Building a production line - key steps, costs and best practices

Estimated reading time: 8 minutes

TL;DR

• Carefully conduct an analysis of business needs and objectives to optimise the implementation process.
• Computer-aided design and simulations avoid many costly mistakes.
• Tests and the commissioning phase reveal bottlenecks and enable optimisation.
• Robotisation is particularly cost-effective for repetitive and demanding processes.
• Ensure regular maintenance and staff training to minimise downtime.

Table of contents

• Introduction
• Preliminary planning and analysis
• Design and documentation
• Implementation and assembly of the production line
• Testing, optimisation and commissioning
• Maintenance and further expansion
• Robotisation as part of production line construction
• Practical tips and best practices
• Summary
• FAQ

Introduction

The construction of a production line is a topic that is always of interest in the industrial sector. At a time when companies in Poland are struggling with rising labour costs and the need to deliver high-quality products, industrial automation solutions are increasingly being used. In this article, we outline the step-by-step process of building a production line, what to look out for in the context of integrating different systems and what solutions are worth implementing so that production runs smoothly and is adapted to market needs.

You will learn why proper planning and optimisation already at the project stage are crucial for the profitability of your investment. We will also tell you what mistakes to avoid and when it is worthwhile to turn to robotisation and automation. You will understand the most important aspects to pay attention to in order to achieve high productivity and quality in finished products.

Preliminary planning and analysis

Analysis of business needs and objectives

The first step in building a production line is a precise analysis of the company's needs. In this step, it is worth asking yourself the questions:

• What production volumes are anticipated?
• Which processes are currently bottlenecks and to what extent can automation improve them?
• What is the business objective of implementing the new line - is it mainly to reduce costs, improve quality or increase employee safety?

Clear answers to the above questions make it possible to determine the direction of investment and the type of technology to go for. This is the moment when the management or owner of the company decides how to finance the initiative, sets the budget and the timeframe.

Assessment of existing infrastructure

Another important point is the verification of the current state of the infrastructure and the possibilities for expansion of the plant. This includes, among other things, an analysis of:

• available production space,
• distribution of utilities (energy, compressed air, control systems),
• possible equipment that can be used in the new project.

It is also advisable to check whether existing machinery and equipment can be connected to the new line by means of automation system integration. This step can be crucial, especially if the aim is to reduce costs by making maximum use of the equipment already in place.

Definition of performance indicators

Already at the planning stage, it is worth adopting specific indicators to assess the effectiveness of the implementation. These include, for example, OEE (Overall Equipment Effectiveness), productivity indicators (number of products per hour) or defect levels. At a later stage, these can be compared with the actual results and, on this basis, decisions can be made on possible modifications to the process.

Design and documentation

Technical concept development

The design of a production line begins with the development of a technical concept. Architects, engineers and automation specialists work together on the layout of the individual workstations and establish the material flow diagram. It is important to take into account:

• ergonomics at work,
• operator safety,
• the ability to flexibly adapt the line to changing market needs,
• the prospect of possible future expansion of the system.

Project documentation

In the next stage, specialists prepare design documentation, including electrical schematics, PLC control systems, robot specifications (if applicable), and detailed mechanical drawings. The documents take into account:

• layout plan for machinery and equipment,
• description of the communication interfaces of the control systems,
• detailed implementation schedule.

At this stage, it is also worth thinking about how to ensure seamless integration with the plant's IT environment, such as with systems like MES (Manufacturing Execution System) or ERP (Enterprise Resource Planning). This will enable real-time production monitoring and better resource management.

Simulations and virtual tests

Increasingly, computer simulations are being carried out after the initial design has been developed. These make it possible to assess the performance of the designed lines, identify potential bottlenecks and even check whether the planned cycle times are achievable in practice. The use of simulations can significantly reduce implementation time and minimise the number of corrections already at the commissioning stage, which translates into lower costs.

Implementation and assembly of the production line

Monitoring construction progress

Once the documentation is approved, the actual construction phase begins. It is very important to stick to the schedule, but at the same time to remain flexible in case of unforeseen events, such as delays in component deliveries. During assembly:

• Individual equipment and systems are installed in a predetermined order.
• The control software is being implemented.
• Motion tests are carried out to ensure that each station is functioning correctly and in accordance with the design.

Installation of automation systems

The construction of a production line relies heavily on modern industrial automation solutions. From simple PLCs to advanced SCADA (Supervisory Control and Data Acquisition) software systems, these can all be part of the project. Qualified engineers take care of the correct configuration of sensors, actuators and safety systems to guarantee stable and safe line operation.

Integration with industrial robots

Industrial and collaborative robots (so-called cobots) are used in many industries, especially where repetitive processes are required. Michale Automation is the official distributor of SIASUN robots, which are perfect for production lines. When integrating robots, additional aspects must be taken into account:

• compatibility of robots with existing infrastructure,
• the appropriate configuration of vision systems if robots are to recognise and locate details,
• adaptation of the software to the individual requirements of the plant.

Testing, optimisation and commissioning

Test and commissioning phase

Once assembly is complete, the time comes for the testing phase. This is one of the decisive stages in the process of building a production line, as errors detected at this stage can cost a lot, but eliminating them is crucial to achieving the intended performance. Testing includes:

• Control measurements of operating parameters (speeds, torques, precision of movement).
• Simulations of emergency situations (e.g. stopping the line in an emergency).
• Operator safety tests (guards, sensors, safety features).

If necessary, engineers make modifications to the control software and adjustments to the hardware configuration. It is also during this phase that it is verified that all line components, including robots, are operating in a synchronised manner and that the production stations created do not create bottlenecks.

Process optimisation

Sometimes it is only practical production trials that reveal less obvious organisational problems, such as misplaced components or waiting times between operations that are too long. It is therefore worthwhile to analyse data from monitoring systems on an ongoing basis and look for opportunities to increase efficiency and reduce waste. For example, a higher throughput can be achieved when the path taken by workpieces between stations is shortened.

Initial start-up and evaluation of indicators

The test phase is followed by the start of trial production. This is the moment when it is possible to assess for the first time whether the line is achieving the desired indicators (e.g. OEE, productivity, claims levels). Establishing the real values of these parameters in a production environment is invaluable for further investment and optimisation decisions. If the indicators deviate from the targets, engineers together with project managers look for solutions to improve production.

Maintenance and further expansion

Operator training and technical support

Professional staff training is an invaluable factor. Operating a modern production line, especially if robotisation has been introduced, requires skills in automation, programming and knowledge of safety procedures. It is worth ensuring that:

• The production team understood the basics of how control systems work.
• Designate persons responsible for the rapid identification and rectification of faults.
• Provide regular training, including as the line is extended with further modules.

Maintenance strategy

To keep a new production line running without downtime, a well-planned maintenance strategy is essential. This includes regular inspections, replacement of wear parts and maintenance of machines at convenient times (e.g. during scheduled downtimes). Increasingly, so-called predictive maintenance solutions are being used here, where an impending breakdown can be detected in advance on the basis of sensor data.

Expansion and modernisation

A dynamically changing market may require the introduction of new products or increased production volumes. A well-designed production line offers the possibility of flexible expansion. Sometimes it is sufficient to implement an additional robot or duplicate some stations. However, it is crucial to allow a 'margin' for such modifications at the design stage, so that the upgrade does not incur excessive costs.

Robotisation as part of production line construction

When is it worth reaching for industrial robots?

Modern production lines are increasingly using robots. However, their use is not always the optimal solution. Typically, robotisation works particularly well when:

• The process requires a high degree of repeatability and accuracy.
• Difficult or hazardous working conditions for humans occur.
• The lines are to operate on a multi-shift or continuous basis.
• It is planned to increase production volumes without a commensurate increase in employment.

Advantages of robotisation in a linear context

There are many benefits to integrating industrial robots into line production:

• Maintaining quality - machines are not prone to fatigue and making mistakes.
• Reducing labour costs - especially at a time of rising wages and staff shortages.
• Scalability - more robots can be purchased if demand grows.

At Michale Automation (now Michale Automation), we have extensive experience of integrating robots in a variety of industries. For more information on which solutions will work best for your line, we encourage you to take a look at our offerings robotisation of repetitive production.

Practical tips and best practices

Early involvement of the project team
In addition to external engineers and technology suppliers, it is very important to include plant employees already in the initial phases of the project. Machine operators and managers have a unique knowledge of the realities of production, making it easier to avoid planning errors.

Attention to safety and ergonomics
Particularly in modern plants, the aim is for robots and humans to work together safely and efficiently. Appropriate guards, vision systems or safety sensors must be implemented in accordance with legal standards and health and safety guidelines. It is better to pay for quality solutions than to put people at risk of accidents.

Compatibility of systems and data integration
In modern factories, the concept of the Industrial Internet of Things (IIoT), which assumes the connectivity of production equipment and the exchange of data in real time, is gaining popularity. If future expansion with such solutions is planned, the possibility of standardised communication between machines and IT systems must be taken into account at the design stage.
For more information on design support and implementation of such stations in other areas of production, see our section Automation and Robotics Services.

Accurate calculation of ROI
The most common doubt when investing in a new line concerns payback time. While the machine or line itself may be expensive, its efficiency in the long term often translates into real returns in the form of reduced labour costs, higher quality or reduced raw material losses.
If you are interested in calculating return on investment ratios, you can use a simple tool available on our website: ROI calculator - welding robotisation. Although this is an example application for welding processes, in many situations a similar calculation methodology can be transferred to other production stages.

Summary

The construction of a production line is a multi-stage process, the success of which depends largely on proper planning, sound design and the skilful integration of automation systems and possibly industrial robots. In today's design, increasing attention is being paid to the possibility of further expansion, ease of integration with IT systems and safety and ergonomics.

Michale Automation specialises in a comprehensive approach to production automation - from design, machine building and implementation of robotic workstations. If you are interested in our full range of solutions, please also check out the section Services on our website.

We encourage you to read on and also to contact us to discuss your specific project. Building a production line is an investment that, if approached correctly, can bring a quick return to a company and stable, predictable production for years to come. If you have additional questions or are looking for advice on robotics and automation, please do not hesitate to consult our team.

Thank you for reading the article. We hope that the information it contains will help you to better understand the process of setting up modern production lines and facilitate your decision-making about a potential investment. Please share it if you think it might also be useful to your friends or industry partners. Good luck with your future projects!

FAQ

How long does it take to build a production line?
This largely depends on the complexity of the project and the available infrastructure. For simple solutions, the process may take a few weeks, while more extensive developments may require up to several months.

Does automation mean redundancies?
As a rule, automation does not directly lead to job cuts. Employees often move to higher-skilled positions and the company gains in productivity and quality.

When is it most worthwhile to deploy industrial robots?
Robotisation works especially well for repetitive and high-precision processes. If the line has to run in multiple shifts and you do not want to increase the number of employees, industrial robots can be a beneficial solution.

What are the key benefits of computer simulations before the line is launched?
Simulations make it possible to identify bottlenecks, test various production scenarios and check whether the assumed cycle times are achievable. In this way, many costly corrections can be avoided after the physical assembly of the equipment.