Industrial automation systems - the key to more efficient and safer production

Estimated reading time: approx. 10 minutes

TL;DR:

• Automation of industrial processes translates into higher productivity and stable quality.
• The implementation of automation systems allows production costs to be significantly optimised.
• Industrial robots take over dangerous and repetitive tasks, increasing worker safety.
• The right choice of controllers, sensors, software and integration services is key.
• Thoughtful investment planning and the support of an experienced partner ensures a rapid return (ROI).

Table of contents

• Introduction
• What are industrial automation systems?
• Why are industrial automation systems so important?
• Key elements that make up industrial automation systems
• Types of industrial automation systems
• How to plan the implementation of an industrial automation system?
• The most common challenges in implementing industrial automation
• In which industries are industrial automation systems most relevant?
• Examples of robotic workstation applications in Michale Automation
• Practical tips - how to succeed in automation
• Summary - what do you gain from industrial automation systems?

Introduction

Industrial automation systems are the cornerstone of modern manufacturing. In an era of rising labour costs and constant pressure to increase efficiency, many companies are looking for solutions that enable them to automate and optimise their manufacturing processes. In this article, we explain what exactly industrial automation systems are, what types of solutions they include and how to implement them effectively. You will also learn why more and more companies are choosing to make this type of investment and how Michale Automation can help you select and integrate comprehensive automation systems.

What are industrial automation systems?

Industrial automation systems are complex systems comprising control and measurement devices, controllers, software, and a variety of actuators (e.g. robots, drives, valves, sensors). The aim of their implementation is to automate selected stages of production, often repetitive or hazardous to humans, so as to ultimately increase productivity, improve product quality and reduce operating costs.

The growing popularity of industrial automation systems is largely due to the versatility of these solutions. They automate both simple, repetitive activities (e.g. assembly of small components) and complex processes with high variability (e.g. supervision of welding in robotised production lines). Modern solutions make it possible to monitor the condition of machines in real time, as well as to collect key data on quality or productivity. Michale Automation, as an experienced integrator and official distributor of SIASUN robots, supports companies in matching the right technology to specific needs.

Why are industrial automation systems so important?

1. Increased productivity
   - Replacing human labour in repetitive tasks translates into reduced production times and less downtime.
   - Many machines can operate 24/7, enabling continuous production and faster order fulfilment.
2. Improved product quality
   - Process automation eliminates errors related to human factors.
   - Modern visual and inspection and measurement systems can detect quality defects in real time.
   - This minimises the number of complaints and production rejections.
3. Reducing operating costs
   - Reducing material losses and machine downtime results in significant savings.
   - Real-time parameter control helps to better manage energy resources.
   - Automation also supports workforce optimisation - staff can be redeployed to other areas that require creative thinking and monotonous tasks are performed by machines.
4. Improving safety
   - Many dangerous and unhygienic tasks (e.g. working in high temperatures, dusty zones) are being taken over by robots.
   - This increases worker health protection and also reduces the risk of downtime due to accidents on the production line.

Key elements that make up industrial automation systems

Industrial automation systems are complex and multidimensional. However, their components can be grouped into a few basic categories:

PLCs

The PLC (Programmable Logic Controller) is often referred to as the 'brain' of the production line. Its role is to receive signals from sensors (e.g. temperature, pressure, filling level) on an ongoing basis, process the information according to programmed rules and control the actuators (motors, valves, robots). PLCs are designed to operate in harsh industrial environments, such as high temperature or dust, making them suitable for a wide range of manufacturing industries.

Control and measuring devices and sensors

For industrial automation systems to operate precisely, it is essential that key process parameters are constantly monitored. This is ensured by various types of sensors (e.g. inductive, optical, pressure, ultrasonic) and measuring devices (measuring apparatus, recorders, transducers). In day-to-day production, they are used to control the position of workpieces on the line, to supervise the condition of machines and even for advanced vision systems to support quality control.

Industrial robots

At the heart of many of today's industrial automation systems are robots. They make it possible to speed up the production cycle and significantly reduce labour costs. Depending on the specifics of the plant, robots with different load capacities and levels of sophistication (including welding, painting and palletising robots) can be implemented. Michale Automation is the official distributor of SIASUN robots. One example of robot models that can increase line productivity is (in selected applications) SIASUN SR25A robot. These robots are distinguished by their reliability, flexibility and high precision of movement.

SCADA and HMI software

- SCADA (Supervisory Control and Data Acquisition) are tools for real-time process monitoring and analysis. They provide the operator or maintenance engineer with a comprehensive view of key production parameters, e.g. temperature, pressure, machine speed.
- HMI (Human Machine Interface) operator panels are touchscreens that visualise the operation of machines and lines. They provide a user-friendly platform for ongoing operation or for quickly changing settings. An example is configuring the speed of an assembly line using a slider on the panel screen, without having to stop the entire process.

MES and ERP systems

- MES (Manufacturing Execution System) are classes of IT systems that supervise and coordinate production processes on the shop floor. They allow, for example, the distribution of orders, the tracking of product history or the reporting of production progress.
- ERP (Enterprise Resource Planning), on the other hand, manages all areas of the company (production, logistics, warehouse, finance). Increasingly, ERP is being combined with MES to exchange real-time data on inventory, orders or production efficiency.

Types of industrial automation systems

Depending on the specifics of production and the needs of the plant, there are several basic categories of automation systems:

1. Control systems (PLC, DCS)
   - PLCs are the most common solution in discrete production (e.g. assembly lines).
   - DCS (Distributed Control System) is mainly used in continuous processes (e.g. in the chemical, petrochemical industries).
2. Supervisory Control and Visualisation Systems (SCADA)
   - They enable remote monitoring of equipment operation and early detection of faults.
   - They allow reports and alarms to be generated and adjustments to be made to operating parameters.
3. Production management systems (MES)
   - They streamline order scheduling, process documentation and quality analysis.
   - They offer detailed reports on machine and operator performance.
4. Robotic systems
   - Used in applications where precision, short cycle times, repeatability and safety are important.
   - Robotisation is used in, for example, welding, palletising, machine operation, packaging or assembly.
5. Vision systems
   - They use cameras, lighting and image processing algorithms to control quality or identify defects.
   - They significantly increase the level of automation in industries where accurate in-line product inspection is required.
6. Communication systems (IoT, 5G, industrial networks)
   - Increasingly, innovative data exchange protocols are being used to remotely monitor and control machines.
   - Wireless technologies are growing in importance, making it easier to upgrade existing lines.

How to plan the implementation of an industrial automation system?

Successful implementation of industrial automation systems requires careful preparation. Each industry, and indeed each company, can have very different requirements. The best approach is to go through several key stages:

1. Analysis of needs and definition of objectives
   - Determine whether the biggest priority is increasing productivity, improving quality or saving energy.
   - Identify current bottlenecks in the production process.
   - Consider the future growth of your business - do you plan to expand your product range, enter new markets?
2. Selection of technology and integration partner
   - At this stage, it is worth reaching out to an experienced company such as Michale Automation, which offers comprehensive support: from analysis to design to service.
   - It is important to consider communication standards (modbus, profinet, etherCAT), types of controllers and robots.
   - If you want to extend the system with an additional robotisation step, you can familiarise yourself with on the implementation of robotic workstations.
3. Design and implementation schedule
   - Plan which departments will be most involved (production, IT, maintenance, health and safety).
   - Prioritise - it may be better to automate the packaging area first, for example, and only later to robotise the welding of steel structures.
4. Implementation and testing
   - Start by installing the necessary infrastructure (cables, industrial networks, controllers).
   - Implement PLC software, SCADA and (if necessary) visualisation systems.
   - Conduct functional and safety tests.
5. Crew training and service support
   - A key success factor is the training of operators and technical staff in the use of the new solutions.
   - Also consider regular servicing and periodic maintenance of the machines to ensure the stability of the system.
   - For example, you can use service automation Michale in the area of robotic workstations and beyond.

The most common challenges in implementing industrial automation

While the benefits of automation are huge, it is worth being aware of the challenges you may face in the process:

1. Initial costs and expected return (ROI)
   - The investment in robots, controllers or vision systems may seem high.
   - However, it is worth conducting a thorough ROI analysis. With robotic welding, for example, in many companies the return is already achieved within 1.5-2 years. You can check this out initially, using the ROI calculator.
2. Lack of experience and staff resistance
   - People who have no knowledge of automation and robotics may be apprehensive about new technologies.
   - Scheduling appropriate training is key, which not only boosts morale but also reduces the number of potential errors in machine operation.
3. Integration with existing solutions
   - New systems often have to work with older machines.
   - This requires taking care of the compatibility of communication protocols and possibly upgrading some components.
4. Work safety and compliance
   - The implementation of robots or automated lines requires consideration of current health and safety standards and often industry regulations (e.g. in the food or pharmaceutical industry).
   - Care should be taken to ensure that adequate safety fencing, emergency stop switches and marking of robot work zones are in place.

In which industries are industrial automation systems most relevant?

Industrial automation plays a huge role in many market segments. Here are some examples of industries that are particularly benefiting from automation:

1. Automotive
   Automotive assembly lines have been one of the most automated sectors for years. Welding and painting robots, vision systems for inspecting the quality of body components and precise control of assembly processes all significantly increase productivity and reduce errors.
2. Food industry
   High repeatability and high sensitivity to hygiene standards make automation systems (especially packaging robots or conveyor systems) crucial. Vision systems are also often used to assess the quality of food products.
3. Electronics and white goods
   Miniaturised components and short production runs require very high precision, which is difficult to achieve manually. For this reason, robots and automatic changeover lines are becoming increasingly popular in the electronics sector.
4. Chemical, petrochemical industry
   Continuous processes involving chemical reactions need sophisticated control systems (DCS) to ensure the stability of production parameters (temperatures, pressures, flows). It is also often important to protect personnel from contact with hazardous substances.
5. Metalworking
   Welding, laser cutting, rhythmic grinding - these are examples of operations where robotisation is a major support. Robotisation in this industry speeds up production and significantly reduces the risk of burns or injuries to workers.

Examples of robotic workstation applications in Michale Automation

As Michale Automation specialises in the design and construction of both individual workstations and entire lines, it is worth recalling selected examples of areas:

• Robotisation of welding
  Automated welding stations particularly help to increase precision and shorten the work cycle. Advanced robots weld repetitive parts around the clock, minimising the number of quality deficiencies. Find out more about this by visiting robotic welding offer.
• Robotisation of packaging
  Many companies in the food or pharmaceutical industry use solutions in which robots stack products on pallets or in bulk packaging. This saves a lot of time and relieves employees of monotonous tasks.
• Service and maintenance
  To ensure the continuity and stability of the work, Michale Automation supports companies with regular servicing and maintenance of existing workstations. For more information, you can check service.

Practical tips - how to succeed in automation

1. Start with a thorough audit
   - Examine all processes in the company and identify those where automation will bring the quickest benefits.
   - Often companies want to automate too much at once, which prolongs the work and increases costs. It is better to implement the investment in stages.
2. Choose a reliable supplier/integrator
   - Experience and knowledge are key. An integrator such as Michale Automation can help optimise the project both technically and financially.
3. Plan for the long term
   - Think about the future needs of the company right from the system design stage.
   - Ease of expansion and modification (e.g. implementation of further robots) is sometimes crucial with changing market realities.
4. Ensure staff training
   - Investment in technology is only half the battle. Operators, maintenance technicians and engineers must be able to use the new system effectively.
5. Monitor performance and continuously improve
   - Analyse the data collected, respond to problems and make improvements.
   - Over time, you can develop the system, integrate it with additional modules (e.g. advanced data analysis in the cloud).

Summary - what do you gain from industrial automation systems?

- Higher productivity: lines run faster without downtime due to operator interruptions.
- Stable quality: automatic monitoring of critical operating parameters of machines and equipment significantly reduces the number of errors.
- Rapid return on investment: well-chosen solutions pay for themselves by reducing labour costs and minimising material waste.
- Improving safety: machines take over dangerous or tiring activities, protecting the health of workers.
- Flexible scaling of production: as demand grows, you can extend the scope of automation with new stations or robots.

Today, industrial automation systems are a key tool to enable companies to remain competitive in an increasingly demanding market environment. From simple applications, to advanced robots and centralised management systems, to integration with ERP/MES platforms, automation makes it possible to increase productivity and improve operational safety. Implementing modern solutions is a complex process that requires knowledge, planning and proper coordination.

Working with an experienced integrator, such as Michale Automation, provides a solid foundation for designing and commissioning systems tailored to your plant's specific requirements. We encourage you to analyse which areas of your production have the most to gain from automation - and get in touch to discuss potential solutions.

If you are also interested in issues related to the robotisation of a specific process (e.g. welding or packaging) or would like a quick calculation of the potential return on investment, check it out:
- Robotisation in practice - additional information on implementations
- ROI calculator for the robotisation of welding

We invite you to continue to expand your knowledge and browse through Michale Automation's service offerings. Take care of the development, safety and efficiency of your production today!

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.