Industrial machine building - how to effectively plan and implement modern solutions in production facilities

Estimated reading time: 10 minutes

TL;DR

• You will learn about the key stages of industrial machine building.
• You will learn the importance of integrating a new machine into an existing production line.
• You will understand what to look for when choosing a supplier.
• You will discover how Michale Automation supports the mechanical engineering and robotics process.
• You will learn about good practices and concrete examples of implementation in different industries.

Table of contents

- Introduction
- How to plan the industrial machinery process
- Integration of machinery with automation systems and production efficiency
- Good practice in industrial machine building
- The role of robotisation in the development of industrial machinery
- Industry case studies - what to look out for
- Michale Automation - Comprehensive support in industrial machine building
- Practical conclusions and recommendations
- Summary
- FAQ

Introduction

Industrial machine building is a key element in the development of many companies in the manufacturing sector. The significant impact that a well-planned industrial machine can have on a company's productivity and competitiveness can already be seen at the design and integration stage of new solutions. Nowadays, with production automation gaining momentum and the market increasingly attentive to cost and quality, proper preparation and implementation of industrial machinery investments are becoming a key success factor.

In this article you will learn:

• What are the most important steps in the construction of industrial machinery.
• Why the integration of machines into an existing production line or software is so important.
• What to look for when selecting a supplier to make the solution effective and cost-efficient.
• How Michale Automation approaches industrial machine building and how it can help you.

If you are considering implementing a new machine in your production facility or wondering how to upgrade your existing installations, take a look at the following tips and best practices. They will help you maximise efficiency, reduce risk and understand how industrial machine building can translate into long-term business benefits.

How to plan the industrial machinery process

Building industrial machinery is not just about designing a few tools and assembling the various components. It is a complex process that requires the involvement of various specialists (mechanical engineers, automation engineers, technologists, designers, among others). It also requires a thorough analysis of needs, risks and development opportunities.

Stage 1 - Needs diagnosis and process analysis

The first step should be to clearly define the production requirements and the objectives to be met by the new machine. This may include:

• Speeding up production by automating manual operations.
• Improving the quality of products by introducing a precise control and measurement system.
• Reducing staff costs and reducing human error.

It is also worth analysing the existing production process at this stage. Often, it turns out that not only the industrial machine itself will be crucial, but also the integration with other systems, such as a packaging robot or a vision solution that further automates the process.

Phase 2 - Conceptual design and detailed specifications

After the initial needs analysis, the time comes to develop the concept for the new machine. The successful project team prepares detailed documents that include:

• Technical requirements (materials, dimensions of equipment, operating parameters).
• Safety requirements (guards, emergency systems, CE standards).
• Opportunities for future expansion and scaling.

Based on these specifications, construction plans, electrical and mechanical documentation and an approximate implementation schedule can be prepared. At this point, it is also worth noting the availability of spare parts and planned service costs - this will minimise the risk of unplanned downtime in the future.

Stage 3 - Prototype construction and testing

The final design of the machine is transferred to the prototyping phase, i.e. the creation of a pilot or test version. The prototype verifies the theoretical assumptions and allows possible inaccuracies to be eliminated.

• Strength, safety and functionality tests are carried out.
• The way it integrates with the existing machinery fleet works well.
• Confidence is gained that the draft documentation is consistent with the actual working conditions at the production site.

Stage 4 - Installation and integration on site

The successful outcome of the prototype tests is followed by the actual construction and installation of the industrial machine at the target workplace. Here, it is important to properly anchor the equipment, ergonomically layout the production line and connect all electronics and automation systems. Often, it is necessary to involve health and safety officers, as the transfer of the new equipment into the plant requires certain safety procedures.

Stage 5 - Staff training and commissioning of the machine

Once the machine is integrated into the production process, it remains to set it up and train the operators. The better the employees understand how the machine works, the sooner they will be able to exploit its full potential. It can also be helpful to implement performance monitoring systems (e.g. MES, SCADA) to keep track of operating parameters and react quickly to any irregularities.

Integration of machinery with automation systems and production efficiency

Many companies are wary of implementing new equipment because of the apparent difficulty of integrating it into an existing production line. Meanwhile, it is the right integration that is key to achieving optimum performance.

When it is worth considering automating the entire process

• When the number of operators required to operate the production line is large and this creates bottle bottlenecks.
• When we are dealing with monotonous, repetitive operations in which human error is easy.
• When we want to scale up production quickly for large orders and cannot afford long process downtimes.

With many years of experience in industrial machine building and production line implementations, Michale Automation offers comprehensive support in the full integration of automation and robotisation solutions. Our team carries out a thorough audit of the plant to determine how to most advantageously plan the entire project from conceptual, technical and implementation aspects.

Practical benefits of a well-executed integration

• Ability to monitor key performance indicators (KPIs) in real time.
• Seamless control of several machines simultaneously from a single operator panel.
• Reduced downtime - the automation system will inform itself of an impending failure or need for maintenance.
• Adaptation of machine operating profiles to changing production needs.

When implementing such projects, it is also worth thinking about after-sales service and maintenance to avoid long downtimes. Our experience shows that well-thought-out integration pays off quickly and companies gain a real competitive advantage.

Good practice in industrial machine building

The following tips will help you plan your investment comprehensively, reduce the risk of mistakes and give you peace of mind for the long term.

1. Opt for reliable suppliers

Choosing an experienced partner - such as Michale Automatics - means you can count on professional support at every stage of the project. It is essential that the supplier not only makes the machine for you, but also ensures that it is compatible with your existing production environment.

2. Require transparent documentation

Complete technical documentation (including 3D drawings, electrical diagrams, spare parts lists) will facilitate the future operation and servicing of the equipment. Transparent documentation is also a guarantee that, in the event of changes or modifications to the machine, critical points will be easier to identify.

3. take into account future service and maintenance

The best manufacturers of industrial machinery additionally offer support in terms of warranty and post-warranty service. You will thus strengthen your production security - in the event of a breakdown, you will know who to turn to. If you would like to find out more about job maintenance options, check out servicing and maintenance of stations.

4. Remember safety and legal standards

Industrial machinery must comply with strict health and safety standards. Some solutions cannot do without CE certification or other industry-specific requirements. The safety of the employees operating the machinery is an absolute priority, which is why it is advisable to plan appropriate guards, emergency stop systems or evacuation procedures as early as the planning stage.

5. Analyse ROI and TCO indicators

An ROI (return on investment) and TCO (total cost of ownership) analysis is also a key element of any investment. The construction of industrial machinery should always take into account whether the project will be economically viable over the assumed time horizon.

The role of robotisation in the development of industrial machinery

Many companies find that traditional automation is sometimes insufficient when it comes to rapidly growing production and the need for greater flexibility. Therefore, a large proportion of new industrial machines are already being enhanced with robotic modules.

In what situations is it worthwhile to robotise a workplace

• When repetitive tasks (e.g. handling, packing, welding) predominate.
• When the key is to maintain high-precision repetition in short time cycles.
• With frequent staff turnover causing difficulties in maintaining consistent productivity and quality.

Sometimes customers are concerned about the costs associated with robotisation. However, it is worth remembering that more and more solutions are available on the market, including in the affordable cobot (collaborative robot) segment. In addition, Michale Automatyka is an official distributor of SIASUN robots, which gives companies access to advanced, yet highly efficient solutions.

If you would like to learn more in depth about robotisation and see what we have to offer in this area, take a peek at robotisation.

Industry case studies - what to look out for

On the Polish market, we can find numerous examples of industrial machinery implementations that have significantly improved production performance. In most of these, it proved crucial to incorporate the customer's business objectives into the project and to carry out a profitability analysis at an early stage - so that the investment can be easily defended before management or investors.

For example:

• The metal components plant decided to build a new welding machine and introduce robotisation, which enabled a three-shift operation without having to increase the number of employees. Production increased by 30% and errors were reduced by 80%.
• A food and beverage company needed a customised automatic packaging machine for delicate foods. It invested in a solution that combined an integrated vision system and robotic sorting arms. As a result, the production line was accelerated by 20% and the risk of damage during the packaging stage was eliminated.

In doing so, it is worth bearing in mind that achieving similar results requires a diligent approach - from the consultation to the careful execution of the system.

Michale Automation - Comprehensive support in industrial machine building

Michale Automatics is a team of specialists with many years of experience in designing and implementing innovative solutions for automated production lines. We carry out turnkey projects - from the initial analysis, through the construction of industrial machines to the integration with robots and vision systems.

• We provide full support:
  - we advise on how best to implement a project in order to achieve tangible benefits,
  - we take responsibility for the timeliness and final quality of the machines,
  - we guarantee training and professional service.
• We offer a personalised approach:
  - Every machine is different, so we always tailor solutions to the needs of the individual plant,
  - we help you plan future expansions and facilitate scaling.
• We are active in the area of robotisation:
  - We are an official distributor of SIASUN brand robots,
  - we implement robotised welding, packaging and other workstations based on the highest standards.

If you would like to see examples of the types of processes we can robotise, visit robotisation of packaging.

Practical conclusions and recommendations

The following are the most important tips for industrial machine building, collected in the form of a brief summary.

• Define the requirements at the start. Clearly defining your needs and key objectives (e.g. quality improvement, cost reduction, cycle time reduction) will allow you to select the right machine parameters.
• Ensure integration. A properly designed and configured machine should work with existing processes. Also take into account the possibility of expanding with additional robotic modules in the future.
• Plan service and maintenance. Regular servicing and maintenance avoids breakdowns and expensive downtime. Manufacturer's service support can be crucial in emergency situations.
• Measure effects. Establish ready-made KPIs such as line productivity, waste percentage and set-up time. Analysis of these indicators will help you verify the real benefits of the machine you have implemented.
• Take advantage of external support. An experienced company such as Michale Automation will help you through the entire process from design to construction to implementation and integration.

Summary

Building industrial machines today is not only a way to increase production efficiency, but also an opportunity to develop a competitive advantage for your company in the long term. However, it requires reliable planning, cooperation with experienced specialists and attention to every stage of the project - from initial analysis and prototyping to testing and integration with other elements of the production line.

If you are looking for support in industrial machine building or want to develop your infrastructure through robotisation, visit services and find out more about our solutions.

We also encourage you to take a look at other material on our blog to expand your knowledge of automation, robotics and modern technology solutions. If you have additional questions, please contact us and see how together we can implement a new industrial machine in your facility.

Thank you for reading! If you found the article helpful, please share it with people who can also benefit from this information. You can also subscribe to our company newsletter to receive regular updates on the latest trends in the industrial automation and robotics industry.

See you on the next topics related to mechanical engineering and process improvement!

FAQ

How long does it take to implement a new industrial machine?
Implementation time depends on a number of factors, including the complexity of the project, the availability of parts and the degree of integration with the existing production line. It can range from a few weeks to even several months in the case of highly complex implementations.

Does robotisation only work in large production facilities?
Absolutely not. More and more small and medium-sized companies are investing in robotisation as solutions become cheaper and more flexible. It is important to match the technology to the actual needs of the company.

What are the most common mistakes when building industrial machinery?
These are most often due to a lack of proper needs analysis, underestimation of service costs and overlooked integration with existing processes. It is also important to properly train operators and maintain high safety standards.