Robotisation of technological processes - how to implement and succeed in production

Estimated reading time: approx. 10 minutes

TL;DR

• Robotisation improves efficiency and safety in production facilities.
• Key elements include a thorough process audit, equipment selection and an investment plan.
• The integration of robots into existing IT systems is essential in the era of Industry 4.0.
• Changing the organisational culture and training employees is the foundation of a successful implementation.
• The financial and technological challenges can pay off in a matter of months or so.

Table of contents

- Introduction
- Robotisation of technological processes - why is it a good direction?
- How to plan a step-by-step robotisation implementation?
  ◦ Process audit and identification of robotisation areas
  ◦ Robot technology selection and investment planning
  ◦ Integration of robots into existing systems
  ◦ Employee training and process optimisation
- The most common challenges in implementing robotisation
  ◦ Costs and economic justification
  ◦ Integration with ERP and MES systems
  ◦ Organisational culture issues
- Practical examples of robotisation applications in production
- What do you gain by opting for robotisation?
- Where to look for comprehensive support for robotisation?
- Summary - key findings and next steps
- FAQ

Introduction

Robotisation of technological processes is increasingly appearing in the development strategies of small and medium-sized manufacturing companies. It increases productivity, reduces costs and improves the quality of manufactured products. According to the International Federation of Robotics (IFR), global sales of industrial robots have been growing steadily for years, and investment in modern robotic workstations is starting to become an important pillar of competitiveness.

In the following article, you will learn how to plan the robotisation of your processes step by step, what challenges you may face and how to overcome them. You will also learn about examples of practical solutions used in the manufacturing industry. If you want to discover the potential of robotisation in your company and see if such an investment pays off, be sure to read the rest of the article.

Robotisation of technological processes - why is it a good direction?

Process robotisation involves introducing robotic workstations into a production facility that perform repetitive or complex tasks with continuous, precise repeatability. One of the most important effects of robotisation is increase work safety. Machines take over the most onerous and risky tasks. In addition, the work of the robots is not subject to change as a result of employee fatigue or ill-health, which translates into process stability and accuracy.

The Polish industrial sector is also increasingly keen on robotisation due to recruitment difficulties and rising labour costs. In some industries in Poland, there is a shortage of qualified machine operators, and an automated or robotised position could be an alternative. Michale Automatyka, as the official distributor of SIASUN robots in Poland, supports such implementations - from auditing and planning to integration into the old machine park.

How to plan a step-by-step robotisation implementation?

The following workflow will work well for most companies planning to robotise part or all of their existing production lines. Although each company has specific needs, the steps below allow the work to be systematised and resources to be used optimally.

Process audit and identification of robotisation areas

The first step is to understand which processes in the company can benefit most from robotisation. It is worth asking yourself a few questions:

• Which tasks are the most time-consuming?
• In which processes is there a high level of repeatability or quality errors?
• Are there processes that are dangerous for workers?
• Where in the company are the biggest labour costs generated?

At this stage, an external audit by industrial automation experts is often useful. These specialists will examine processes, analyse cycle times and identify specific improvements. Alternatively, if you have an in-house engineering team, you may be tempted to carry out the analysis yourself. However, it is important to have hard data and figures to assess the real scale of potential savings or production acceleration.

Robot technology selection and investment planning

Once the areas for automation have been selected, it is time to choose the appropriate technologies:

• Type of robot: in industry, stationary robots are used (e.g. for welding, grinding) and mobile robots (AGV/AMR) that can transport materials.
• Technical specifications: lifting capacity, reach, precision, type of joints.
• Additional solutions: vision systems, force sensors, cobots adapted to work in close contact with people.

Budget and ROI considerations should also be taken into account. A tool to roughly calculate ROI, such as the calculator available on the Michale Automation website in the Welding Robotics section (see in practice:
See ROI calculator).

At this stage, it is also worth defining an implementation schedule and preparing management for changes in production processes.

Integration of robots into existing systems

Once the right equipment has been selected and purchased, it is time to integrate it with the existing production line and ERP/MES systems. Many managers fear that synchronising data across the production line and management systems will prove difficult. In practice, however, experienced integrators such as Michale Automation have the knowledge and tools to enable robotic workstations to work seamlessly with systems that oversee production, planning and quality control.

Vision systems are often implemented to help identify the position of workpieces and allow the robot to perform tasks that depend on the position of the workpiece (e.g. palletising, packaging). Well-planned integration also means that the efficiency of the production line can be monitored in real time, and this translates into a quicker response to any downtime or errors.

Employee training and process optimisation

The human factor cannot be overlooked. Although the robot takes over some of the tasks, employees are still needed to supervise its work and respond in the event of a malfunction or the need to update the software. This is particularly important with collaborative robots (cobots) that interact directly with humans.

Training costs and the time needed to learn a new tool need to be taken into account already in the planning phase. Resistance on the part of the workforce may be due to fears of losing their position or uncertainty about operating high-tech equipment. Therefore, it is worth explaining from the outset the objectives of robotisation and the benefits of relieving workers from monotonous or dangerous tasks.

The most common challenges in implementing robotisation

Robotisation of technological processes, while bringing many benefits, can also be demanding. Implementation often presents financial, organisational or technical challenges. Below are the key areas where you should keep a close eye.

Costs and economic justification

One of the most important questions entrepreneurs ask themselves is the profitability of investing in robots. It is not only about the cost of purchasing or leasing, but also about the cost of necessary infrastructure modifications or integration with other machines. It is worth remembering that:

• The robot can work 24 hours a day, seven days a week and 365 days a year.
• Errors due to human fatigue or oversights are eliminated.
• The investment in robotisation often pays for itself within 1.5-2 years (depending on the industry and type of process).

It is a good idea to estimate the expenses and possible savings in advance with the help of an ROI calculator. There are simple tools available on Michale Automation's website to help you make an initial simulation (example:
Robotisation of welding - ROI calculator).

Integration with ERP and MES systems

In the era of Industry 4.0, efficient production means not only the automatic execution of tasks, but also the exchange of information in real time. The extensive experience of integrators makes it possible to link robots to management systems, but sometimes it is necessary to extend networks, introduce appropriate communication protocols or modify existing MES (Manufacturing Execution Systems).

If you are considering implementing systems that will closely monitor and report on production, robotisation and digitalisation should go hand in hand. This requires a good IT plan and collaboration between the IT department and robot suppliers.

Organisational culture issues

The introduction of robots into a company sometimes causes anxiety among employees who fear losing their jobs. In fact, what most often happens is that current staff are redeployed to more creative positions, related to supervision, quality control or production planning.

The competence of the team needs to be developed towards the operation and programming of industrial robots. It is worth providing training and workshops so that employees understand how new technologies will affect the work of the entire company.

Practical examples of robotisation applications in production

- Robotisation of welding - In the metal industry, robotised welding is often used to ensure the repeatability and quality of welds. This avoids human error in long and tedious welding cycles. If you need such a solution, it is worth exploring the offer
robotisation of welding.

- Packaging and palletising - robots ensure fast and efficient operation of packaging lines. They also improve palletisation, eliminating injuries and spinal trauma for workers.

- Sanding and polishing - It is difficult to achieve perfect repeatability in manual machining, especially if the workpieces differ in shape. Industrial robots equipped with force sensors make it possible to achieve a high quality finish.

- Keeping production moving - under harsh conditions (e.g. high temperatures, toxic fumes), robots perform much better than operators because of their safety and stability.

- Transfer of parts - with the integration of robotic manipulators and grippers, robots can automatically load machining machines or injection moulding machines, thus contributing to a smooth production cycle.

Each of these solutions can be extended to include vision systems or programmes with artificial intelligence elements that analyse process data in real time.

What do you gain by opting for robotisation?

Higher efficiency and productivity
The robot does not get tired and is able to perform tasks with the same intensity around the clock. This reduces cycle times, reduces quality deficiencies and maximises the use of available production space.

Maintaining quality and repeatability
Thanks to stable parameters and vision sensors, the robots achieve significantly fewer defective products than with manual handling. As a result, the company improves quality indicators and customer satisfaction.

Flexibility
The advances of Industry 4.0 make it possible to reconfigure workstations quickly. If a new product is added to the company's range, computerised control systems offer the chance to easily adapt the process to different parameters.

Improving safety
Workers are relieved of dangerous or monotonous tasks, which reduces the number of accidents at work. Collaborative robots (cobots) additionally make it possible to co-operate in a single work area without safety barriers.

Lower operating costs
Higher productivity with lower staff requirements reduces production costs. Robotisation also has the effect of reducing material losses, which is important especially with more expensive raw materials.

Where to look for comprehensive support for robotisation?

There is no shortage of companies on the market that offer services for building and deploying robots. However, choosing an experienced partner is crucial. It is worth paying attention to whether the supplier:

• Experienced in your industry (e.g. food, metal or chemical).
• Provides support for integration with existing line and IT systems.
• It offers comprehensive training in operation and service.
• It operates its own service and responds quickly in the event of an emergency.

Our company, Michale Automation, has been involved in the design, construction of machines and production lines and the implementation of robotic workstations for years. We are also an official distributor of SIASUN robots. We work with both large factories and smaller companies that are taking their first steps in the area of automation. You can start your adventure with robotisation, for example, by browsing the services related to robotisation.

Summary - key findings and next steps

- Identify strategic objectives - consider whether you primarily want to reduce costs, increase productivity or improve product quality. A well-defined objective is the basis of any robotisation project.

- Perform a process audit - Remove bottlenecks and prioritise implementation. Select departments where the potential for return on investment will be highest.

- Get the right equipment - It is crucial to determine the type of robots, their functions and additional systems (e.g. vision).

- Ensure integration - include integration with legacy systems (e.g. ERP) in the budget and timetable, as well as the need for staff training.

- Monitor effects and calculate ROI - check the extent to which the investment is paying off. Adjust robot parameters and programmes if necessary.

By implementing process robotisation in your company, you are joining the ranks of entrepreneurs who are committed to growth and innovation. If you are considering your next steps or need detailed information about services and integration options, visit us on the website:
Check the full range of services.

Robotisation of production processes represents not only an opportunity to increase competitiveness, but also to improve the daily operation of a production facility. This process can be implemented gradually, from a single robotic station to an extended production line integrated with vision and AI systems.

The key to success is to plan the project expertly and select an experienced integrator to guide the company through all stages - from conception to employee training. In an era of increasing competition and uncertainty in the labour market, robotisation is becoming a natural development.

If you are looking for inspiration and want to learn more about the possibilities of implementing robots in your industry, feel free to contact the experts at Michale Automation. You can also take a look at a selection of robotisation offers for specific processes, such as.
Robotisation of packaging.

To keep up to date with the latest news and to benefit from practical advice on planning your investment in industrial robots, follow our blog and social media. We also encourage you to comment on this article and share your robotisation experiences.

FAQ

How long does it take to implement robotisation in a manufacturing plant?
The implementation time depends on the scope of work, the degree of automation and the complexity of the processes. In simpler cases, it can be a few weeks, with extensive production lines - even a few months.

Is robotisation reducing the number of jobs?
Many companies are using robotisation to retrain staff and improve team competence. Employees can become robot operators and some monotonous or dangerous tasks are taken over by machines.

Which industries benefit most from robotisation?
It is most commonly found in the metalworking, automotive, food and logistics industries. However, an increasing number of sectors (e.g. cosmetics, pharmaceuticals) are recognising the potential of robots to increase productivity and quality.