Industrial installations - how to plan and implement efficient solutions in a production facility

Estimated reading time: approx. 9 minutes

TL;DR:

• Analysis of plant needs is the basis for an effective industrial installation.
• Selection of components and attention to compatibility guarantee trouble-free operation.
• Robotisation and automation enable increased productivity and safety.
• Planning and scheduling implementations minimise downtime and misunderstandings.
• Regular maintenance and upgrades help to keep installations in excellent condition for years to come.

Table of contents

• Introduction
• What are industrial installations?
• Key aspects of industrial plant design
  • Analysis of needs and objectives
  • Selecting the right components
• How do industrial installations affect efficiency and safety?
• Step-by-step process for implementing an industrial installation
  • Planning and scheduling of works
  • Installation, testing and acceptance
• Robotisation and automation in industrial installations
  • When is it worth betting on robots?
• How to combine industrial installations with automation and robotics systems?
• Support and service - what to look out for in the future?
• Practical lessons - what can you do to improve industrial installations?
• Summary
• FAQ

Introduction

Industrial installations are the foundation for efficient production processes in plants of all kinds - from the food and pharmaceutical industries to the metal or automotive sectors. Their proper design, selection of equipment and implementation translate not only into efficiency and safety, but also into the possibility of further process automation.

In today's reality of rising labour costs and high customer expectations of product quality, properly executed industrial installations are becoming a prerequisite to successfully compete in the market. In this article, we will look at the main elements that determine the efficiency of industrial installations, highlight the implementation steps and examine how to use automation and robotisation to achieve even higher efficiency.

After reading, you will learn, among other things:

• Why an analysis of the plant's needs is crucial before starting a project.
• How the design process and the main phases of the installation implementation work.
• When and how to combine industrial installations with robots or cobots.
• What to look for when planning the service and maintenance of an installation.

What are industrial installations?

Industrial installations can be defined as an assembly of equipment, connections and components that together carry out a specific technological process. They include, among others, production lines, transmission systems (e.g. pipes, conveyor belts, electrical installations), as well as automation and supervision systems. With industrial installations, companies can:

• Perform continuous or automated production processes,
• Maintain high repeatability and quality of products,
• Manage the diversity of technological processes,
• Increase safety and minimise the risk of failure.

For example, in the food industry, industrial installations are responsible for the transfer of raw materials, mixing and processing of products. In the steel or engineering industry, they focus on metal processing, and in the chemical sector, on the production of safe mixtures and the dosing of intermediates. In each of these cases, the industrial installations are complex systems that link the various production departments into a coherent technological sequence.

Key aspects of industrial plant design

Analysis of needs and objectives

The first step is always a thorough analysis of the plant's needs. This determines whether the installation is suitably adapted to the specifics of production, in terms of both capacity and flexibility. It is then worthwhile:

• Collect data on existing processes: volume of production, precision required, frequency of downtime, types of raw materials.
• Determine the business objectives: whether maximum productivity, reduction of labour costs or perhaps flexibility in switching production is key.
• Consult with automation and robotics systems engineers who will identify key points for automation.

Automation Michale when working with clients, always starts by setting priorities together. This makes it easier to work out the technical requirements and prepare the schedule.

Selecting the right components

After the analysis stage comes the selection of equipment and technology. Key elements include:

• Control and automation systems - including sensors, PLCs, operator panels, servo drives.
• Process equipment - processing machines, transport lines, dispensers, mixers.
• Power and safety systems - electrical switchgear, overload protection, fire protection systems.

It is worth ensuring that these components are compatible with each other and of high quality. This will reduce downtime and service costs. Even at this stage, it is also useful to think about possible robotisation, e.g. of welding or packaging stations, in order to provide space and resources for integrating robotic arms in the future.

How do industrial installations affect efficiency and safety?

Thoughtfully implemented industrial installations allow considerable automation of activities that were previously performed manually. We are not only talking about the operation of machines, but also about monitoring, reporting and quality control at individual stages of the process.

• Greater efficiency. An automated installation usually enables continuous operation, which translates into an increase in productivity of several or even tens of per cent (depending on the industry). In addition, thanks to constant monitoring of parameters (e.g. temperature or pressure), the system detects deviations in time and corrects them instantly.
• Maintaining quality and repeatability. Thanks to constant parameterisation and designed operating sequences, the industrial installation ensures reproducible results, which is crucial for large production runs.
• Improving occupational safety. Instead of people, properly protected machines and robots appear in dangerous areas. This reduces the number of accidents and staff can focus on supervision and activities requiring creativity.

For many companies, a major impetus for the modernisation or expansion of industrial installations is the current safety regulations. Compliance with occupational health and safety standards and the use of new solutions to minimise the risk of accidents have become standard in production facilities aspiring to modern standards.

Step-by-step process for implementing an industrial installation

Planning and scheduling of works

Once the data has been collected and the appropriate components selected, it is time to meticulously plan the project. This takes into account:

1. Verification of the condition of existing assets (e.g. machinery, lines, electrical switchgear, software).
2. Technical design, including connection diagrams, 3D drawings and component list.
3. Schedule to include equipment deliveries, installation dates, testing, technical acceptance and staff training.

W Automation Michael - With industrial installation projects for production plants - we place a very strong emphasis on transparency. Every step is discussed with the client to avoid misunderstandings and additional costs.

Installation, testing and acceptance

Once all the components have arrived on site, the assembly and wiring of the installation begins. At the same time, the software that controls the line or machines is prepared. After the initial set-up, the engineers begin testing in the production environment.

Technical acceptance often involves safety training, familiarising employees with the new features and handing over documentation. At this stage, it is already possible to observe the first results of the upgrade and check that everything is as intended.

Robotisation and automation in industrial installations

When implementing industrial installations, many companies rely on solutions that increase automation and reduce human involvement in repetitive or hazardous tasks. Automation Michale specialises in the construction of robotic production lines, which is the next step in the development of traditional installations.

When is it worth betting on robots?

• When low production costs and fast turnaround times are key. Robotisation, for example of welding processes, can reduce errors and labour costs (see details in our Robotisation of welding).
• When a company experiences staff shortages. In difficult times, finding skilled workers can be a challenge. A robot takes people out of monotonous tasks and they can focus on strategic tasks.
• When precision and high repeatability count. Examples include robotisation of packagingdeveloped to streamline logistics operations for the shipment of goods.
• When a facility seeks to reduce costs associated with downtime. Automated workstations, working with industrial installations, are able to operate virtually 24/7.

One of the key advantages of robotisation is the ability to integrate with vision systems, which further enhances quality monitoring, shape recognition or automatic adjustment of process parameters. Such extensive systems, integrated with industrial installations, allow a stable and smoothly functioning production line to be maintained.

How to combine industrial installations with automation and robotics systems?

Although traditional industrial installations are usually based on specialised PLC devices and control systems, they are increasingly being joined by industrial robots or cobots (the next generation of robots, working in close proximity to humans). To ensure that integration runs smoothly, it is worth paying attention to:

1. Open communication standards
   Regardless of the robot or controller manufacturer, systems should be able to exchange data (e.g. via EtherNet/IP or Profinet protocols). This provides transparency in the management of the entire installation and allows quick configuration and parameter modification.
2. Coherent software architecture
   Industrial installations usually run on dedicated SCADA (Supervisory Control and Data Acquisition) or MES (Manufacturing Execution System) software. When deploying robots, it is important to be able to control them from central software and to combine sensor data and monthly reports in one place.
3. Safety and ergonomics
   The use of robots and advanced automation increases the number of potentially hazardous areas. To ensure personnel safety, installations require the installation of light curtains or guards to protect against synchronised operation of machines and people. In addition, modern designs often incorporate remote monitoring modules so that engineers and operators can view key parameters without having to be right on the line.

Attention to these three elements (communication standards, consistent architecture and security) ensures that industrial installations enhanced with robotisation are stable and efficient. W robotics department Automation Michael We focus on configuring the equipment so that it works together fully automatically and to the highest safety standards.

Support and service - what to look out for in the future?

No industrial installation is complete once and for all. Changing market needs, the introduction of new products into the range or increasing production volumes make it necessary to regularly service and upgrade systems.

• Periodic reviews. It is advisable to schedule them at least once a year, and even more frequently in the case of heavy-duty equipment. Checking the condition of bearings, drive belts, sensors or cables can prevent unforeseen downtime.
• Software updates. New versions of controllers, operator panels or SCADA modules can increase functionality and operational safety.
• Predictive diagnostics. Increasingly, companies are supporting themselves with software that can predict potential failures based on analysis of signals from machines and robots. This prevents sudden stoppages and reduces losses.
• Modernisations and expansion. Expansion of the installation with new modules, integration of further robots - this is only possible with a proven partner who knows the specifics of the system and can adapt it to changing business expectations.

Thanks to service and maintenance of stations w Automation Michaelcompanies are assured that any modernisation or maintenance is carried out to strict safety standards.

Practical lessons - what can you do to improve industrial installations?

• Analyse the current processes. Note the sections of the line where the greatest downtime, breakdowns or loss of raw materials occur.
• Assess the level of automation. It may be worth investing in robotic workstations - for example for welding or packaging - to relieve the workload and reduce costs.
• Design a scalable architecture. Both installations and control systems should be flexible enough that the introduction of a new product line does not mean having to build everything from scratch.
• Plan for the development and replacement of key elements. The lifespan of individual components is limited and the risk of sudden failure can be costly.
• Opt for a partner with experience. By entering into a partnership with an established company - such as Automation Michale - you are assured that it will not only carry out the installation and commissioning, but will also guarantee service support at every stage of use.

Summary

Industrial installations are much more than just the technical infrastructure in a plant. It is a complex system that determines the stability of processes, the quality of products and the efficiency of the entire production. Correctly planned and implemented, they can bring real savings, facilitate an increase in production volumes and allow the company to focus on innovation rather than troubleshooting outdated technology.

In this article, we have looked at the key success factors in the design and installation of a plant: from needs analysis, to the selection of equipment, to the implementation of robotisation at strategic points in the process. We highlighted the importance of solution compatibility and safety, as only a coherent concept allows the entire line to operate smoothly and safely.

If you are considering upgrading or planning to build a new industrial installation, it is worthwhile to learn about the advantages of automation and robotisation in industry (see section robotisation on our website). Also consider the optimum service plan so that your investment in a new installation pays off quickly and maintains its efficiency at the highest level for years to come.

By taking a holistic approach to design and implementation - and understanding that industrial installations should grow with the business - companies gain a competitive advantage. At a time when speed of production, precision and certainty of delivery matter, well-designed installations become the key to success.

Feel free to raise questions and concerns in the comments. If you found the article helpful, please share it with others in the industry. Interested in exploring the topic further or approaching a production system upgrade at your facility? Feel free to contact Automation Michael. Together, we will choose the best 'tailor-made' solutions and build a truly efficient production system.

FAQ

How long does it take to design and implement an industrial installation?
Time depends on the scale of the project and the complexity of the processes. For simple upgrades it can be a few weeks, while for complex systems it can be several months.

Can an existing production line be robotised?
Yes, in many cases it is possible to retrofit existing installations and attach robots or cobots. However, it is crucial to check the available space, the condition of the machines and the compatibility of the control systems.

How much does robotisation and process automation cost?
Costs vary and depend on the sophistication of the technology, the type of machinery and the sensors and controllers required. However, needs analysis and careful planning allow the budget to be optimised and a high return on investment to be achieved.