Industrial automation: how to prepare your company for implementation step by step

Estimated reading time: approx. 8 minutes

TL;DR:

• Industrial automation improves productivity, reduces costs and standardises production quality.
• When planning the implementation, a thorough needs analysis and the appointment of a project team are key.
• Selecting the right robots and IT systems has an impact on the final success of the investment.
• Regular maintenance and staff training minimise downtime and increase return on investment.
• External consultation and funding is worthwhile, especially for companies in the development phase.

Table of contents

- Introduction
- What is industrial automation and why does it matter?
- Key benefits of implementing industrial automation
- How to prepare a company for automation?
- An example from the Polish market: Implementation of SIASUN robots
- Costs and return on investment of automation
- The most common challenges and how to deal with them
- Where to look for additional solutions and support?
- Practical conclusions / summary

Introduction

Industrial automation is one of the key developments in modern industry. In the face of rising labour costs, increasing consumer demands and the pursuit of perfect quality and production repeatability, the implementation of automation and robotisation solutions is becoming almost indispensable. The implementation of modern technologies makes it possible not only to improve manufacturing processes, but also to increase safety and the competitiveness of the company on the market.

In the following article, we present step-by-step how to prepare your company for the implementation of industrial automation. You will learn why automation is important for Polish entrepreneurs and the benefits of implementing advanced solutions, including robotic workstations. We also discuss examples of activities that will help your organisation move smoothly through the entire process, from the planning stage to team training.

What is industrial automation and why does it matter?

Industrial automation is the implementation of technology, information systems and robots to improve production processes. It includes, among others, automated production lines, industrial robots, vision control systems or the integration of management software (ERP, MES). The implementation of automation makes it possible to reduce the number of manual tasks and minimise the risk of human error, which is of great importance with the increasing pressure for quality and stable productivity.

Global trends and the situation in Poland

According to market analyses, the implementation of automation and robotisation will accelerate in the coming years, especially in areas such as welding, assembly, packaging, painting or CNC machine operation. In Poland, we are seeing a growing interest in robotisation in medium and large enterprises. A decade ago, automation was mainly the domain of global corporations, but now smaller companies are increasingly opting for it, looking for a competitive advantage and solutions that enable production to be scaled without loss of quality.

Industry reports show that although Polish companies still have a lot of catching up to do in the area of automation, the manufacturing industry is dynamically catching up, often relying on intelligent robots or cobots that can be easily implemented on existing production lines.

Key benefits of implementing industrial automation

Implementing industrial automation and robotisation can bring a number of tangible benefits to an organisation. The following are those most commonly cited and most noticeable.

Increased productivity and repeatability of processes

• Elimination of human error: Automatic systems and industrial robots are characterised by high precision. This avoids costly downtime or complaints resulting from production errors.
• Greater stability in the production cycle: Robotised workstations are capable of continuous operation, which translates into higher production capacities.
• Ability to operate in harsh environments: Robots are perfect for tasks that are dangerous for humans, such as welding and grinding processes.

Improving quality and safety

• Consistent product quality: Industrial automation minimises deviations from set parameters, resulting in a lower percentage of shortages.
• Employee safety: Workers are relieved of the most monotonous or risky tasks, which reduces the risk of occupational accidents.
• Rapid response to irregularities: Vision systems and sensors monitor the production process in real time, facilitating the early detection of faults.

Cost optimisation

• Better use of raw materials: With precise batching, cutting or assembly, the company can reduce material waste.
• Lower labour costs: Robots can work 24/7, which in the long term translates into a significant reduction in the expenses associated with manning several shifts.
• Decrease in quality costs: Less downtime, fewer complaints and stable quality levels mean better supply chain and operational cost management.

How to prepare a company for automation?

The implementation of industrial automation requires careful planning and the involvement of various departments within a company. Below, we describe the various steps to consider before deciding to invest.

Step 1: Needs analysis and goal setting

Initially, a comprehensive audit of production processes should be carried out, focusing on the most loss-making areas - e.g. under-utilised human resources, the most common causes of downtime and key points where errors occur.

• Identify which processes are the most labour-intensive and error-prone.
• Determine the main objective of the implementation (e.g. cost reduction, increase in production volume, improvement in quality).
• Consider the scale of production and the financial capacity of the company.

Step 2: Formation of the project team

Implementing industrial automation requires knowledge of mechanics, electronics, IT, as well as an understanding of production needs. Ideally, you should take a multidisciplinary approach:

• Make sure there is a finance person on the team to help you accurately determine your budget and return on investment.
• Involve staff from the production department who can identify the specifics of the process and potential constraints.
• Consider working with external experts, especially if the company does not have sufficient in-house expertise.

Step 3: Selecting the right technology

Each process requires a different type of automation or robot. At this stage, the following questions need to be answered:

• Will basic industrial robots suffice, or is it better to bet on more advanced cobots?
• Is it necessary to implement an intelligent vision control system (e.g. for sorting or defect detection)?
• Which support software (e.g. MES, ERP system) will best integrate with the new automation line?

At Michale Automation, a machine and production line builder, we are happy to advise on the optimal technology depending on the business objective and size of the company.

Step 4: Implementation of robotisation and systems integration

Once the choice of equipment and technology is defined, the crucial integration phase follows. It is worth paying attention to:

• Layout planning: The positioning of the robot, feeders and workstations affects material flow efficiency and ergonomics.
• Software integration: Control systems, PLCs or the data cloud must work cohesively to enable efficient control and real-time monitoring of production.
• Conducting tests on a single line or bench (so-called proof of concept): Before full automation is an integral part of the process.

When looking for specific solutions, it is worth taking a look at the robotisation offer prepared by our company.
Find out more about our robotisation services

Step 5: Testing, optimisation and training

Once the new equipment has been installed and the first series of tests carried out, continuous optimisation begins. The aim is to fine-tune the machine settings to the expected level of productivity and to reduce any bottlenecks.

• Post-implementation audit: Check that the solutions deliver the expected benefits in terms of cost, quality and efficiency.
• Delivery of training: Employees need to learn how to operate the new machines and how to deal with typical breakdowns.
• Continuous improvement: Many companies are gradually extending their lines with further modules, such as additional packaging or component storage stations.

An example from the Polish market: Implementation of SIASUN robots

The Polish market is increasingly turning to robots from the most advanced manufacturers in the industry. One of them is SIASUN, whose official distributor in Poland is Automatyka Michale. The brand's robots stand out for their excellent quality-to-price ratio and wide configuration possibilities.

Why SIASUN?

• Flexibility in configuration: Varying load capacities, ranges and degrees of freedom allow the solution to be tailored to the needs of almost any industry.
• Ease of programming: The intuitive interface is conducive to quick implementation and less time needed to learn how to use it.
• High level of security: The robots comply with strict safety standards, allowing them to be integrated even in a 'shoulder-to-shoulder' working environment with humans.

Take a look at the parameters of one of SIASUN's popular robots:
SIASUN Robot SR25A 12-2-01

Examples of SIASUN robot applications in Polish companies

• Robotisation of welding: The metal industry benefits greatly from the high precision and repeatability of robotic welds.
• Robotisation of packaging: Plants in the FMCG and food sector are increasingly investing in automated packaging lines that increase productivity by up to several tens of per cent.
• Robots to support assembly processes: Thanks to the high speed and precision of the robots, companies can respond quickly to changing market needs and customer requirements.

Costs and return on investment of automation

One of the main objections when deciding to implement industrial automation is the initial financial outlay. However, it is worth remembering that the benefits are accounted for over a horizon of several years.

• Return on investment (ROI): Depending on the complexity of the project and the type of solutions being implemented, the return on investment can be between 1.5 and 2 years. This largely depends on the volume of production, labour costs and the technological level from which the company started before automation.
• Reducing errors and omissions: Savings also mean fewer rejected products and a lower risk of complaints. With stable conditions and repeatable quality, production becomes more predictable, making supply chain management easier.
• Simple ROI calculator: To get a better understanding of the rate at which your investment in robotising a particular process will pay off, you can use the
  ROI calculator for welding robotisation

The most common challenges and how to deal with them

Even the best design assumptions will not be fully effective if the company does not prepare for the typical challenges that accompany automation implementation.

• Workers' resistance to technology: Many people fear that robots will replace human labour. It should be clearly communicated that automation solutions allow people to focus on tasks that require creativity. Additionally, it is worth investing in training so that the team feels confident in using the new equipment on a daily basis.
• Integration with older machinery: Often companies have production lines that were not designed with robotisation in mind. It is then crucial to plan the modernisation appropriately, even in stages. It is worth considering working with companies with experience in systems integration.
• Service and maintenance selection: Taking care of maintenance and regular servicing of robotic stations is a guarantee of a long equipment life. Already at the automation planning stage, maintenance resources should be planned. At our company, we offer services including servicing and maintenance of existing automation and robotics stations.

Where to look for additional solutions and support?

The implementation of automation does not end when robots are deployed. In order to maximise the potential of advanced technologies, it is worth constantly analysing the next stages of production and considering further developments.

• Consultation with experts: Check out the offerings of companies such as Michale Automation, which provide comprehensive support in building machines, production lines and robotic workstations. If you are interested in other areas of robotisation application, such as packaging, you can
  learn more about the robotisation of packaging
• Trend analysis and industry conferences: Keep up to date with current trends in the area of Industry 4.0. Attend trade fairs and conferences to gain new inspiration and exchange experiences with other practitioners.
• Subsidies and investment allowances: Both in Poland and in the countries of the European Union, there are various forms of support for enterprises planning to invest in modern technologies. It is worth checking the available subsidies and operational programmes, which can significantly reduce initial costs.

Practical conclusions / summary

- Set clear objectives for automation: Consider what effect the implementation is expected to have - whether it is a cost reduction or an increase in the efficiency of production lines.

- Create a multidisciplinary team: Involve both engineers and finance people to provide a full picture of needs and constraints.

- Conduct an ROI analysis: Check how the investment will affect profitability and whether it consolidates your development plans.

- Choose partners with experience: It is essential to work with an established company in the field of industrial automation to help select and implement solutions.

- Remember the employees: Training and transparent communication will reduce resistance to new technologies and facilitate smooth implementation.

- Continually develop processes: Automation is not a one-off investment, but rather a continuous improvement that translates into the development of the entire company.

Summary: Industrial automation today is not just a fad or staying on the wave of global trends, but a real support in optimising costs, quality and productivity. Companies that choose to implement robotisation and integrate advanced control systems can count on tangible business benefits and faster growth.

If you are considering the introduction of automation in your company and want to find out more, we invite you to contact Michale Automation. We design and build machines and production lines, integrate robots and implement robotic workstations in companies in various industries. As an official distributor of SIASUN robots in Poland, we are able to offer comprehensive support at every stage of the investment.

We also encourage you to read other articles on the blog, visit our website, as well as comment and share your experiences of industrial automation implementation. By sharing knowledge, together we can build a modern, competitive industry based on innovative technological solutions.

FAQ

How long does it take to implement automation in a company?
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 more extensive projects involving extensive integration of various systems.

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, more and more small and medium-sized companies are turning to robotisation due to the decreasing cost of these technologies and the increasing availability of flexible solutions. This means that the return on investment can be favourable even for smaller scale operations.