Mechanical and plant engineering - how to effectively integrate robotisation into an existing production line?

Estimated reading time: approx. 12 minutes

TL;DR

• Integrating robots into an existing production line reduces costs and increases productivity.
• When designing machines, it is worth considering potential expansion with robotic systems from the start.
• ERP and MES systems help monitor production efficiency and quality in real time.
• The flexibility and modularity of the equipment ensures scalability and simpler adaptation to changing needs.
• Gradual implementation and staff training minimise the risk of failure of the robotisation investment.

Table of contents

• Introduction
• Why is it important to build machines and equipment with a view to robotisation?
• Key steps for integrating robots into an existing production line
• Machine and plant construction - important building blocks in robotisation
• Best practices in the implementation of robotisation in the context of mechanical and plant engineering
• Example of complete integration - robotic packaging station
• Is it worth investing in robotisation if the company is still growing?
• The most common errors in the construction of robotisation machines and equipment
• Practical lessons - how to successfully implement robotisation within mechanical and plant engineering?
• Summary
• FAQ

Introduction

Machine and plant construction is a key part of the development of modern industry. At a time when companies are struggling with rising labour costs, the increasing demand for production flexibility and the need to maintain high quality, the integration of robots and fully automated solutions is becoming not only attractive but often essential. Already at the design and manufacturing stage of machines, their future collaboration with robotic systems must be taken into account in order to guarantee process efficiency and faultlessness.

In this article, we provide a comprehensive overview of the key aspects to look out for when deciding to expand or upgrade a production line towards robotic automation. You will learn:

• What are the benefits of implementing robotic workstations in a company.
• How to plan the process of integrating robots into an existing line, taking into account ERP and MES systems.
• What are the best practices in the design and construction of machinery and equipment in terms of robotisation.

With this knowledge, you will effectively prepare your company to optimise production, eliminate interruptions and respond more quickly to changing market needs.

Why is it important to build machines and equipment with a view to robotisation?

Building machinery and equipment with the prospect of future robotisation in mind allows companies to create more efficient, flexible and profitable processes. Among the benefits worth mentioning:

• Reduction in labour costs - industrial robots and other automated solutions operate continuously 24/7, minimising the expense of delegating people to repetitive tasks.
• Improved quality - thanks to the repetitive movements and precision of the machines, we reduce human error, maintaining a uniform level and standard of product.
• Scalability - modern robotic technologies can very easily be expanded with additional stations or robots that seamlessly take over part of the load on the production line.
• Flexibility - If there is a change in product range, robots can be reprogrammed for new tasks and materials can be adapted quickly, whereas in classic production without robots, changes often require large amounts of money.

The Michale Automation team designs and implements solutions with future expansion in mind. Knowing the needs of businesses, we always strive to ensure that the machines and equipment installed are as scalable as possible.

Key steps for integrating robots into an existing production line

The successful integration of industrial robots, or in other words: a production line with robotics components, requires responsible planning and close cooperation between engineering teams and management.

Product and technology needs analysis

The first step is to understand where specifically in the production process robots can add the most value. It is important to identify:

1. Which operations on the current production line are the most difficult or time-consuming.
2. Potential savings that could result from shifting some tasks to works.
3. How large is the volume of production (or the planned increase in production) for the investment in robotisation to have an adequate return on investment.

In many companies, it is processes such as welding, packaging or CNC machine operation that can be successfully performed by industrial robots. You can find out more about such implementations in our services section:
Robotisation - effective implementation in your plant

Bench design and component selection

The next step is to design the workstations with robotisation in mind. In practice, this means:

• Workspace dimension assessments - so that the robot can be freely mounted and operated.
• Matching loads - the robot must be able to carry the necessary weight and provide the required working speed.
• Consideration of safety - Depending on the type of equipment used (industrial robot or so-called cobot), either mechanical security or vision systems will be required.

At Michale Automatics, we have many years of experience in the design of machinery and equipment, which allows us to plan the most optimal solutions right from the conceptual stage.

Integration with ERP and MES systems

An important element of modern automation is the increasing implementation of ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) systems. This allows the ongoing monitoring of production processes, inventory control and analysis of individual machine performance. In turn, readings from robots can be automatically transmitted to systems, which has an impact:

• More precise production planning in real time.
• Faster response to potential outages (alerts allow failure to be detected immediately).
• Easier quality tracking (the system can record the parameters of each item produced).

The close integration of robotic stations with an existing ERP or MES brings a number of benefits. For example, by integrating robotic systems in the packaging area, we can automatically generate labels and shipping documents, which speeds up order picking.

Machine and plant construction - important building blocks in robotisation

When designing machines and equipment with robot integration in mind, several key design aspects need to be analysed.

Robust and modular design

Equipment designed to work with robots should have high rigidity and an adequate reserve of strength. Industrial robots are able to work with great speed and precision, which generates high dynamic loads. Therefore, the design of the workstation must be:

• Stable - minimise unwanted vibrations, ensuring that the robot's movement is fully repeatable.
• Modular - New modules can be added if required (e.g. vision system, palletising system or conveyors).

Integration into the control and safety system

Advanced safety systems are a must in a robotic production line. These include:

• Safety curtains and guards - ensuring that no human enters the danger zone while the robot is in operation.
• Safety door closing and opening system - integrated into the main PLC to shut down the robot when the door is opened.
• Light and sound signalling - informing operators of line status (e.g. automatic mode, emergency mode).

Innovative solutions in the area of cobots (collaborative robots) often use built-in force and torque sensors that immediately stop the arm's movement when contact with the worker is detected.

Compatibility with other machines

Fully automated lines often consist of multiple machines from different manufacturers (e.g. conveyors, injection moulding machines or welding machines). It is essential that the machines built are compatible with communication protocols and industry standards such as:

• Profinet, Profibus, EtherNet/IP - for communication in the industrial automation environment.
• OPC UA - increasingly popular in the context of Industry 4.0.
• Safety standards (EN ISO 13849-1) - providing the required risk reduction factors.

Best practices in the implementation of robotisation in the context of mechanical and plant engineering

Use of specialised simulation tools

Before you proceed with the physical construction of the line, it is useful to use tools to simulate material flow and robot operation. These programmes allow you to:

• Anticipate possible collisions.
• Determine the optimum positioning of posts.
• Verify that the pace of individual robots corresponds to real production needs.

Gradual implementation and pilot testing

It is not always a good solution to fully upgrade an entire line in one go. To minimise risk, consider a pilot project that:

• It will only cover a selected production segment (e.g. a robotic packaging station).
• It will allow the team to test work with new equipment.
• It will reduce the time it takes to achieve expected productivity and gain staff confidence in the effectiveness of the new technology.

Support for operators and staff

Many people are concerned that the introduction of robots threatens to reduce the workforce or quickly lose their current role. In practice, it is most common to see people being redeployed to more demanding tasks, supervision or quality control, thus ensuring the development of competencies within the company. Therefore:

• Organise dedicated training.
• Implement additional security monitoring systems.
• Create clear documentation and emergency instructions.

Example of complete integration - robotic packaging station

To illustrate the whole process, let's consider a practical example - the automation of packaging at the end of a production line. The machine built should:

1. Have a conveyor to deliver products to the receiving chambers.
2. Be equipped with a vision system (optional) for quality control or identification of product defects.
3. Work with a robot that grabs products and places them in a carton (or on a pallet).

Such a solution can be implemented as part of the services we offer. We encourage you to take a look at one of our proposals:
Robotisation of packaging - increase the efficiency of the final stages of production

We start the implementation by analysing the current line layout and comparing it with the performance requirements. We then design the machines so that they are suitably braced and suitable for rapid communication with the robot. Teams of engineers and operators go through a testing phase, verifying the correct layout and performance levels.

Is it worth investing in robotisation if the company is still growing?

Many times management wonders whether it is worth investing capital in expensive machinery and robotic workstations in a rapidly growing company. The truth is that in an era of increasing competition and difficulty in recruiting skilled staff, robotisation is one of the most effective ways to ensure continuity and high quality production.

As part of Michale Automatyka's offering, thanks to our long-standing partnership with leading robot manufacturers (e.g. we are an official distributor of SIASUN robots), we guarantee professional support and advice on the selection of equipment best suited to specific processes. You can also check the approximate return on investment using available online tools such as:
ROI calculator for welding robotisation

The most common errors in the construction of robotisation machines and equipment

Underestimation of integration costs

Companies often conceive of robotisation as the purchase of the robot itself, forgetting the costs associated with preparing the infrastructure, developing the machines and training staff. It is crucial to make every effort to reliably estimate the total costs of the project, including:

• Upgrading (or purchasing new) machinery.
• Additional safety apparatus (curtains, interlocks, operator panels).
• Integration with ERP and MES systems.

Lack of flexibility in the design

A common problem is to build machines strictly for the production of one type of part. When the product range changes, it becomes necessary to make costly modifications to the entire production line. It is much better to opt for a modular design and components that can be retrofitted with different grippers or additional functions in the future.

Insufficient post-launch testing

Even the best-planned implementation can run into difficulties - from small collisions to incorrect welding parameters to problematic data transfer to the ERP system. This is why multi-stage testing and regular monitoring of the line's performance, especially in the first months after commissioning, is so important.

Practical lessons - how to successfully implement robotisation within mechanical and plant engineering?

- Identify the processes most amenable to automation: Firstly, analyse which tasks cause downtime, high costs and their automation will ensure a quick return on investment.
- Invest in universal solutions: Choose modular systems that can be easily extended with additional functions in the future. In this way, you will not close the way to further development.
- Plan integration with IT systems: Advanced robotisation is not limited to mechanical work. Real-time data communication to accurately monitor and optimise processes is also key.
- Support staff: Employee training is as important as the machine itself. Without people's awareness and knowledge, it will be difficult to exploit the full potential of new technologies.
- Choose the right partner: Consulting an experienced company such as Michale Automatics will avoid many unnecessary mistakes and speed up the entire implementation process.

Summary

The construction of machines and equipment, combined with the clever integration of robots, is the foundation of modern Industry 4.0. With the right analysis, preparation of technical background and cooperation with experienced engineers, production lines can be created that operate efficiently, precisely and flexibly respond to changing market trends.

In order to realise the full potential of automation, it is worthwhile:

1. Invest time in sound planning and process analysis before the machine design stage begins.
2. Opt for pilot phases, avoiding complex investments carried out at a single point in time.
3. Select a partner who, in addition to supplying the robot itself, will provide support in integrating it with IT systems, as well as staff training.

We invite you to visit
our services
and contact experts in the field of industrial automation and robotisation in its broadest sense. If you would like to see how the topic of robotisation in the field of welding looks - be sure to take a look at the subpage
Robotisation of welding.

With the support of Michale Automatika, your company can move to a higher level of automation in a short period of time, increasing competitiveness in a rapidly changing market. Modern technology - such as SIASUN robotic workstations, vision systems or integration with ERP - is an investment that quickly begins to bring tangible benefits.

Do you have questions or want to see how to plan a line upgrade for robotisation? Contact us and get professional support at every stage of implementation!

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.

Which industries benefit most from robotisation?
Robotisation is widely used in many sectors, including automotive, food, pharmaceuticals and electronics. However, it is also increasingly being used by smaller companies in various areas of industry.

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.

How do you keep a robotic production line in good shape?
Regular inspection, maintenance of machines, implementation of software updates and continuous monitoring of key performance parameters are essential to maintain process continuity and avoid breakdowns.