Industrial process automation - how to prepare your company for successful implementation

Estimated reading time: approx. 10 minutes

TL;DR:

• Automation significantly increases productivity and reduces production costs
• Successful implementation depends on reliable process audit and practical training of the team
• Selection of suitable technology and integration with IT systems are the key to high efficiency
• Safety and ergonomics jobs must be a priority
• Continuous monitoring of indicators and process optimisation bring long-term benefits

Table of contents

• Introduction
• Why is industrial process automation so important?
• Step 1 - Needs analysis and process audit
• Step 2 - Choice of technology and implementation strategy
• Step 3 - preparing the infrastructure and workstations
• Step 4 - Training and support for employees
• Step 5 - testing and gradual commissioning of the new line
• Step 6 - continuous improvement and monitoring of effects
• The most common mistakes when implementing automation and how to avoid them
• Examples of automation applications in various industries
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

The automation of industrial processes is becoming a priority for an increasing number of manufacturing companies. In an era of rising labour costs, high quality requirements and the need for ever-increasing production volumes, plant owners and managers are looking for solutions to increase productivity, minimise errors and become independent of staff fluctuations. Current industry reports show that Poland is steadily catching up with world leaders in robotisation and automation. According to the latest IFR (International Federation of Robotics) statistics on European countries, the number of robot installations has increased by 9%, which means that entrepreneurs are increasingly willing to invest in technologies that improve production.

In this article, we explain what to look for when implementing industrial process automation and how to properly prepare a company for such a transformation. We have also included practical tips to help reduce the risk of possible implementation mistakes. After reading this publication, you will gain concrete guidelines to help you start planning the automation process and go through the steps of integrating new solutions.

Why is industrial process automation so important?

Industrial process automation is not just about reducing the contribution of human manual labour. Today's systems are able to integrate robots, vision sensors and ERP/MES software in a way that translates into overall efficiency improvements, easier process monitoring and faster responses to potential quality issues. Let's consider why there is so much interest in automation.

Increasing competitiveness

The global market is undergoing dynamic changes. Products have to meet ever higher quality standards, which entails continuous improvement. Automation allows companies to level the playing field against larger players, as automated tools increase production efficiency, reduce scrap rates and lower operating costs.

Responding to staff shortages

In many industries, employers are struggling to attract skilled workers. One solution is becoming the implementation of robotic systems that take over some of the repetitive and physically engaging tasks. This allows staff to focus on more creative and complex duties, often resulting in improved morale and employment stability.

Improving quality and safety

Manual operation of production lines increases the risk of errors and work accidents. Automatic systems, including collaborative robots and dedicated machines, ensure a high level of repeatability. This significantly reduces the number of defective products or unnecessary downtime. Automation also includes precision inspection tools (e.g. vision systems) that detect defects even before the goods are packaged and dispatched.

Step 1 - Needs analysis and process audit

Before starting any implementation work, the current shape of the production processes must be carefully analysed. To this end, an audit is carried out, which includes material flow, identification of bottlenecks and identification of locations where the most repetitive and manual activities occur.

Define business objectives

At the outset, it is important to understand what the company wants to achieve with automation. Is the priority to increase productivity and production volume by several tens of per cent? Or is the goal to halve the number of defective products or reduce energy costs? Having a clear business objective makes it easier to choose the right automation methods and to measure the results after implementation.

Assess the volume and variability of production

Not every process is worth automating straight away. The costs of purchasing and integrating robots or machines can be disproportionate to the benefits if a company produces small batches or has a high level of product range variability. It is therefore worth examining the stability of the order book and calculating the potential return on investment. If a company is considering automation of welding processes, among other things, it can use tools such as ROI calculatorwhich provides a better estimate of the scale of savings.

Step 2 - Choice of technology and implementation strategy

The next stage is to decide how to implement automation and which specific technologies will be best for the factory in question. This is where an integrator company such as Michale Automatyka, which has experience in building machines and production lines from scratch as well as implementing robotic workstations, can come to the rescue.

Robotisation or classic automation?

Much depends on the nature of the processes. If there are long series of repetitive operations in a plant (e.g. packaging, cutting, painting or welding), industrial robots will prove to be an ideal solution. If you are unsure whether robotisation is the right direction, traditional automation systems can be considered. The priority is always to analyse the costs and real benefits.
Before making a decision, most companies use specialists who can advise on which robots and automated lines provide the highest return on investment. Michale Automatika, as an official distributor of SIASUN robots, can offer a fully integrated system - from the selection of a specific model (e.g. SIASUN SR25A robot) right through to preparing the workstation on the production floor.

Integration with software

Modern automation is not only about physical equipment, but also about software. ERP/MES systems help monitor production in real time, manage inventory and sometimes even forecast raw material requirements. Make sure your planned automation system can work with your existing IT infrastructure.
Lack of such compatibility can cause delays in implementation and generate additional expenses.

Step 3 - preparing the infrastructure and workstations

Before robots or automated lines can start operating, it is necessary to adapt the production floor. This includes safety issues, material flow logistics and possible modifications to the environment in which the robots will move.

Safety and ergonomics

The basis for implementing automation is to ensure safe conditions for workers and machines to work together. A risk assessment must be carried out and, depending on the results, it must be decided where to place safety curtains or special barriers restricting access to the robot's working area.
It is worth remembering that even the most advanced robotic structures require proper design of the workspace - keeping minimum distances from heat emitters, protecting the electrical system or arranging the space so as not to create collision points.

Access to utilities and resources

The proper operation of automation systems depends on a stable power supply and access to compressed air and possibly other process media. It may be necessary to install additional ducting or upgrade the electrical installation in the hall to cope with the increased power demand.
In the case of high-precision applications or welding robots, it is also important to ensure that the ventilation system is in good condition so that smoke and dust do not interfere with the operation of vision equipment or sensors.

Step 4 - Training and support for employees

The automation of industrial processes also means changes in the tasks and skills of employees. Instead of operating workstations manually, those employed will be able to concentrate on supervising automated lines and optimising the entire process.

The role of the implementation team

In any company carrying out an automation project, it is worth setting up an implementation team made up of employees from the various departments: production, maintenance, quality control and IT. The task of such a team is to ensure that the implementation takes place in the right sequence and meets daily operational needs.

Operating and programming training

One of the key dimensions of an automation project is learning how to operate and the basics of machine programming. Appropriate technical support from the integrator is important at this stage. In the case of Michale Automatyka, experts provide comprehensive instruction and training materials on robot programming or station maintenance.
Comprehensive training enables the production team to understand how service and bench maintenance is carried out in practice (see service description for details: servicing and maintenance of stations). This approach increases the sense of control and commitment of employees and minimises the risk of future downtime.

Step 5 - testing and gradual commissioning of the new line

Once the equipment has been installed and configured, it is time for testing. It is advisable to carry out a series of trial runs, during which staff will verify production data, safety parameters and the quality of the manufactured products.

Verification of key parameters

During the tests, attention is paid to factors such as the speed of the robots or the efficiency of the line, but also the stability of the communication between the machines and the management system. It may be necessary to correct control algorithms, e.g. the time a workpiece is held in the station or when the next operation is started.

Fault elimination and optimisation

Well-planned tests allow errors (e.g. minor downtimes in material flow or communication problems between sensors) to be caught. This ensures that the automation implementation project does not end when the equipment is switched on, but is an ongoing process of optimising performance.
The real benefits of automation and robotisation are only likely to become apparent when a company understands that a machine can be rebuilt at a later date or its functionality extended with further sensors or manipulators.

Step 6 - continuous improvement and monitoring of effects

Industrial process automation is not a one-off investment, but rather an evolution of the way a company manages its production. In order to get the maximum benefit from the newly installed solutions, it is necessary to regularly monitor the indicators and make any improvements.

Key performance indicators (KPIs)

The most commonly analysed indicators include:

• OEE (Overall Equipment Effectiveness) - a measure of the efficiency of line use,
• machine set-up time,
• percentage of shortages and customer complaints,
• capacity utilisation rate.

Measuring these elements and comparing them with native performance prior to implementation allows the tangible benefits of automation to be observed.

Software updates and service

Automation systems are subject to periodic maintenance and updates. It is important that the integrator company provides ongoing support and expert service. In the case of industrial robots, maintenance includes checking drives, control systems and safety, among other things. Regular maintenance is the key to maintaining operational stability over many years.
The need for regular servicing applies to purely mechanical systems as well as sophisticated vision systems or manipulators. With reliable service care, costly downtime can be avoided while ensuring that the highest product quality is maintained.

The most common mistakes when implementing automation and how to avoid them

While the benefits of automation are enormous, there are also often situations where the implementation process does not deliver the expected results or generates unplanned costs. Below, we list some common reasons for such problems.

Underestimation of the need for team training

Even the best technology will prove ineffective if staff do not know how to use it. Robots and vision systems require a basic understanding of programming and safety. Sometimes businesses cut back on training expenses or assume that the process is intuitive. Meanwhile, the smallest mistakes can generate additional service costs and increase implementation time.

Failure to match the type of automation to the production profile

A common problem is the wrong choice of technology. For example, an oversized robot may not be cost-effective in a plant that runs small and variable batches. Conversely, in a company with a stable, mass production profile, the lack of a suitably efficient automation system can lead to repeated line congestion. Requirements should therefore always be analysed in detail and juxtaposed with the range of solutions available.

Underestimated budget for total implementation costs

It is worth remembering that the purchase price of a machine or robot alone is not everything. There is also the integration with the IT infrastructure, modifications on the shop floor, staff training and the configuration of safety systems. If the budget does not take these aspects into account, the automation project may be prolonged or even put on hold.

Examples of automation applications in various industries

Here are a few selected scenarios where automation brings tangible benefits to companies.

Robotisation of welding in series production

The welding process is repetitive and involves the risk of quality errors when working manually. A robotised workstation is able to maintain constant parameters, resulting in consistent quality and reduced shortages. In addition, this form of automation makes it easier for companies to adapt to high order volumes. It is worth taking a look at offers of robotised welding.

Packaging automation in the food industry

Packaging machines and product handling robots eliminate errors that often occur when filling and closing packages manually. By implementing fully automated solutions, companies can significantly speed up packaging or palletisation even with a large number of lines and a variety of product formats.

Robotised special applications

The metal and plastics manufacturing industry often uses robots for tasks such as grinding, painting or laying out parts. These processes generate loads and expose workers to harmful agents. Robotic solutions improve safety and productivity. For example, a wide range of services are available, including grinding, painting or robotisation of other repetitive tasks (see: robotisation of repetitive production).

Practical conclusions and recommendations

• Opt for a solid audit processes prior to implementation - this promotes more efficient machine selection.
• Define specific business objectives and expectations of automation to be able to measure its effects.
• Plan the adaptation of the infrastructure technical (power, ventilation, space) with safety and ergonomics in mind.
• Set up a multidisciplinary implementation teamto include production, quality and IT perspectives.
• Invest in trainingbecause a committed and educated team means less risk of mistakes at the start-up stage.
• Monitor effects (OEE, number of defects, downtime) and regularly optimise the parameters.
• Take into account integration, maintenance and service costs in the total project budget.

Summary

Industrial process automation can become a turning point in the development of a company. However, it requires a thorough baseline analysis, professional implementation support and an understanding that organisational changes go hand in hand with increased productivity and quality.
If you are considering streamlining your production and would like to know more about specific solutions, take a look at our robotisation offer or consult the experts at Michale Automation. As an official distributor of SIASUN robots and an experienced integrator, we help companies select the right not only machines, but also software and maintenance services that facilitate the continuous improvement of production management.

Feel free to leave a comment, ask questions and subscribe to our newsletter to keep up to date with the latest trends in the field of automation and robotics. Share the article on social media so that other entrepreneurs and managers can also benefit from practical tips on industrial process automation. Good luck in implementing innovations!

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.