Modernising production lines - the key to increasing industrial competitiveness

Estimated reading time: approx. 12 minutes

TL;DR:

• Modernisation is a response to growing market expectations and the need to reduce costs.
• Phased planning and ROI analysis is the key to profitable investment.
• Automation and robotisation increase productivity, reduce errors and failure rates.
• Choosing an experienced partner determines the success of the integration and service.
• Staff training is essential to take full advantage of new technologies.

Table of contents

- Introduction
- The importance of modernising production lines in times of market change
- Setting objectives and scope for modernisation
- Step by step: how to prepare for a line upgrade
- Examples of modernisation areas: from automation to robotisation
- Implementing innovative solutions - how to avoid the most common mistakes
- Case study: practical benefits of modernisation
- How Michale Automatics supports the modernisation process
- Summary of main conclusions and recommendations
- FAQ

Introduction

Modernising production lines is one of the most important steps companies can take to remain competitive in a changing economic environment. In an era of high labour costs and increasing demands on quality and productivity, efficiently executed modernisation becomes crucial. In the rest of this article, we explain why upgrading production lines is so important nowadays, how to plan the process step-by-step and what practical benefits it brings - from cost reductions to increased occupational safety and better product quality.

The importance of modernising production lines in times of market change

The impact of global trends on Polish companies

The manufacturing market in Poland is constantly growing, but increasing customer needs, pressure to reduce costs and constant technological changes mean that maintaining competitiveness requires continuous process modernisation. According to rough market data, more than half of medium and large companies in Poland are increasingly investing in digitalisation and automation to improve efficiency and product quality.

At the same time, companies that do not undertake modernisation measures quickly experience difficulties in delivering products that meet market demands. Even among small production facilities, there is a growing understanding that modernising production lines is not just a whim, but often a condition for survival in the face of dynamic competition and labour shortages.

Development of new technologies as a catalyst for change

The emergence of Industry 4.0 technologies - including robotics, machine learning or advanced vision systems - is creating new growth opportunities. Companies that invest in innovation can achieve clear productivity gains while reducing costs. Experts estimate that increasing the level of automation and digitalisation can help companies increase productivity by several tens of per cent within a few years.

Setting objectives and scope for modernisation

Defining the starting point - diagnosis of the current state of the line

The first step before starting to modernise is a thorough baseline analysis. Much depends on the industry, the scale of production, the level of automation and the state of the machinery. For this purpose, it is worthwhile to make:

• Review of key performance indicators (e.g. productivity, level of quality defects, machine maintenance costs).
• Condition assessments of lines and components.
• Quality and repeatability analyses of processes.

On the basis of such a diagnosis, it is easier to determine which elements require repair, replacement or expansion with additional modules, and in which areas it is best to introduce modern solutions.

Definition of business objectives

The modernisation of production lines should translate into specific business objectives. These may include:

• Increasing the volume of production.
• Improving product quality while maintaining or reducing manufacturing costs.
• Reduce downtime and eliminate failure rates with modern automation.
• Improving the flow of raw materials and reducing material wastage.

In the ever-growing food industry, for example, part of the modernisation can be the implementation of solutions that allow products to be packaged and sorted faster, while maintaining the highest hygiene standards. In the metal and machinery industry, production capacity is being increased, while the precision of machining or welding is being strengthened.

Step by step: how to prepare for a line upgrade

Viability analysis

An integral part of modernisation is a capital requirements analysis and ROI (Return on Investment) assessment. At this stage, estimate the costs associated with replacing machinery, implementing automation systems, expanding the IT infrastructure or necessary staff training. The prospect of the sustainability of future solutions is also important. If the modernisation is phased, it is worth presenting a schedule with checkpoints to keep the budget up to date.

Selection of a technology partner

Regardless of the scale of the planned modernisation, it is crucial to work with an experienced partner who understands the industry and can assess the needs of the company. Michale Automatics includes in its offer both the design and construction of new machines or entire lines, as well as the modernisation of existing ones to increase their efficiency and reliability.

In addition, it is important to pay attention to:

• References and realisations of a partner in a similar industry.
• Service availability and the ability to respond quickly in the event of an emergency.
• Expertise in automation and robotics with full integration, e.g. with ERP/MES systems.

Change design and proof-of-concept testing

Once the objectives have been defined and a partner selected, the time comes for the technological design of the new solution. This stage may involve preliminary computer simulations (Digital Twin), machine tests in near-production conditions, as well as consultation with the workforce. Proof-of-concept tests in a selected area of the line can be valuable to assess whether the solution is likely to meet expectations.

Examples of modernisation areas: from automation to robotisation

Mechanisation and automation of key processes

Many plants still use human power in areas where the process can be effectively automated and relieve the crew of repetitive tasks. The implementation of automated conveyors, product gripping arms or integrated production belts can clearly reduce cycle times and errors.

The automation of the packaging process, for example, is one of the most frequently upgraded tasks - especially in the FMCG industry. You will find more information related to this topic on our sub-page on packaging robotisation.

Integration of robots into production lines

The next step in automation is the robotisation of selected processes. Michale Automatika, which is the official distributor of SIASUN robots, can offer a wide portfolio of solutions - from small robots for precision tasks to large welding or palletising arms.

Industrial robots are proving their worth in a wide range of applications, including welding metal parts with complex shapes or packaging and palletising products in bulk quantities. It is worth exploring more modern options within Robotisation of welding, CNC machine operation or painting.

The advantage of robotisation is not only an increase in productivity and precision, but also process consistency. By integrating vision systems and appropriately programmed sensors, the robot is able to work continuously, significantly reducing the occurrence of quality deficiencies.

Integrated vision and AI systems

Solutions based on artificial intelligence and vision systems are becoming the next step in the modernisation of production lines. These make it possible to:

• Real-time detection of defects.
• Intelligent sorting of products by shape or colour, for example.
• Precision control of a robot that 'sees' the object and adapts movement to the current situation on the line.

Combined with the appropriate AI software, detailed analysis of production data can be performed - for example to predict failure points or optimise the sequence of steps in a process.

Implementing innovative solutions - how to avoid the most common mistakes

Insufficient staff training

One of the most common problems that arise with modernisation is that the team is not involved enough in the new process. Even the best technical solution will not fully benefit if the staff is not prepared to operate it. That is why Michale Automatika pays special attention to the training and support services stage - engineers impart knowledge of daily machine operation and maintenance activities.

Lack of coherence with infrastructure already in place

Sometimes companies decide to purchase new machines or robots without carefully analysing whether they can be integrated into existing elements of the production line. The result is chaos and a lack of fluidity in the operation of individual modules. It is therefore necessary to take a comprehensive look at the entire production chain.

Excessive savings at the expense of the quality of the technologies implemented

Poor quality automation components or robots can quickly lead to unplanned downtime. By investing in cheaper solutions, you risk delays and additional maintenance costs. Then the whole project may not be very profitable.

Case study: practical benefits of modernisation

Examples of numerical effects from the metal industry

To better illustrate the benefits, let us follow the case of a medium-sized company in the metal industry that decided to upgrade its welding production line.

• Objective: Increasing production while maintaining high quality standards.
• Scope: Integration of a welding robot, state-of-the-art quick-change workpiece holders and a weld vision inspection system.
• Effect:
  - A jump in productivity by 40% with less risk of welding errors.
  - Reduction in downtime by 25%.
  - Return on investment (ROI) in just over 1.5 years.

Those interested in streamlining similar processes at their sites can take a closer look at the options developed Robotisation of welding.

Case studies from the food market

Another example concerns a plant in the food industry that decided to upgrade its packaging line. The results include:

• Stabilising the quality and tightness of packaging and maintaining food safety standards.
• Reduced packaging time by 35%, allowing more orders to be accepted and ultimately increasing the company's turnover.

The upgrade also included the introduction of sensors and vision systems, which minimised waste by instantly detecting packaging irregularities.

How Michale Automatics supports the modernisation process

Comprehensive advice and personalisation

An essential part of Michale Automatyka's business is to guide the customer through the full investment process - from conception through design, machine building, testing to integration and training. The company focuses on an individual approach, so that solutions are tailored to the specific production conditions of each factory.

Service and maintenance support

Any upgraded line requires regular maintenance and possible repairs. Without the right support, unnecessary downtime can occur. This is why Michale Automation offers a package of services to improve the operation of robotic and automated workstations, including servicing and maintenance of stations.

Official partnership with SIASUN

Thanks to its partnership with SIASUN, a global manufacturer of industrial robots, Michale Automation has access to the latest robotisation solutions, which allows for the flexible configuration of workstations and their full integration into existing systems.

Summary of main conclusions and recommendations

Modernising production lines is not only a response to dynamic market changes, but above all a real opportunity to improve the efficiency and quality of products. If properly planned, it can bring lasting benefits to a company, including:

• A clear increase in productivity and a reduction in costs.
• Improve quality control and reduce shortages.
• Increase competitiveness and improve market position.

Key elements to look out for are:

• Diagnosis baseline and the definition of specific objectives.
• ROI analysis and strict planning of action steps.
• Choosing the right partner with experience in the sector.
• Provision of training to employees and maintenance for the new infrastructure.
• Successive expansion automation with robotisation and digitisation.

If you would like to find out more about mechanical engineering and automation, and learn about examples of implemented solutions, we encourage you to visit the Michale Automation website. There you will find information about the robotisation of various production processes and additional services.

We also encourage you to comment and ask questions - we will be happy to provide detailed data or prepare a customised offer for the modernisation of your production line. If you are interested in calculating the ROI of your robotisation investment, take a look at the ROI tools available and see that modernisation is a strategic investment in the future of your business.

We hope that the examples and recommendations provided will help you make the right decisions related to the modernisation of your machinery and production processes. Good luck in modernising your company!

FAQ

How long does it take to implement a production line upgrade?
The implementation time depends on the complexity of the projects and the scope of work. This can range from a few weeks (e.g. modernisation of a selected area) to several months or even a year with extensive lines and a large number of machines.

Is robotisation cost-effective with smaller scale production?
Today, more and more small companies are opting for robotisation. Modern solutions can be scaled so that the return on investment is also possible for small and medium-sized companies.

How do you ensure workplace safety after modernisation?
Modern machines and robots are designed with safety in mind, equipped with sensor and interlock systems. However, it is also important to train staff in health and safety and to use a service that ensures equipment maintenance.

Does the introduction of automation mean job cuts?
More often than not, no. The role of automation is to relieve employees of monotonous and repetitive tasks, allowing them to focus on more creative or specialised duties. Additionally, many companies use modernisation to retrain their staff.