The production line in practice: how to integrate robots and optimise company processes

Estimated reading time: approx. 9 minutes

TL;DR:

• Robot integration improves the efficiency and stability of production processes.
• Needs audit and ROI analysis are crucial when choosing a specific solution.
• Robots and cobots increase reproducibility and quality, while easing the burden on employees.
• Security is based on appropriate sensors, standards and training.
• Implementation and service require the support of an experienced integrator and continuous optimisation.

Table of contents

• Introduction
• Why is it important to integrate robots into the production line?
• Higher productivity and better quality control
• Relief of staff and new development opportunities
• How to prepare for the integration of robots into the production line?
• Audit of processes and identification of priority tasks
• Choosing the right robot or cobot
• Layout preparation and simulations
• Steps of integration - step by step
• Analysis and design
• Site construction and offline testing
• Assembly and commissioning on the production line
• Optimisation and monitoring
• The most common challenges in robot integration
• Safety and health standards
• Condition of machinery in the plant and compatibility with the robot
• Acceptance of changes by the team
• Examples of robotisation applications on the production line
• Robotisation of welding and packaging
• Robotisation of repetitive production and assembly stations
• Support and service - essential elements of an efficient production line
• Practical tips for companies embarking on production line modernisation
• Summary and conclusions
• What's next? How to exploit the potential of robotisation in your company
• FAQ

Introduction

In today's market reality, a company's production line plays a key role in building a competitive advantage. The higher the degree of automation, the greater the guarantee of stable, reproducible and efficient results. Increasingly in this context, the question arises: how to integrate robots - including collaborative robots (so-called cobots) - into an existing production line in order to improve productivity, reduce costs and, at the same time, not disorganise plant operations? This is where the role of the specialists at Michale Automatika, who build machines and production lines and integrate industrial automation systems on a daily basis, comes into play.

In this article:

• We will explain the step-by-step process of integrating robots into existing production lines.
• We will advise on which areas in the company can be robotised to bring tangible benefits.
• We will show why, in an era of limited resources and rising employment costs, robotisation and automation are even inevitable.

If you are looking for answers to questions such as "How do I implement a cobot step-by-step in an existing line?", or "Is it worth upgrading older machines to work with a robot?", we invite you to read on.

Why is it important to integrate robots into the production line?

Robot integration fulfils many key functions in modern industrial plants. On the one hand, it reduces monotonous and repetitive tasks performed by employees and, on the other, it allows processes that can take a considerable amount of time in manual terms to be significantly accelerated.

Higher productivity and better quality control

When production is mainly carried out by humans in variable working conditions, it only takes fatigue or even a brief moment of distraction for errors to occur that affect the final product. Industrial robots or cobots:

• ensure perfect repeatability of every movement,
• work 24/7,
• do not require long downtimes due to, for example, employee breaks.

Consequently, one can quickly observe:

• increase in product quality,
• decrease in the number of deficiencies,
• stability of the production cycle at high volumes.

Relief of staff and new development opportunities

The implementation of automation and robotics, despite the frequent concerns about 'replacing people with machines', usually has a positive effect on the workforce. Employees can concentrate on tasks that require more creativity, experience or quality supervision. Instead of repetitively feeding parts into a machine, the worker:

• controls the results of the robot,
• takes care of production documentation,
• optimises processes so that the robot (or cobot) completes them as efficiently as possible.

In a well-structured environment, humans and robots complement each other, allowing the company to direct more complex tasks to a creative team and outsource monotonous operations to safe and precise machines.

How to prepare for the integration of robots into the production line?

The first step is a sound analysis of needs and possibilities. Even the best robot will not meet expectations if it is not fully tailored to the company's specific processes.

Audit of processes and identification of priority tasks

The expert (often a project leader from the client side or an integration company such as Michale Automatics) conducts a series of meetings in the production department and with management to

• trace every step of the process on the production line,
• identify bottlenecks (e.g. manual packing, time-consuming handling of components),
• assess the possibilities for modifying the layout of machinery and equipment.

In doing so, it is also a good idea to gather data from ERP systems (e.g. on production cycles, number of complaints) - so as to best see where robotisation will bring the fastest return on investment.

Choosing the right robot or cobot

In the next step, we tailor a specific solution. The aim is to determine whether we need a classic industrial robot (with a higher payload, longer reach and a higher level of protection in harsh environments) or rather a cobot that can work side-by-side with a human if necessary.

Noteworthy among others:

• load capacity (e.g. 10, 25, 50 kg),
• degree of protection against contamination (IP, e.g. IP67 for operation in damp or dusty environments),
• the reach of the arm (e.g. 1.5 m for simple applications or more if we need to reach an adjacent line).

At this stage, the specialists at Michale Automatika often suggest SIASUN robots, as we are their official distributor. One of the popular models, for example, is the SIASUN SR25A-12-2-01 robot, characterised by high precision and robustness in daily work.

Layout preparation and simulations

Before moving on to practical operations on the line, an integration design is created. Today's engineers use sophisticated simulation software to:

• check for possible collisions (e.g. robot - conveyor, robot - human),
• plan the sequence of movements,
• assess whether the robot will require additional equipment (gripper, welding torch, painting tools).

This can reduce costly downtime resulting from rework on the actual production line.

Steps of integration - step by step

Analysis and design

This stage involves an in-depth process analysis and the preparation of a visualisation of the future production station. The project team assesses what changes to the line layout will be necessary - sometimes it is sufficient to insert a robot at the final stage, where a human has been carrying out manual packing, and sometimes it is better to redesign the entire machine sequence so that the robot carries out more operations in one cycle.

Site construction and offline testing

Once the project has been approved, the integrator (e.g. Michale Automatics) constructs the position. This may mean, among other things:

• building a metal cage with safety sensors,
• installation of conveyors or turntables,
• PLC configuration,
• testing communication with production management systems (MES, ERP).

Offline tests (e.g. computer simulations) are still active here in order to confirm the assumed parameters and catch possible errors before commissioning.

Assembly and commissioning on the production line

When the workstation is ready, it goes to the target location in the plant. Here, the integration team carries out:

• installation and calibration of the robot,
• wiring connection,
• safety tests (emergency shutdowns, light barriers),
• operator training.

At this stage, it is crucial to work with the maintenance department, which is most familiar with the actual conditions and 'habits' of the production line in question.

Optimisation and monitoring

After commissioning, a so-called process start-up is done - we check that the whole process is running as expected. Usually minor adjustments are made to the robot software, tool holders or motion sequences. After some time, the line starts to work stably. However, it is worth constantly monitoring key indicators (e.g. OEE) to ensure that the robot is actually having the intended effect in terms of increased productivity and quality of work.

The most common challenges in robot integration

Safety and health standards

Many investors are concerned that the robot will introduce new risks for workers on the production line. With a properly designed safety system, such as vision sensors or work area scanners, the risk is minimal. If we are installing a cobot, its design, force and mode of interaction with a human are designed to avoid collisions and, if a collision potentially occurs, limit the force of impact to a safe level.

Condition of machinery in the plant and compatibility with the robot

Older devices often do not have sufficient communication interfaces to work with advanced robots or cobots. The integrator must then:

• add the appropriate control modules,
• upgrade the software,
• sometimes replacing parts of the line or entire machines with newer solutions.

Acceptance of changes by the team

An equally important aspect is the preparation and training of staff. Robots always arouse emotions, especially among people who fear losing their jobs. It is therefore crucial to explain the benefits - the robot performs repetitive, often heavy or non-ergonomic tasks, thus employees are given the chance to develop and take on more interesting positions.

Examples of robotisation applications on the production line

Robotisation of welding and packaging

In the metal industry, the implementation of robots in the area of welding or grinding is particularly popular. This makes it possible to achieve:

• reproducible, high-quality welds,
• less strain on operators in strenuous work,
• reducing chipping and defects due to human factors.

For food companies and exporters of bulk goods, on the other hand, it is worth considering automated packaging. A robot or cobot can pack the products with great precision in bulk packaging and then transfer them to the pallet. If you are interested in this topic, we refer you to information on different types of packaging solutions, such as our service robotisation of packaging.

Robotisation of repetitive production and assembly stations

Another area where robots and cobots perform brilliantly is in the operation of production lines with high repeatability. With them, individual components can be separated and arranged in an ideal way, gluing, screwing or otherwise combining into a finished product. Accuracy of handling and reproducible quality are the main advantages of such an implementation.

If you are interested in what other areas are affected by automation and robotisation in companies in Poland, check out robotisation of repetitive production.

Support and service - essential elements of an efficient production line

Implementation alone is not always enough. It is crucial that the integrating company provides support in the subsequent operation. Examples of such activities include:

• regular maintenance of robotic stations,
• training of operators for subsequent shifts and newly recruited staff,
• rapid service response in the event of failure.

At Michale Automation, we are aware that well-organised service and bench maintenance is a guarantee of stable, long-term robot operation. You can check our website for more information on the scope of support: servicing and maintenance of stations.

Practical tips for companies embarking on production line modernisation

1. examine the actual needs.
Analyse your processes and you will find the best data from your employees - they are the ones who know where downtime and quality problems occur most often.

2. consider flexible posts with the possibility of expansion.
Changing business realities may necessitate the rapid conversion of a production line to a different type of product. Robots and cobots can often be reprogrammed and the line layout does not always require radical modifications.

3. don't forget the ROI (return on investment).
Before implementation, it is worth calculating the expected return. For welding, you can use useful tools - e.g. ROI calculator in welding robotisation. This is a good reference point when planning the budget and implementation schedule.

4 Ensure that staff are trained.
Operators and maintenance staff need to know and understand the principles of working with a robot well. However, the support of integrator engineers is only the beginning - in the long term, it is crucial to develop internal competence within your company.

5. Develop a service and maintenance plan.
Robots and robotic stations, like any equipment, require regular maintenance. This will minimise the risk of sudden breakdowns and costly production downtime.

Summary and conclusions

Sealing success in the industrial market today requires flexible solutions and the right scale of automation. A production line equipped with robots can significantly increase productivity, quality and delivery stability. At the same time, if the integration and implementation process is carried out properly (from needs analysis to design to employee training), chaos and problems typical of major technological changes can be avoided.

• The key lies in choosing the right type of robot - be it a heavy industrial manipulator or a collaborative cobot.
• The return on investment can come quicker than expected, especially for companies with high production volumes or those requiring high precision.
• In parallel with the installation of the robot, it is worth considering wider process improvements, such as adapting the ERP system or implementing vision systems to guide the robot in real time.

If you would like to take a closer look at the topic of modernising your production line, we recommend taking a look at our comprehensive robotisation offer (from consultancy to design to implementation): robotisation services.

What's next? How to exploit the potential of robotisation in your company

- Contact the experts.
Specialists in robotics and industrial automation will help to assess the possibilities of developing your production line and accurately estimate potential costs and profits.

- Remember to communicate well within the company.
Whether you are integrating a single cobot or an entire robotic workstation, your employees need to know the purpose and benefits of these changes.

- Look to the future.
The next steps could be, for example, the automation of other processes, including the robotisation of painting or the robotisation of product stacking on pallets. The development and acceleration of production can be gradual, and over time will translate into savings and higher operational efficiency.

If the topic of integrating robots into an existing production line interests you, please visit the Michale Automation to find out more about our services. It is also worth checking out the servicing and maintenance of stations - is the basis for keeping the line in optimum condition. For those interested in calculating profitability, we also recommend ROI calculator in welding robotisation whether the possibility robotisation of packaging in your establishment.

Share this article to your colleagues and friends in the industry. We also encourage you to comment and contact us for a specific quote - at Michale Automatika we have been involved in the construction of machines and production lines, industrial automation and the implementation of robotic workstations for years. As a result, we can offer comprehensive support - from the audit stage, through design and implementation, to the long-term maintenance of the automated production line.

We hope that this article has helped you to understand how important a properly integrated production line can be and why robotisation is becoming an integral part of today's economy. Good luck with your automation projects!

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 robotisation mean job cuts?
Usually no. A key advantage of robotisation is that it relieves the team of monotonous and physically demanding work, allowing employees to focus on strategic and creative tasks.

Can small and medium-sized companies benefit from robot integration?
Yes, advances in technology and falling equipment costs are making robotisation increasingly accessible to businesses of all sizes. All it takes is a good identification of the areas where automation will bring a rapid return on investment.