Manufacturing automation - why it is key today and how to prepare for it

Estimated reading time: approx. 8 minutes

TL;DR:

• Automation increases the efficiency and quality of production.
• Reports IFR confirm the growing dynamics of robot installation.
• Advance implementation a sound analysis processes and resources.
• Automation is not only available to large corporations, but also to smaller companies.
• The key ones are step-by-step implementation and appropriate service.

Table of contents

• Introduction
• Automation of production - definition and importance in the economy
• Trends and data from industry reports (including IFR)
• How to assess a company's readiness for production automation
• Step-by-step automation: from analysis to implementation
• Key benefits of automation for small and medium-sized enterprises
• Case studies and examples from the industry
• Summary and next steps
• FAQ

Introduction

Manufacturing automation is one of the most important trends in modern industry. As indicated by industry forecasts, especially those published in IFR (International Federation of Robotics) reports, the use of industrial robots and robotic workstations is increasing year on year, and many companies see it not only as a way to reduce costs, but also to ensure better quality and stability in their supply chains.

In this article, you will learn what modern production automation is, why so many companies are choosing to invest in robotisation right now and how to prepare your company step by step to implement this type of solution. You will also learn practical tips and the benefits you can gain from a well thought-out automation strategy.

Automation of production - definition and importance in the economy

Manufacturing automation encompasses a variety of activities related to the improvement of manufacturing processes, making it possible to increase efficiency and quality while reducing labour costs and human error. In practice, this can mean the introduction of process control devices (e.g. sensors, vision quality control systems, PLCs) or the complete robotisation of selected production tasks.

In the context of companies such as Michale Automatika, which specialises in the construction of machines and production lines and the implementation of robotic workstations, automation means creating an integral system in which the various modules work together in real time. As a result, the company benefits:

• Stability and repeatability of processes.
• Improving the quality of the final product.
• Lower labour costs.
• Greater flexibility in responding to changing market needs.

On a macroeconomic scale, manufacturing automation translates into higher competitiveness of the economy and the creation of new jobs in areas related to the design, servicing and programming of robots and automation systems.

Trends and data from industry reports (including IFR)

The latest IFR reports repeatedly highlight the growing dynamics of industrial robot installations. Although only a decade ago, many companies were hesitant to invest in robotisation, recent years have seen a huge growth in this market - according to IFR analyses, in some industries (e.g. automotive or food), the number of robots installed has grown by up to several percent year-on-year.

What's more:

• Trends point to an increased role for AI-based systems. Artificial intelligence and machine learning are finding applications in both advanced quality control processes and predictive maintenance analyses.
• Growing popularity cobots (collaborative robots) allows the introduction of automation in companies that until recently considered this option too costly or too complicated.
• In Poland, there has been a strong increase in interest in robotisation among small and medium-sized enterprises, which also reflects the continuing demand for solutions such as robotisation of repetitive production.

This development has resulted in falling prices and an increasingly wide range of robot manufacturers, including SIASUN, whose official distributor in Poland is Michale Automatyka.

How to assess a company's readiness for production automation

The implementation of production automation should be preceded by a thorough analysis of the processes within your own company. Regardless of whether you manage a small plant with several dozen employees or a medium-sized enterprise with several production lines, you should:

1. Identify the processes and areas most susceptible to automation

Analyse which production steps are most repetitive, disruptive to workers or require very high precision. These are the areas where robotisation will yield the fastest return on investment (ROI).

2. Check the cost-effectiveness of implementation

Before you start planning your budget specifically, it is worth estimating the potential financial return. To do this, you can use free tools such as an ROI calculator (e.g. calculator available at). Of course, ROI alone is not everything, as qualitative factors are equally important, but it gives an overall view of the profitability of a project.

3. consult specialists

If you do not have automation and robotics experts on your team, seek external support. Companies such as Michale Automatika perform an audit of your processes and will help you select the right solutions, taking into account the size and nature of your production.

4. assess human resources and infrastructure

• Are the workers competent enough to operate and maintain the robots?
• Is the current factory infrastructure (space, power, security systems) suitable for the installation of new solutions?

Once you have answered these questions, you will have a clear picture of the investment you need to make beyond the purchase of the machines themselves.

Step-by-step automation: from analysis to implementation

Once you have assessed the readiness of your business and selected the key processes you want to automate, it is worth following a proven pattern.

1. pre-implementation analysis

At this stage, together with your integrator company (i.e. automation specialists such as Michale Automation), you identify not only your business goals, but also areas of risk. It is worth determining what level of automation is optimal. Sometimes a simple robotic station, e.g. for packaging or welding, is sufficient, while other times you will need a complex integration of robots into your ERP system.

2. design and prototyping

For more advanced implementations, a 'proof of concept' is prepared, i.e. a prototype site to check that the intended effects are achievable. A target design is then developed and a work schedule planned.

3. installation and training

In the practice of companies such as Michale Automatics, one of the key elements is the training of the team. Even the best robot without an operator who understands how it works and knows how to service it will not fully benefit the company.

4 Integration with the rest of the systems

Depending on the level of complexity of production, robots or other automation machines should be synchronised with a production management system (ERP, MES), for example. In this way, results can be tracked in real time and any downtime can be addressed.

5. testing and optimisation

No production line is perfect from day one. Therefore, testing, adjustments and continuous optimisation are very important. Only after the stability of the generated results has been verified and potential adjustments have been made can we speak of a truly completed implementation.

6. service and maintenance

Robotisation is a long-term process. Regular servicing of automated workstations avoids unscheduled downtime and quickly identifies potential problems. This reduces breakdown costs and production losses incurred. You will find service and maintenance of robot workstations here.

Key benefits of automation for small and medium-sized enterprises

Although production automation is often associated with large corporations, in practice more and more smaller companies are also opting for robotisation. This is due to several factors:

• Falling costs robot purchasing and integration. Increasing competition in the robotics market is making unit prices for machines and integrator services affordable for smaller players as well.
• Production flexibility. Small and medium-sized companies often have to produce products in short, but frequent batches. Modern robots can be configured for a variety of tasks in a relatively short time.
• Reducing the problem of staff shortages. In the face of rising labour costs and a shortage of skilled workers, automation keeps competitiveness high.
• Improving quality and repeatability. Very important for the company's image, as products of varying quality are harder to sell in more demanding markets.

An example is the robotisation of tasks such as painting or sanding. Implementing a robotic painting station in a small industrial company can result in a significant improvement in the quality of the finish and a reduction in turnaround time, while giving workers the opportunity to focus on other, more complex tasks.

If you are interested in implementing robots in general or in a specific field, also visit a dedicated page on robotisation.

Case studies and examples from the industry

1. small manufacturer of metal components

The company, which employs around 40 people, was facing staff shortages in manual positions. Implementation of automated packaging and CNC machine operation stations:

• Reduced the time taken to ship products from 3 days to 1 day.
• It has allowed some staff to be redirected to the quality department, which has helped to improve customer relations and reduce complaints.

2. medium-sized packaging printer

A company handling orders from a wide range of industries decided to robotise its palletisation process. A SIASUN industrial robot was installed, which fully automatically transferred the stacked layers of packaging onto pallets - minimising the risk of product damage and shortening the entire process by 30%.

3. implementation in the food industry

A company in the food processing sector relied on a quality control automation system (e.g. a vision system to verify the correct packaging of goods). The result? Improved product flow and reduced complaints related to labelling errors.

In each of the above cases, automation has proven to be not only a cost-saving tool, but also a key to increasing competitiveness in the market.

Summary and next steps

Manufacturing automation is no longer reserved exclusively for the biggest players. With dynamic market developments encouraging the introduction of robots and systems to support manufacturing processes, investment in automation is fast becoming a standard rather than an exclusive solution. A well-planned implementation brings long-term benefits, including higher quality, more stable production and less dependence on external factors such as staff shortages.

Highlights and recommendations:

• Before the start of the investment carry out a thorough analysis processes in your company.
• Determine whether you have qualified staff to operate and maintain the robots, and if not - consider training or external support.
• ROI is an important element in investment planning. Use the tools available (e.g. ROI calculators) to estimate the profitability of the project.
• Start by automating those areas where shortage of workersand activities are monotonous and repetitive.
• Don't forget that automation is continuous process. After implementation, carry out tests and make improvements.

We encourage you to familiarise yourself with services of Michale Automation and an offer for robotisation of repetitive production. If you have any questions or concerns, please contact our team - we will help select the most beneficial solutions for your facility.

Summary
Manufacturing automation is not just a fashionable topic, but a real necessity if you plan to remain competitive in today's market. Today's trends - supported by data from reports including the IFR - clearly show that more and more companies are relying on robotisation and systems integration to protect themselves from market fluctuations, rising labour costs and skills shortages. To get started with automation, it is advisable to approach the subject comprehensively: from process analysis and the selection of appropriate solutions to their implementation and maintenance.

If you want to implement a robotic workstation in your company or are just considering your first steps towards automation, find out about our offer and experience in building intelligent, integrated manufacturing systems. As the official distributor of SIASUN robots in Poland, Michale Automatyka supports companies in upgrading their production lines and shows that automation does not have to be difficult.

Share your opinion in the comments, subscribe to our newsletter and keep an eye on future articles - we periodically publish material on trends in robotics and practical advice for entrepreneurs interested in improving production. You are welcome!

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.

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.