How to successfully integrate production robots into an existing line - a practical guide

Reading: approx. 9-10 minutes

TL;DR

• Integrating robots into an existing line requires precise planning and analysis.
• Ensure that the ERP or MES system is ready to work with robots.
• Safety and correct service procedures are key to production continuity.
• Start with the most monotonous and repetitive tasks.
• It makes sense to work with an experienced partner in the area of robotisation.

Table of contents

- Introduction
- What is actually the integration of production robots into the line?
- Key steps in integrating robots into the production line
  ◦ Stage 1 - Needs analysis and design
  ◦ Stage 2 - Programming and configuration
  ◦ Stage 3 - Testing and optimisation
- Is your ERP system ready for robotisation?
  ◦ Benefits of integrating robots with ERP
  ◦ Key technical challenges in the collaboration between robot and ERP
- Best practice in the integration of production robots
- Potential barriers and ways to overcome them
- Which processes are worth robotising first?
- Support at every stage - the importance of a trusted partner
- Practical conclusions and recommendations
- Summary
- FAQ

Introduction

Manufacturing robots are increasingly revolutionising industry. They are the answer to the challenges of cost pressures, skills shortages and the constant drive to improve production quality and efficiency. However, integrating robots into an existing line can seem complicated, especially for companies entering the field of robotisation for the first time. In this article, we will discuss step-by-step how to approach the process of linking robots to systems already in place, what aspects to pay special attention to and where to look for support. You will also learn how Michale Automatika approaches integration projects - so you will be able to better plan your investment and avoid common pitfalls.

If you are thinking about robotisation and would like to know what the possibilities are for combining robots with your machinery fleet, you can read our discussion of services right now Robotisation. In this text, you will also gain practical tips on how to prepare your plant for integrating production robots into your existing line.

What is actually the integration of production robots into the line?

The integration of production robots into an existing line involves designing, configuring and implementing robots so that they work with existing systems - machines, conveyor belts or even production supervision software. In practice, this means that the robot ceases to be a stand-alone station working 'alongside' the rest of the plant and becomes an integral part of the line.

Today's production robots are capable of performing a wide range of tasks, from material handling, welding, packaging or sorting, to the most complex assembly operations. The key to success is to closely match the characteristics of these tasks to the technological capabilities of the system in place and to the company's prevailing processes. Poorly planned integration can generate additional downtime, increase maintenance costs and ultimately prevent the optimum use of the robot's advantages.

Key steps in integrating robots into the production line

Stage 1 - Needs analysis and design

The first step is a thorough analysis of the production processes to be automated or robotised. Recognition is crucial at this stage:

• Product characteristics (e.g. weight, size, deformability).
• Possible points of integration of the robot with machines.
• Capacity needs (e.g. how many details should be processed in a certain time unit).
• Safety requirements - including the need for special guards, curtains or signalling.

The data collected allows the design of a robotic station or new solutions within the current line. You should also analyse whether your company has an ERP or MES system that can be used to monitor and control the robot's performance. If you are planning to implement robots for a relatively simple activity, it is important not to overdo the level of technology - in many cases, a simple configuration and a few additional sensors are enough for the robot to interact effectively with the line.

Stage 2 - Programming and configuration

Once the concept has been designed and approved, the software of the robot or robot team is approached. Here, it is necessary to take into account:

• Robot movement paths - so as to avoid collisions with other machines and elements in the environment.
• Control algorithms - key to performance and safety.
• Integration with sensors, vision systems, PLC control system components.

If the target plant uses even relatively simple continuous transport systems (e.g. a conveyor belt), it is a good idea to create separate safety zones and programme emergency procedures - so that, in the event of an unforeseen event, the robot and the rest of the line can quickly stop or go into safe mode.

Stage 3 - Testing and optimisation

Deployment tests are the key to finally confirming that the robot works as intended and integrates correctly with the rest of the line. In practice, tests should be run in all load scenarios, checking, among other things:

• Whether the robot maintains stable operation at maximum load.
• How the robot reacts to small deviations in workpiece positioning.
• Whether the control system is able to transmit correct data in real time.
• What does the pace of work look like in practice and do critical delays not occur.

At this stage, modern technologies are becoming increasingly important - for example, collecting data from IoT sensors and analysing it using Machine Learning and AI systems. This allows process anomalies to be caught and service downtime to be predicted. A well-configured data set (from sensors and from an ERP or MES system) allows you to keep track of the effectiveness of robotisation and make small adjustments quickly.

Is your ERP system ready for robotisation?

In many companies, production robots do not operate in isolation from IT systems - it is increasingly common to see the integration of robotics with ERP (Enterprise Resource Planning), MES (Manufacturing Execution System) or SCADA (Supervisory Control And Data Acquisition). The key is not only to streamline the physical operation through the use of robots, but also to digitally map the process in real time.

Benefits of integrating robots with ERP

• Tracking production: Possibility of generating real-time reports (e.g. number of finished parts per hour).
• Integrated resource planning: The ERP system coordinates the robots with material deliveries, warehouse management and production scheduling.
• Faster response to change: If a robot in one area of the line detects a shortage of raw material, the ERP can automatically order the necessary components or divert resources from another area.

Key technical challenges in the collaboration between robot and ERP

• Communication protocol: Robots from different manufacturers, including those distributed by Michale Automatika (e.g. SIASUN models), use different communication protocols. It is important that the ERP system is able to 'get along' with the robot controller.
• Interface configuration: Implementing a typical protocol requires programming knowledge and detailed hardware documentation.
• Data consistency: If the information on production batches is organised differently in the ERP system than in the robot control system, difficulties may arise in assigning identifiers, recording defective pieces, etc.

From the perspective of a company that is taking its first steps in robotisation, finding proven implementation partners is key. One such option is to carry out a pilot implementation in a narrower scope and only after confirming the results gradually scale up the project.

Best practice in the integration of production robots

The process of integrating robots into an existing line requires experience, but there are a few universal principles that increase the chances of a successful project:

1. Involvement of a multidisciplinary team
   Even at the planning stage, it is good to have automation engineers, PLC programmers, Lean Manufacturing specialists and machine operators on the team. Cooperation between different specialists avoids situations where one department implements a solution that clashes with the assumptions of another department.
2. Early determination of safety requirements
   Even if a plant has high health and safety standards, the introduction of robots may require additional risk verification. This applies in particular to collaborative robots (so-called cobots), but also to traditional robots that may work in the immediate vicinity of operators on a daily basis.
3. Documentation of each modification
   Every change in the area of integration - whether in the controllers or in the ERP software - should be properly documented and tested. This will maintain the integrity of the entire system and avoid confusion in the event of an advanced failure.
4. Regular service and maintenance
   New workstations and lines integrated with robots must be covered by a maintenance cycle. It is worth adding at this point that in the offer service and maintenance of Michale Automation you will find comprehensive support for the maintenance, diagnosis and modernisation of robotic workstations. Regular inspections reduce the risk of unplanned downtime and maintain high production efficiency.

Potential barriers and ways to overcome them

While the advantages of robotisation are undeniable, in practice a number of barriers can be encountered that slow down or hinder implementation.

• Financial barrier.
  Purchasing a robot, a control system and the necessary infrastructure, as well as carrying out the integration, can be expensive. It is therefore worth accurately calculating the return on investment and using the tools available to verify how quickly the purchase will pay for itself. For example, an ROI calculator designed for robotic welding workstations, such as the ROI calculator, helps to estimate potential savings in other production processes as well, if similar performance parameters are assumed.
• Lack of qualified staff.
  Production robots require people capable of programming and supervising the system on a daily basis. The solution may be to work with external implementation companies (such as Michale Automatics), which provide full support from the design stage through to crew and operator training.
• Integration with multiple machine manufacturers.
  In large plants, there are often different brands of equipment. The robot must be able to communicate effectively with all of them, which places high demands on the control layer. The experience of an integrator who is familiar with the standards of different industries and manufacturers is crucial here.
• Concerns about downtime.
  Virtually every integration project involves holding the line for at least a short time. Therefore, it is important to plan the implementation schedule well. Sometimes it is a good solution to test integration on a smaller scale - only when satisfactory results are obtained is the project rolled out to the entire line.

Which processes are worth robotising first?

In practice, companies often decide to robotise the most repetitive and error-prone activities. These types of tasks provide the fastest return on investment and the benefits are extremely easy to measure (high repeatability translates into a reduction in scrap).

• Assembly of components with regular shapes and little variability - e.g. fitting gaskets, screwing in screws, gluing small components.
• Packaging and palletising tasks - the robot can easily stack products evenly and quickly, minimising damage and errors in quantity.
• Welding, especially in the metal sector - here the use of a robot allows not only precision but also improved ergonomics for welders.

Many companies, taking advantage of the integrator's know-how, choose to robotise repetitive processes robotisation of repetitive production. It is in these areas that efficiency gains can most easily be seen - both in volume growth and waste reduction.

Support at every stage - the importance of a trusted partner

Implementing a robot into an existing line can sometimes be a multi-faceted project. It often requires:

• Mechanical modification of posts,
• Control system conversions,
• Configuration of the surveillance software,
• Conduct operator and maintenance training.

By working with an experienced partner such as Michale Automatika, companies can significantly reduce the overall implementation time and reduce the risk of major errors. As an official distributor of SIASUN robots, Michale Automatika has access to leading technologies, guaranteeing the highest level of safety and flexibility. In addition, the ability to order an end-to-end service (from design to installation and service) protects against fragmented responsibilities and minimises unforeseen downtime.

Practical conclusions and recommendations

As discussed so far, the process of integrating manufacturing robots can be complex, but certainly remains achievable for companies of all scales. The following are my key recommendations:

• Carefully plan the implementation goals
  Specify what tasks the robots are to perform and what metrics you want to improve - e.g. line efficiency, error reduction, changeover time.
• Ensure you have the support of specialists at the design stage
  Involving an experienced integrator brings tangible benefits in the long term by eliminating the risk of basic design or programming errors.
• Use ERP and MES systems to monitor performance
  By integrating with ERP and MES systems, you will be able to monitor profitability and robot utilisation levels on an ongoing basis, as well as respond more quickly to emerging challenges in production.
• Focus on continuous optimisation
  Robotisation doesn't end when the line starts up. Collect data, analyse the effects and make improvements - often a small modification to an algorithm can increase productivity by another percentage.

Summary

Manufacturing robots are well suited to the needs of modern industry, but the key to their successful operation is thoughtful integration into an existing line. This process involves careful needs analysis, design and programming, followed by testing and optimisation. At the end stands an ERP or MES system that allows the full potential of automation and data collection to be realised.

We encourage:

• Use consultancy and integration services to design and implement the robot in line with the business objective.
• Review the tools available, such as ROI calculatorto estimate the profitability of the project.
• Ensure that new posts are properly maintained (servicing and maintenance of stations) to keep the line in optimum production condition.

If you need comprehensive support, Michale Automatika offers a full implementation service, from technology concepts to design to the commissioning of robots in your plant. Thanks to its experience and status as an official distributor of SIASUN robots, you can count on state-of-the-art solutions, expert training and after-sales service.

Robotisation is becoming a standard in modern industry, so consider implementing it now. A properly integrated robot will not only increase the efficiency of your line, but will also help to eliminate errors and improve workplace safety in your plant.

FAQ

How long does it take to integrate the robots into an existing line?
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.

Does robotisation mean job cuts?
In most cases, no. Robotisation allows employees to focus on more strategic and creative tasks. At the same time, it reduces the need for monotonous and repetitive tasks.

What qualifications should the person operating the robot have?
Technical skills, knowledge of basic programming and safety principles are essential. Many integrators, such as Michale Automatics, provide dedicated training to prepare the team for the daily operation of robots.

Where do we start if we want to robotise a small production line?
It is a good idea to start by consulting an experienced integrator, who will audit your processes, propose the most cost-effective solutions and support you in the further stages of implementation.