial automation service - how to reduce downtime and ensure production continuity

Estimated reading time: 7 minutes

TL;DR

• The industrial automation service ensures the continuous operation of lines and machines in production plants.
• Inadequate maintenance leads to breakdowns and costly downtime.
• Predictive maintenance and efficiency-enhancing upgrades are key.
• There is a growing role for remote monitoring and AI systems to support diagnostics.
• Choosing a proven service partner, such as Michale Automation, optimises costs and avoids breakdowns.

Table of contents

• Introduction
• Why is an industrial automation service so important?
• The most common problems with industrial automation - what is worth knowing?
• Key areas of industrial automation service
• Trends in automation service for 2024
• How to reduce downtime costs with good service?
• Examples of steps in implementing a professional service
• The role of a proven service partner - or why you should choose Michale Automation
• Internal linking - where to look for additional information?
• Practical tips and best practices in the service
• Bottom line - what do you gain from an efficient service?
• Completion
• FAQ

Introduction

Industrial automation service is a key element in maintaining the continuous operation of lines and machines in production plants. In the face of increasing market demands, a shortage of qualified staff and growing expectations of product quality, proper care of automation systems is becoming a prerequisite for successful competition. Why is it so important to properly plan and carry out plant upgrades today? What trends can we expect in 2024 and what practices will help avoid expensive downtime?

After reading this article, you will learn what a professional industrial automation service looks like, the benefits of a comprehensive maintenance service and how your company can reduce costs through regular maintenance and condition monitoring of machines.

Why is an industrial automation service so important?

Industrial automation service is the foundation of efficient production. Today's factories increasingly rely on complex control systems and robotic workstations, which - with the development of Industry 4.0 and the Internet of Things (IIoT) - are gaining in sophistication and flexibility. If machines are running continuously and the production line is integrated with vision solutions or artificial intelligence, any unexpected failure can generate high costs and negatively affect order fulfilment.

It is not just about the possibility of downtime. Lack of service or inadequate service planning is also linked to:

• increased risk of failure and damage to expensive components,
• a decline in the quality of products or services,
• greater risk of non-compliance with industry standards,
• personnel problems: employees react badly to frequent stoppages.

In response to growing needs, more and more companies in Poland - including medium-sized enterprises - are beginning to pay attention to increasing the level of automation and providing it with ongoing service support. As a result, there is a growing demand for specialists and suppliers who offer comprehensive maintenance as well as predictive maintenance services.

The most common problems with industrial automation - what is worth knowing?

Machine downtime due to breakdowns

A control failure, a broken data chain in the SCADA system or incorrect signalling from sensors - any of these problems can effectively bring an entire line to a halt. The situation is complicated by the fact that automation is often a collection of many integrated devices (e.g. robots, actuators, manipulators and visualisation). If one component fails, the others stop working or malfunction.

Staff shortages and insufficient training

Another challenge is the insufficient number of skilled workers in the maintenance department. Operating modern equipment requires knowledge of PLCs, industrial networks or collaborative robots (so-called cobots). Employees, especially in small companies, often perform several roles at the same time. This can lead to hasty servicing and a lack of proper safety procedures.

Inadequate predictive maintenance

Late detection of a worrying vibration, overheating component or oil leak can sometimes be a major cause of costly repairs. Companies that do not have remote monitoring systems in place (e.g. the use of IoT and artificial intelligence support in data analysis) often only take action when a problem has grown large and requires the replacement of multiple components. For this reason, predictive maintenance in the broadest sense - based on systems that record data in real time - is considered one of the pillars of production optimisation.

Key areas of industrial automation service

Control system diagnostics

Today, advanced manufacturing lines are dominated by PLCs, servo drives and distributed control systems (DCS). Diagnostics therefore require not only cyclical physical inspections, but also real-time insight into operating parameters. Specialised software (e.g. SCADA), on the other hand, enables an immediate response to deviations from the norm.

Mechanical inspection and maintenance

Industrial robots (including SIASUN robots, whose official distributor in Poland is, among others, Michale Automatyka) and other actuators are equipped with numerous joints, gears and moving parts. Their service life depends largely on proper lubrication, adjustment or balancing of the movement. Regular mechanical maintenance protects the plant from potentially costly replacement of the entire module.

Modernisation and upgrading

Industrial automation service does not end with repairs. Machine and system upgrades, such as replacing sensors with more precise ones, integrating cobots into a common database or updating control software, are becoming increasingly important. Successful upgrades can not only extend the life of equipment, but also increase productivity and allow the introduction of new functionalities.

Trends in automation service for 2024

Staying in line with the analyses of the market (estimated at more than $170 billion in 2022 and continuing to grow rapidly), there are several directions of relevance in the coming years:

• Faster development of distributed control systems (DCS) and greater use of 5G networks. New communication standards will encourage improved real-time data transmission to facilitate predictive monitoring.
• Implementing vision systems and AI technology. Increasingly, we are seeing robots equipped with intelligent cameras in industry, capable of instantly detecting defects or deficiencies on the production line. From a service perspective, this translates into extended diagnostic procedures.
• There is an increasing focus on the energy efficiency of equipment. Companies are looking for solutions to reduce the consumption of electricity, water or compressed air. In the context of maintenance services, this means including additional utility metering and installing sensors to analyse the level of usage.
• Development of remote monitoring and 'service 4.0' services. The automatic transfer of data from the line to the cloud speeds up the fault identification process - service technicians receive an alert even before production stops.

How to reduce downtime costs with good service?

Many owners of small production facilities hesitate to implement extensive maintenance plans, fearing high costs. Meanwhile, a lack of proper service and late response to faults can generate far greater expenses. A proper approach to the subject of servicing can reduce costs associated with:

• Production interruptions - A well-functioning monitoring system and rapid response by service technicians reduce downtime.
• Excessive energy consumption - out-of-sync drives or out-of-date sensors can overestimate current consumption or degrade line performance.
• Defective batches of products - The lack of calibration of equipment translates into the use of incorrect production parameters, which increases the percentage of shortages.
• Emergency breakdowns - Preventive replacement of critical parts (e.g. bearings, hoses) avoids the sudden escalation of minor damage.

Examples of steps in implementing a professional service

Condition audit of machinery and infrastructure

To begin with, it is worth conducting a comprehensive review of your existing equipment - from PLCs and operator panels to robotic manipulators and conveyor lines. As a result, you can identify the most sensitive points and prioritise actions.

Development of a maintenance schedule

A plan for maintenance and possible upgrades is then established. Many companies opt for a quarterly or half-yearly cycle of service visits, taking into account the specifics of production (e.g. downtime).

Installation of sensors and predictive systems

It is worth implementing devices that allow continuous data collection on vibrations, temperatures and component performance. Analysis of such signals (often in combination with artificial intelligence) facilitates early fault detection.

Training for employees

A properly trained team is the foundation for long-term success. In the case of modern solutions (e.g. integration of cobots into an ERP system), the employees operating the line should be familiar with the basics of diagnostics. In this way, they will be able to spot minor irregularities themselves or support the service remotely.

The role of a proven service partner - or why you should choose Michale Automation

Michale Automatics has specialised for years in the construction of machines and production lines, as well as in complex industrial automation, including service and maintenance of robotic workstations. With experience gained from complex projects in a variety of industries, Michale Automatics provides comprehensive technical support - from predictive maintenance to full upgrades and integration of new solutions.

As an official distributor of SIASUN robots, the company also offers access to the latest robotic technology, allowing existing lines to be effectively upgraded while reducing the risk of failure.

Internal linking - where to look for additional information?

• If you are looking for comprehensive automation and production optimisation services, visit:
  Check out Michale Automation's service offering
• It is also worth taking an interest in regular maintenance of the robotic workstations, which increases the safety and productivity of the machines:
  Service and maintenance stands - more information
• Would you like to find out what robotisation tasks a professional partner can take over?
  Explore the benefits of full robotisation
• If you're thinking about long-term savings, it's worth checking the possible return on investment of robotisation:
  Try the ROI calculator for welding robotisation

Practical tips and best practices in the service

1. Opt for more frequent but shorter reviews. Instead of one extensive audit per year, schedule several smaller audits over a 12-month period. This will help you catch operational wear and tear on components quickly.
2. Implement remote monitoring systems. In Poland, an increasing number of companies are choosing to install IoT sensors and SCADA software - such a solution can quickly detect anomalies and alert the maintenance department.
3. Update the software. PLCs, operator panels or vision systems often have new versions to download that improve stability and extend functionality.
4. Remember safety. Checking machine protection systems (safety curtains, photoelectric sensors) and health and safety training for operators should also be part of the service.
5. Document every inspection and upgrade. This will make it easy to verify repair history, wear and tear of components, as well as calculating the actual cost of maintaining the equipment over the long term.

Bottom line - what do you gain from an efficient service?

• More certainty and security - you reduce the risk of unplanned downtime.
• Lower production costs - you prevent major breakdowns, which often result in expensive repairs.
• Stable production quality - Well-calibrated and serviced machines ensure a uniform result.
• Greater customer and partner confidence - companies with an efficient maintenance system find it easier to comply with ISO or GMP requirements.

Completion

Regular and professionally carried out industrial automation maintenance is one of the most effective ways to maintain high plant productivity while reducing the risk of failure. In an era of intense market changes and dynamic technology development, it is worth taking the time to choose the right service partner, such as Michale Automation, which will comprehensively take care of the maintenance, modernisation and optimisation of your production lines.

If you need more advice or would like to learn more about the capabilities of the latest robotic solutions, we encourage you to read the additional materials listed in this article or contact us. Together, we will plan an effective service strategy that will keep your company one step ahead of the competition.

FAQ

How often should industrial automation be serviced?
Much depends on the intensity of machine use and the specifics of production. Most often, quarterly or semi-annual inspections are recommended, but constant observation of parameters and early reaction to deviations is crucial.

Is it always necessary to replace components as part of a service?
Not necessarily. In most cases, maintenance and minor adjustments are sufficient. Replacement of components is justified when serious damage or significant wear of critical components is detected.

Is it expensive to implement predictive systems?
Initial costs may be higher (including the purchase of sensors and software), but the investment pays off quickly. Predictive maintenance avoids costly downtime and reduces the response time to faults.

What about worker safety in an automated environment?
The professional service also includes verification of safety systems (e.g. curtains, photoelectric sensors). This ensures that operators can interact safely with robots and machines in accordance with health and safety regulations and industry standards.