Manufacturing a machine step by step - why it's a key process in modern industry

Estimated reading time: 7 minutes

TL;DR:

• Manufacturing a machine is a process combining design, construction and integration with automation systems
• It is crucial to precisely define the business objective and needs
• Careful selection of components and testing and quality control must be carried out
• Automation and robotisation increase production efficiency and flexibility
• Regular service and maintenance ensure the long-term efficiency of the machines

Table of contents

• Introduction
• Definition of machine manufacturing in the context of Industry 4.0
• Planning and design of machinery - foundations for success
• Construction and assembly of systems - from prototype to finished solution
• Integration with automation and production support systems
• Why work with a professional machine manufacturer
• The role of service and maintenance - long-term efficiency
• Examples of specific benefits of complex machine manufacturing (case study)
• Internal linking
• Summary and recommendations
• FAQ

Introduction

The production of a machine is much more than simply putting components together. In today's increasingly automated reality, the correct design and manufacture of machines is key to keeping processes running smoothly in manufacturing companies. In this article, we explain what the step-by-step production of a machine consists of, why it is worth approaching the subject in a comprehensive manner and the benefits of having this process carried out professionally. Right from the outset, we look at what the reader will gain after reading - above all, practical tips for planning and implementing machinery in a company. In addition, we highlight aspects of automation and robotisation that can be taken into account during the design and construction phase of machinery.

Definition of machine manufacturing in the context of Industry 4.0

Machine manufacturing is a multi-stage process involving the conception, design, manufacture and implementation of a device (or an entire production line) with a well-defined function. In the era of Industry 4.0, it can be said that machine manufacturing is even the foundation of the modern manufacturing sector. Why? Because it combines traditional engineering aspects - such as mechanical engineering - with advanced tools, such as vision systems, IoT sensors or industrial robots.

In practice, this means that integration issues with production management systems (ERP, MES) and even the use of artificial intelligence algorithms to aid quality control are taken into account right from the design stage. The result is a machine that is not only efficient, but also flexible and easy to configure for different types of tasks.

Planning and design of machinery - foundations for success

A well-conducted planning and design process defines the effect the machine will have over its lifetime. This step is crucial, as it is only after a sound recognition of the needs of the investor and the specifics of the industry that solutions can be proposed that will actually deliver the desired result.

Establishing business needs and purpose

The first task is to determine precisely what tasks the machine will be created for and how it will be used in the company's daily operations. Let's assume that the aim is to improve the packaging process in a production facility. In this case, the project team needs to gather all the data related to the type of product, batch size, type of packaging or the level of automation the company can currently implement.

It is also worth paying attention to future adaptability. Sometimes companies operate in fast-moving industries (e.g. food, e-commerce), which requires scalable solutions.

Choice of technology and components

Once the necessary information has been gathered, there is a moment of technology and component selection. This often includes:

• Selection of controllers and automation modules (e.g. PLC, HMI)
• Determining the type of electric, pneumatic or hydraulic drives
• Decision on safety systems (sensors, laser curtains, emergency stops)
• Fitting umbrella solutions - e.g. integration of a cobot or industrial robot

At this stage, it is crucial to strike a balance between cost and functionality in order to create a machine that is both cost-effective and reliable.

Construction and assembly of systems - from prototype to finished solution

Once the design is ready and approved, the actual construction can begin. Typically, the process starts with the creation of a prototype or test module to assess whether the assumptions made work in practice.

Selection of raw materials and components

The manufacture of a machine requires a precise selection of materials and raw materials. Depending on the industry, these can be stainless steel, special metal alloys or high-strength plastics. In the food sector, for example, materials resistant to corrosion or intensive use in humid environments are usually chosen.

A key aspect here is strict quality control at the supplier verification and acceptance stage of individual parts. High-quality components mean fewer breakdowns and a significantly longer service life for the production line or the machine itself.

Testing and quality control

Once the machine has been assembled, a series of tests must be carried out. These consist of:

• Performance tests - verification that the equipment achieves the target operating speed
• Quality tests - checking that the resulting products meet the specified standards
• Safety tests - confirmation that the machinery is fitted with systems to protect workers (compliance with CE directives and standards)

It should not be forgotten that tests under near-real conditions (so-called prototype tests) allow any design flaws to be revealed even before the machine is handed over to the target plant. As a result, the time for possible corrections is reduced and the machine itself is more refined.

Integration with automation and production support systems

Today's industry is striving for an increasingly high degree of automation and robotisation of processes. When producing a machine, it is worth thinking in advance about integrating it with various digital systems in order to fully exploit the potential of modern technology.

Fundamentals of industrial automation

Industrial automation focuses on the optimisation and control of manufacturing processes using controllers and sensors. It plays a key role in the machine, allowing the control of motors, modules or conveyor lines. If surveillance software is added, the company can analyse in real time:

• Energy consumption
• Number of components produced
• Potential downtime and causes of failure

The result is dynamic production management, which translates into full quality control and resource planning within the company.

Implementing robotisation throughout the entire machine production cycle

Often, the production of a machine goes hand in hand with the implementation of robotic solutions - especially where precision and repeatability are important. At Michale Automatika, we are an official distributor of SIASUN robots and integrate them into a variety of processes - from welding to packaging to robotic CNC machine workstations.

In some situations, a simple pick-and-place robot, providing rapid transfer of parts between stations, is sufficient; in others, an extensive set of welding or painting robots. It is important to identify early in the planning phase how robots can improve the efficiency of the resulting machine.

A natural extension of integration is also the use of vision systems or AI sensors, which allow robots to 'see' and respond intelligently to changes in the environment.

Why work with a professional machine manufacturer

Many companies wonder whether it is worthwhile to opt for external partners when building and implementing machinery. Here are some key arguments:

• A comprehensive approach. Professionals provide support from the conceptual phase to service and staff training.
• Expertise. A qualified team guarantees knowledge of regulations, industry standards and the latest technological trends.
• Reducing implementation risk. Experience makes it possible to anticipate the most common errors and prevent them in advance.
• Comprehensive advice. It is often necessary to modify requirements during the course of work. A machine manufacturer with many years of experience can offer better or cheaper solutions in time.

As Michale Automation, we offer not only the construction of machines and production lines, but also the integration with automation and robotics systems. Used correctly, these technologies will increase productivity and reduce labour costs in the first years of operation.

The role of service and maintenance - long-term efficiency

Setting up and commissioning a machine is just the beginning of the adventure with a new machine. An equally important stage is professional service and systematic maintenance. Without this, all the effort put into careful design and production can go to waste.

Regular maintenance ensures:

• Early fault detection
• Higher machine availability (less downtime)
• Longer equipment life
• Operator safety

In this way, the investment in a new machine pays off quickly and the company gains stability and a market advantage. This is why, at our company Michale Automatyka, we always recommend full service packages. It is worth exploring our offerings, for example (e.g. servicing and maintenance of stations).

Examples of specific benefits of complex machine manufacturing (case study)

To illustrate how important the role of precise, complex machine manufacture is, let us recall a brief example from practice.

A company in the plastics industry (a medium-sized plant) approached us with the problem of generating a large amount of waste and a lack of qualified staff to operate the machinery. In response, we designed a component cutting and forming machine that:

• Allowed for zero downtime - increased productivity by 30%
• Reduced kickbacks through precision cutting
• It was integrated with a small robot (company SIASUN) that transferred raw materials between stations

We carried out the full project from the concept phase through to the implementation of the production line on the client's shop floor. The result? The investment paid for itself within 2 years, and the company has since planned further expansion and the next phase of robot integration.

In another example - in the repetitive metal component manufacturing industry - the key was to reduce production time while maintaining high weld quality. We proposed welding robotisation, presented as a Robotisation of repetitive production.

This step not only ensured a stable process, but also treated the staff shortage in the area of welders as an opportunity for automation.

As a result, the company has gained:

• Cost reduction by 20%
• Reduction in welding time by 15%
• Wider production capacity (increased product diversity)

Internal linking

When designing and manufacturing machines and robotic workstations, it is often useful to take a broader look at the company's automation capabilities. If you are interested in enriching your production line with robots, we invite you to read our guide on the different types of such implementations: Robotisation.

If, on the other hand, you already have an initial idea for the introduction of robotic solutions, but you are not sure what the return on investment will be, you can use a useful tool to calculate ROI: ROI calculator - Welding robotisation.

Summary and recommendations

Machine manufacturing is a complex process combining many areas of knowledge: from mechanics and electronics to automation and robotics. In the context of Industry 4.0, it is even a pillar of modern manufacturing, opening up wide-ranging prospects for companies to optimise costs and increase productivity.

Key findings from the article:

• Accurate recognition of the needs and tasks the machine is to perform is the foundation of the entire process
• Design requires a detailed selection of technology and components - it is not only the price that counts, but also reliability and the possibility of future development
• Integration with automation or robotics pays off with faster production, fewer errors and better control over the manufacturing process
• It pays to work with experienced manufacturers who provide support at every stage: from design to service.
• Proper servicing and maintenance is essential to ensure that the machine lasts as smoothly as possible for as long as possible and delivers the expected return on investment.

How can you put this knowledge into practice?

1. Define key areas for improvement in your plant and carry out an analysis of the processes that generate waste and repetitive errors.
2. Consider implementing not only a new machine, but also advanced automation technology or industrial robots (e.g. with the support of official distributors of such technology).
3. Ensure that you have a service plan and regular maintenance - this will ensure that you achieve sustainable efficiency and that your appliances remain in full working order.

In an era of rapid technological change, machine manufacturing is increasingly becoming a key element of competitive advantage. It is worth considering the latest trends and using professional support to avoid costly design mistakes. If you would like to learn more about the possibilities of automation and robotics, we encourage you to browse our offer (e.g. implementation of robotic solutions for repetitive production) or contact our consultancy department.

We also invite you to share your questions and insights in the comments - we are happy to help tailor the optimal solution for your plant. We encourage you to subscribe to our newsletter to keep up to date with the latest information on machine design and manufacturing, as well as news on robotisation implementations in companies.

Thank you for your time and we wish you success with your own plans in the area of production machine building and integration!

FAQ

How long does the machine take to manufacture?
Time depends on the complexity of the project. In simpler cases, it can be a few weeks, or even a few months for more complex production lines.

Does automation require a lot of money?
The initial cost can be high, but automation often pays for itself quickly through increased productivity and reduced machine running costs.

When is it worth considering robotisation in the production process?
Robotisation is particularly suited to processes that require repeatability and precision. It is worth considering when manual operation or current automation does not deliver the expected productivity.

How is the machinery serviced after implementation?
A professional manufacturer provides after-sales support, including inspections, maintenance and possible repairs. Regular servicing is crucial to the long-term effectiveness of the machine.