Designing production lines - a practical guide from concept to implementation

Estimated reading time: approx. 10 minutes

TL;DR

• Define business requirements and identify key objectives from the outset
• Conduct a thorough analysis of technology and automation (including robotisation)
• Ensure integration of new solutions into existing infrastructure
• Control costs, plan return on investment (ROI) and provide service
• Focus on continuous staff development and implement the latest Industry 4.0 trends

Table of contents

• Introduction
• Designing production lines - basics and first steps
• Business needs analysis
• Creating a preliminary line concept
• Key stages in the design of production lines
• Simulation and technical documentation creation
• Building and testing a prototype
• Integration of control and automation systems
• Impact of robotisation on production line design
• Increased efficiency and flexibility
• Key aspects of robot integration
• Selected problems in the design of production lines and how to prevent them
• Inadequate integration into existing infrastructure
• Taking robotisation into account too late
• Insufficient staff training
• Designing production lines in practice - ROI planning and cost analysis
• Establishing key profitability indicators
• Operating and servicing costs
• Latest trends in production line design
• How Michale Automation approaches the design of production lines
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Design of production lines is one of the cornerstones of a successful industry. A well-designed line can increase productivity, improve product quality and optimise costs. At a time when many industries are struggling with skills shortages and increasing price pressure, automation and proper process layout are becoming key to staying competitive.

In this article, we will outline a step-by-step approach to production line design and what to look out for in order to make the implementation a complete success. You will learn, among other things:

• What stages are involved in the design process and why it is worth planning from the outset.
• How individual technologies (including robotisation) affect line efficiency.
• What to look out for when integrating new solutions into existing infrastructure.
• How to assess the viability of a project in practice and prevent the most common problems when launching a new line.

Find out how Michale Automatics - a company specialising in machine building, production lines and the implementation of robotisation - can support your business.

Designing production lines - basics and first steps

The design of production lines involves many factors: from the physical conditions of the hall, to the programming of machines and control systems, to the integration of automation and robotics solutions. Each of these elements must interact, which is why working on a line concept often requires an interdisciplinary team: mechanical engineers, automation specialists, logistics specialists or process planners.

Business needs analysis

The first stage in the design of a production line is definition of business requirements. At this stage it is useful to establish:

• What type of products are to be produced and in what volume.
• What are the technical specifications of the product (e.g. size, weight, precision).
• Under which conditions (e.g. temperature, humidity, sanitary requirements) the process will take place.
• Which quality standards and industry regulations should be taken into account.

A sound analysis of these factors avoids costly modifications during later stages. It is at this point that many entrepreneurs decide whether to invest in robotisation or whether to consider future scaling of the line depending on order dynamics.

Creating a preliminary line concept

The next step is to create an overview, or so-called concept. It includes:

• Identify the sequence of key production operations.
• Rough selection of the machinery and equipment required for the process.
• Consideration of the space available in the production hall.

Potential areas where industrial robots will be used can already be planned at this stage. If a company is planning to automate certain activities, such as the operation of CNC machines, it is worth ensuring that the stations are set up in optimal locations and allow for smooth interaction with the robot or vision system.

Key stages in the design of production lines

Once the requirements have been defined and the overall concept outlined, it is time for more detailed engineering work - from modelling and simulation to building a prototype and launching the actual line.

Simulation and technical documentation creation

Modern CAD/CAM/CAE software makes it possible to accurately design each component of the production line. This makes it possible to:

• Rapid detection of collisions or potential failure points even before construction.
• Material flow analysis and pre-optimisation of cycle times.
• Using virtual models of industrial robots to determine their range and precision of movements.

Done properly technical documentation - containing mechanical diagrams, electrical plans, descriptions of control algorithms - is the basis for further modifications and implementation work.

Building and testing a prototype

Depending on the scale of the project, either a prototype line segment or a full line at the target location can be built in the next step. Tests include:

• Verification of theoretical assumptions and cycle times.
• Checking the safety of operators and machinery.
• Quality assessments of the finished product.

If industrial robots or cobots (collaborative robots) are involved, tests related to the compatibility of their software and the safety of their interaction with humans are performed at this stage.

Integration of control and automation systems

Another important element is the integration of the machines with the control system (e.g. SCADA, PLC) or ERP/MES systems. This makes it possible to:

• Continuous process monitoring and real-time error reporting.
• Collection of data needed for analysis of performance indicators (KPIs).
• A more precise production schedule, reducing downtime.

At this stage, it is worth considering integration with vision systems if product features need to be recognised (e.g. print quality verification or vision-based validation of the inserted part).

Impact of robotisation on production line design

Although not every production line needs to be fully robotic, more and more companies are choosing to implement robots and cobots. How can they be effectively integrated into the line design process and what benefits does this bring?

Increased efficiency and flexibility

Industrial robots operate with high precision 24 hours a day. When implemented in a classic, manual line:

• Cycle times can be reduced by up to several tens of per cent.
• The number of errors and rejections decreases significantly.
• The line becomes more flexible - it is easier to adapt the robot's programme of work to a new product range than to make major changes to the entire infrastructure.

In practice, this also means a faster return on investment. According to industry analyses, in many companies the payback time for robotisation is between 1.5 and 2 years.

Key aspects of robot integration

For the robots to be of real benefit, they need to be considered from the line design stage. This requires, among other things:

• Provide adequate working space and a safe working area.
• Selection of grippers and vision sensors if the robots are to recognise workpieces or handle differently shaped parts.
• Design transport paths for materials and finished products so that robots work seamlessly with other machines.

This avoids the so-called bottlenecks associated with product transfer or manual line changeovers.

Selected problems in the design of production lines and how to prevent them

Even the best-prepared concept can encounter difficulties at the point of implementation. Here are some of the most common and proven solutions.

Inadequate integration into existing infrastructure

Trying to add a new part of the line to the old infrastructure proves to be a frequent problem. The result? Connections may require additional peripherals, and this generates unforeseen costs. To avoid this:

• Verify the condition of the machines you already have and consider whether they will need upgrading.
• Check that the existing control system (e.g. PLC) is sufficiently efficient.
• Think of a modular solution - free-standing stands that can be easily moved and combined into different layouts.

Taking robotisation into account too late

If no space for industrial robots was envisaged in the initial phase of the project, and it becomes apparent during construction that it is worthwhile to implement them, costly reconstruction may be necessary. It is therefore recommended that:

• Decide already at the concept stage which production steps can be robotised.
• Create a line development plan that looks ahead - even if robots are added in the next stage, it is worth planning for adequate space and tooling.

Insufficient staff training

Even the best-designed line will operate below capacity if the crew is not properly trained. This is particularly important for robotic deployments:

• Staff should be familiar with the basic principles of robot programming and operation.
• It is essential that all employees are familiar with health and safety procedures - with industrial robots, collisions can occur if the work zone is not clear.
• It is advisable to update the knowledge periodically so that the staff can diagnose minor faults and quickly restore the line to operation.

Designing production lines in practice - ROI planning and cost analysis

Estimating the cost of a production line in detail is one of the biggest challenges. It is not just about the cost of purchasing machinery, but also implementation, integration, training or subsequent maintenance.

Establishing key profitability indicators

For most companies, indicators such as:

• Unit cost of production before and after implementation of the new line.
• The expected volume of production in a given time frame.
• Return on investment (ROI) - NPV or IRR are also often analysed in the industry.
• Energy and operating costs (e.g. need for more compressed air, higher power consumption).

If you are considering robotisation, it is worth considering the calculations available in online tools. On the ROI calculator - welding robotisation you can see the general rules for calculating the profit from automation.

Operating and servicing costs

In addition to the implementation itself, service and maintenance costs need to be kept in mind. Over time, it will be necessary to replace wear and tear components, update controllers or maintain the entire infrastructure. W Michale Automation This process includes both machines and robotic workstations - as part of the service and maintenance of posts comprehensive care of the equipment can be provided.

Latest trends in production line design

In the era of Industry 4.0, smart factory concepts are developing. The integration of vision systems, IoT or data analysis in the cloud makes production lines even more autonomous and efficient. A few trends worth noting:

1. Digital Twins (Digital Twins)
   Creating a virtual mapping of the line allows continuous monitoring and optimisation of the process. This allows potential failures to be identified before they occur in reality.
2. Predictive maintenance systems
   Using sensors and AI algorithms, the line informs itself when a component needs to be replaced. This reduces the risk of unplanned downtime and allows better management of the maintenance schedule.
3. Collaborative robots (cobots)
   Unlike classic industrial robots, cobots can work safely around people. Their popularity is growing especially among small and medium-sized companies that want to avoid building enclosed work zones.
4. Mass personalisation
   The lines are designed to adapt quickly to the production of short runs of differentiated products. Greater flexibility means lower changeover costs and faster response to changes in demand.

How Michale Automation approaches the design of production lines

Michale Automation specialises in the construction and automation of production lines. Thanks to its experience in robot integration, implementation of complete control automation and provision of comprehensive services, the company can take responsibility for the entire process - from initial conception, through design and construction, to service and post-implementation care.

Our services include:

• Design and implementation of robotic workstations (including integration with vision systems).
• Consultation and production audits to assess where automation will bring the greatest benefit.
• Adapting the line to the specifics of the industry - whether food, furniture or metal.

To see the full range of activities, visit Automation services Michale. See also the company's approach to robotisation in industry and how he links it to existing production processes.

Practical conclusions and recommendations

To sum up, production line design requires:

• Accurate identification of business needs and product specifics.
• A comprehensive view of the process - from production sequences to logistics to software integration.
• Include robotisation (if appropriate for the production in question) from the initial concept stage.
• Systematic staff training and periodic servicing of machines and robotic workstations.

Companies that want to remain competitive should take into account the latest trends, such as digital twins, predictive maintenance or collaborative robots (cobots). All of these work best when introduced in line with Industry 4.0 and based on sound data analysis.

Summary

Design of production lines may seem like a challenge, but a well-planned and implemented project guarantees many benefits: cost reductions, increased flexibility and significant improvements in product quality. The evolution of robotic technology and automation systems today offers unlimited possibilities for integrating machines and software, making it possible to increase the scale of production and adapt it to dynamic market needs.

Key tips:

1. Start with a solid identification of your needs - don't just focus on the here and now, but think about a multi-year perspective.
2. Include elements of robotisation and automation in the design from the outset - you will avoid costly structural changes.
3. Invest in simulation tools and the creation of digital twins - you will reduce the risk of failure and get more precise performance data.
4. Provide staff with adequate training - every key operator should know the basics of machine and robot operation.
5. Don't forget servicing and regular maintenance - it is the maintenance of robotic workstations and machines that extends their uptime and reduces long-term running costs.

If you would like to find out more about the construction and automation of the line, as well as a detailed offer - including comprehensive service support - take a look at the section Service and maintenance stands.

We also encourage you to put the tips from the article into practice. If you need support in designing or upgrading your production line, please contact us for a free consultation. The Michale Automation team will be happy to answer your questions and offer customised solutions.

We hope our guide will help you to better understand aspects of production line design and inspire successful implementations that increase the competitiveness of your business. Share the article with your industry friends, leave a comment with your experiences and don't forget to follow our blog to keep up to date with the latest trends in automation and robotics.

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.