Industrial lines - how to design and integrate them to increase production efficiency?

Reading time: 8 minutes

TL;DR

• Industrial lines are a set of automated workstations and equipment that streamline the manufacturing process
• Implementation of the line increases productivity, reduces costs and improves production quality
• The key to success is the proper design of the bench layout and the integration of automation and robotics systems
• New trends include robotisation, vision systems, Big Data and Industry 4.0
• ROI analysis confirms that investment in industrial lines pays off for most companies

Table of contents

• Introduction
• What are industrial lines and why should they be implemented?
• Key elements of an efficient industrial line
  • Ergonomics and workstation layout
  • Integration of automation and robotics systems
• How to design an industrial line? - key implementation steps
  • Stage 1 - Needs analysis and conception
  • Stage 2 - Selection of technology and preparation of documentation
  • Phase 3 - Construction, testing and commissioning
• Challenges of integration - what to look out for in line implementation
• New trends in industrial line design
  • Robotisation in practice
  • Vision systems and artificial intelligence (AI)
  • Big Data and Industry 4.0
• Industrial lines in practice - examples of applications in various industries
  • Food industry
  • Furniture industry
  • Metal industry
• Do industrial lines pay off? - ROI analysis
• Practical tips - how to get started?
• Summary and conclusions for your company
• Summary - Plan your future industrial line
• FAQ

Introduction

Industrial lines are one of the key elements of modern manufacturing. They enable companies to achieve higher productivity, optimise costs and ensure reproducible product quality. Nowadays, when competition in the market is constantly increasing, a properly designed and automated industrial line becomes not only a convenience, but often a necessity. In this article, you will find out exactly what industrial lines are, how their design is carried out and which trends and technical solutions are worth implementing in order to respond even better to the challenges of the market. In the text, you will also find examples of real-life applications and tips that you can use immediately in your company.

What are industrial lines and why should they be implemented?

Industrial lines are a set of equipment and workstations connected in such a way as to maximise the speed and automation of the manufacturing process. These can range from fully robotised workstations to semi-automated systems integrated with each other. It is worth remembering that modern industrial lines are not limited to connecting machines. Increasingly, they are complex ecosystems in which advanced software (e.g. ERP, MES systems), real-time process monitoring and data management play a key role.

The implementation of an industrial line often opens up opportunities for companies:

• Increased productivity - through continuous operation without rest breaks or changing operators.
• Better quality control - each station verifies the correctness of the operation, which reduces the number of deficiencies.
• Reducing fixed costs - automation minimises the impact of the human factor on repetitive processes and reduces potential mistakes.
• Scalability of production - industrial lines can be expanded, combined and modified as market demand increases.

An interesting example is the food industry, where industrial lines enable large volumes of products to be manufactured while maintaining high hygiene standards. Similarly, in the metal and furniture sector - control of individual stages and automatic transport of components between workstations are essential elements for efficient, profitable operations.

Key elements of an efficient industrial line

When many people hear the term 'industrial lines', they think only of a conveyor belt and a dozen or so machines. Meanwhile, the real essence of an effective industrial line lies in the details.

Ergonomics and workstation layout

The basis for success is the proper layout of the workstations and the planning of the material flow. In a well-designed industrial line:

• The incoming materials go straight to where the first stage of processing or assembly takes place.
• The subsequent equipment is positioned in such a sequence as to eliminate unnecessary transport.
• Operators (if they still play a role on the line) are provided with safe and ergonomic working conditions.

Integration of automation and robotics systems

Modern industrial lines increasingly rely on robots - both industrial robots and so-called cobots that work together with humans. Michale Automatyka, also known as Michale Automation, specialises in the design and implementation of such solutions in various industrial sectors. What's more, we are an official distributor of solutions from SIASUN, one of the world's leading robot manufacturers.

In practice, the integration of robots into the production line can include:

• Automatic feeding of components onto the belt, e.g. using a robot with a gripper.
• Robotisation of selected operations, such as welding, packaging or painting.
• Communication with ERP/MES systems to monitor inventory and production progress in real time.

How to design an industrial line? - key implementation steps

Designing and implementing an industrial line yourself can be an extremely challenging task. It is usually a good idea to use the services of a company specialising in mechanical engineering and industrial automation, such as Michale Automation. We work with teams of engineers, technologists and experienced contractors to complete the project comprehensively.

Stage 1 - Needs analysis and conception

The first step is to obtain detailed information on the production processes of the company in question, the available space, the volume of products manufactured and the process mill, i.e. all the equipment that supports production. It is important to recognise the specifics of the industry (e.g. food, metal, furniture) and possible restrictions (e.g. health and safety regulations, HACCP). The basic concept of the line is then created - the number of workstations, the type of machinery and the method of transporting semi-finished products are determined.

Stage 2 - Selection of technology and preparation of documentation

At this stage, a decision is made as to what equipment and robots will be used. Does the line require specialised machinery, for example for precision metal cutting, or will robots designed for packaging or sorting products on the belt be important? The integration of IT systems and how data will be monitored must also be considered. 3D visualisations are created and the whole thing is technically documented.

Phase 3 - Construction, testing and commissioning

Once the documentation has been approved, it is possible to proceed to implementation. In this phase, the key is:

• Create prototype solutions (if the project is particularly complex).
• Preparation of appropriate electrical and pneumatic structures and installations.
• Assembly of line equipment, robots and associated equipment.
• Carry out pre-testing and pilot testing.

Finally, there is the actual commissioning of the line at the target site, as well as staff training and possible modifications.

Challenges of integration - what to look out for in line implementation

Effective implementation of an industrial line requires not only engineering expertise, but also project management experience. During integration, issues often arise in matching machines with different specifications and ensuring that they communicate seamlessly.

Key challenges include:

• Compatibility of equipment and robots with existing infrastructure (e.g. need to match already installed machinery).
• Integration of control and monitoring systems (e.g. SCADA, PLC) so that the whole is managed from one place.
• Ensuring the safety of people and machinery - including proper separation of zones, use of safety sensors, curtains and other safeguards.
• Adequate employee training in the operation of the automated line.

It is also important to develop a maintenance system to prevent failures lower down the production chain. To this end, it is worth visiting the 'Service and maintenance' section of our website, where we describe in detail how we ensure failure-free line operation (see: Service and maintenance stands).

New trends in industrial line design

Technology is constantly evolving, and thus new opportunities for optimising industrial lines are emerging. In the era of Industry 4.0, digitalisation, robotisation and the use of advanced algorithms for real-time decision-making are gaining importance.

Robotisation in practice

Robots and cobots can replace humans in repetitive, hazardous or high-precision tasks. At Michale Automatika, we have experience in implementing workstations for automated welding, packaging, as well as painting or grinding. When considering the robotisation of a selected stage, it is best to familiarise yourself with the broad possibilities of such solutions - learn, for example, about the benefits of robotisation of welding.

Vision systems and artificial intelligence (AI)

Modern industrial lines are moving beyond simple mechanical-electrical schemes. They are increasingly equipped with vision systems that integrate with real-time image analysis software. Such solutions make it possible to:

• Quality control at every stage - the computer identifies possible defects and rejects non-compliant components.
• Precise positioning of components, e.g. in packaging and palletising.
• Working with AI algorithms that decide how to set the parameters of the equipment depending on the signals coming from the sensors.

Big Data and Industry 4.0

By integrating production lines with MES (Manufacturing Execution Systems) or ERP systems, production is monitored in real time. This gives managers a full view of progress, allows them to plan logistics activities, manage raw material deliveries or collect data for predictive analyses.

Industrial lines in practice - examples of applications in various industries

Industrial lines are used in almost every industry, from food to automotive. Here are some practical examples.

Food industry

In large confectionery plants, industrial lines enable the mass production of chocolates, biscuits or snacks. Thanks to automatic temperature control and vision systems, the quality and safety of the products remain at the highest level, and workers are not subjected to monotonous and tedious tasks.

Furniture industry

In the furniture industry, precise cutting and processing of material plays a key role. Automated industrial lines work well here, both for large companies exporting finished products to overseas markets and for smaller plants that can better compete with larger players thanks to automation.

Metal industry

Welding, grinding, painting - all these tasks can be robotised to create a complete solution in the form of an industrial line. SIASUN robots, available from Michale Automatyki, make it possible to significantly reduce the execution time of operations and improve their quality. If you are interested in this area, see also the robotisation of repetitive production using modern robotic arms.

Do industrial lines pay off? - ROI analysis

In the long term, industrial lines bring significant savings to companies. The key benefits are increased productivity, fewer production errors and the potential to reduce labour costs. However, it is worth conducting a thorough analysis of the investment and estimating the payback period (ROI).

According to industry reports, many companies that have opted for thorough automation have achieved a full return on investment in the first 2-3 years. In the case of highly repetitive processes, especially in sectors such as automotive or FMCG, ROI can occur even faster. To get an initial indication of the potential ROI of robotic welding workstations, it is worth using the ROI calculator available on the Michale Automatyki website.

Practical tips - how to get started?

1. examine the company's processes. Consider which stages of production are the most taxing on people, the most dangerous or generate the most errors. This is where automation will have the quickest effect.

2. Prioritise according to potential gains. Implementing an industrial line can look different depending on whether your focus is on increasing production volume or improving quality and reducing scrap.

3. consider the support of a technology partner. An external company such as Michale Automatics has years of experience, engineering resources and ready-made solutions. As a result, the whole process can be carried out faster and with less risk.

4 Ensure crew training. Even the best industrial lines will not deliver the expected results if the workers do not know how to operate and maintain them properly.

5. schedule service and maintenance. Regular inspection, cleaning and servicing of key components keeps the line running at peak performance and prevents downtime.

Summary and conclusions for your company

Industrial lines are advanced solutions that bring tangible benefits to virtually every manufacturing industry. With the right integration of machines, robots, production management systems and analytical software, companies can increase productivity, reduce costs and improve the quality of manufactured products.

Key findings from the article:

• Industrial lines require a well-thought-out concept - the key is to plan ergonomics, material flows and the correct integration of hardware and software.
• Robotisation is at the heart of many modern lines - it offers huge opportunities to speed up and standardise production.
• When implementing industrial lines, do not forget to analyse the ROI. Only then will you be sure that your investment translates into tangible business results.
• The support of an experienced partner, such as Michale Automation, makes the whole process quicker and easier.

Want to learn more about specific applications of robots in industrial lines and see implementation examples? Check out our additional materials, e.g. on robotisation of packaging.

Summary - Plan your future industrial line

Whether you are just considering production automation or already have first-hand experience in this area, properly designed industrial lines can clearly increase the competitiveness of your business. Opt for solutions that are tailored exactly to your needs and choose a partner that provides not only the equipment, but also overall expert support - from concept to design to service.

If you have questions or would like to know more about the potential implementation of an industrial line in your company, please contact us. We will be happy to help you plan the entire process based on our years of experience and our wide range of SIASUN robots. You can also subscribe to our newsletter to stay informed about the latest trends in automation and robotics.

We hope this article has given you an insight into the key issues related to industrial lines, their design and integration. If you found it helpful, please share it with your colleagues or industry friends. The better we understand how automation and robotisation takes place, the more efficiently we will be able to raise productivity and grow our economy. We wish you the best of luck with your plans and invite you to contact Michale Automation!

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 simpler solutions to several months for large and elaborate projects.

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 take advantage of this moment to retrain staff and expand their competences.

Does robotisation only pay off for large companies?
Today, advances in technology are leading more and more small and medium-sized companies to opt for robotisation. Investment costs are decreasing and flexible solutions allow for a favourable return on investment, even for smaller operations.