Building production machinery - a practical step-by-step guide

Estimated reading time: approx. 9 minutes

TL;DR

• Production machine building increases productivity and safety
• The project starts with a comprehensive requirements analysis and prototyping
• Machine integration and industrial automation are key to optimisation
• Regular servicing and maintenance ensures long life of solutions
• Robots and modern technology translate into higher efficiency and lower costs

Table of contents

• Introduction
• Why is production machine building so important?
• Planning and design of production machinery
• Machine manufacturing stages
• Integration of machines into production lines
• Cost effectiveness and ROI in mechanical engineering
• Good practice in production machine building
• Robots and modern technologies in mechanical engineering
• The role of the integrator in the mechanical engineering process
• Examples of applications in various industries
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

The construction of production machinery is one of the key pillars in the development of companies in the industrial sector. A well-planned and executed investment in professionally designed systems allows companies to streamline manufacturing processes, increase productivity and improve occupational safety. In an era of rapidly increasing competitiveness in the market, optimal production machinery construction is becoming essential to maintain the pace of growth.

In this article you will find a comprehensive guide to the design, construction and implementation of machines for production lines, as well as practical tips on industrial automation and machine lifecycle management. As Michale Automation, we specialise in the construction of machines and production lines, including robotisation solutions and advanced industrial automation systems. After reading this text, you will know what to look out for during each phase of the project and what trends are worth considering in order to achieve a quick return on investment and long-term production reliability.

Why is production machine building so important?

The construction of production machinery has a significant impact on the productivity and quality of the products manufactured. This applies to both huge industrial lines and smaller plants that want to automate individual operations. In order to meet increasing market demands, companies must not only speed up production, but also maintain a high standard of quality and safety.

Improved process repeatability.
Machines developed according to a well-planned design guarantee reproducible quality and minimise the risk of errors.

Labour cost savings.
A stable and modern production line reduces the need for manual labour. This translates into lower costs and a greater ability to scale the business.

Faster implementation of new solutions.
In the case of industrial automation technology, machines are designed with a view to the possibility of further expansion, the integration of robots or the inclusion of vision systems.

Safety and ergonomics.
Modern production lines must not only meet productivity standards, but also stringent requirements. This translates not only into operator comfort, but also into a reduction in accidents.

Planning and design of production machinery

The construction of production machinery begins at the planning stage. This stage involves the precise definition of the objectives, requirements and constraints of the investment in question.

Preliminary requirements analysis

• Defining business needs. Consider how the new machine is going to support your business and what production problems you are facing (e.g. insufficient capacity, large variations in product quality).
• Scope of application. Determine whether you need a single machine or an entire production line. This will allow an initial estimate of time and cost.
• Legal conditions. Check current quality standards and health and safety regulations to avoid having to make changes at later stages of construction.

Selection of technology and automation

• Drive and control type. Depending on the specifics of your process, you can opt for electric, pneumatic or hydraulic drives, combined with extensive PLC (Programmable Logic Controller) control.
• Integration of automation types. If you are planning to implement robots, vision systems or other peripheral devices, it is a good idea to consider the need to fit in with the existing infrastructure from the design stage.
• Scalability. Assume that your business can grow over the next few years. Look at the possibility of expansion, modernisation and integration with other solutions, such as an MES (Manufacturing Execution System).

Machine manufacturing stages

Once the design is approved, the production part usually begins. This process can be a multi-stage process and requires coordination between engineers, component suppliers and assembly teams.

Prototype construction

• Prototyping. Based on the initial technical drawings, the first 3D models and prototypes are created. This allows possible corrections to be made before the developer incurs the higher costs associated with actual production.
• Functional testing. The strength of the components, the operation of the drive and control systems and compatibility with other equipment are checked.

Quality and safety tests

• Quality control. Once the prototype has been assembled and minor adjustments have been made, it is time for detailed quality tests to detect any design flaws.
• Certifications and approvals. In the manufacturing industry, it is often necessary to obtain safety certification, especially if the machine is to go into the food, medical or automotive sectors.

Integration of machines into production lines

Nowadays, it is not enough to equip a hall with individual machines. In order to achieve maximum benefits, it is essential to integrate machines into existing systems and modern industrial automation.

Elimination of errors and downtime

• Coordination with the machinery fleet. Proper construction of production machinery requires a coherent plan in which equipment is not mutually exclusive and does not cause unnecessary downtime.
• Continuous monitoring. Thanks to IoT (Internet of Things) networks and advanced visualisation systems, any anomalies can be automatically detected in real time.

Implementation of industrial automation

• Robot programming. If you envisage a robotic station as part of your line, it is worth trusting experienced integrators (such as our team at Michale Automation) to fine-tune the scheduling of robotic tasks.
• Central control system. At the heart of automation is often a PLC or a dedicated SCADA (Supervisory Control and Data Acquisition) system. It allows all machines to be supervised in one place.

If you would like to find out more about industrial automation and robotics, we encourage you to take a look at our offer under Robotisation.

Cost effectiveness and ROI in mechanical engineering

One of the main reasons companies choose to build and upgrade machines is the potential return on investment. Although the initial costs can be high (including the purchase of components, software and integrator services), over time the equipment starts to generate savings.

• Fewer errors. Automation reduces the risk of human error, which translates into lower claims and repair costs.
• Shorter cycle time. Depending on the degree of automation, production times can be reduced by up to 30-50%.
• Greater flexibility. Many turnkey systems can be easily adapted to new production formats or changes in market demand.

Want to calculate the potential return on investment of robotic solutions? Use our ROI calculator.

Good practice in production machine building

Below you will find some key recommendations for maintaining a high quality construction process for machines and production lines.

Safety rules

1. Selection of appropriate materials. Use only approved and certified components, especially if the machine is to operate in harsh industrial environments.
2. Ergonomics for operators. When planning the stand, take into account human growth, the need for efficient operation and maintenance, and the flow of raw materials.
3. Locking systems. If the safety guards are opened or the safety zone is crossed, the control system automatically stops the machine.

Documentation and service

1. Clear instructions. Each new machine requires detailed documentation, including descriptions of operating procedures, operating conditions and maintenance.
2. Geolocalisation of spare parts. It is worth introducing a QR code system into the machines' software, which speeds up the identification of components requiring repair.
3. Regular maintenance. Ensuring cyclical servicing extends the life of machines and avoids major breakdowns.

Need support with inspection and maintenance scopes? Check out our offer of service and maintenance stands.

Robots and modern technologies in mechanical engineering

Although the construction of production machines does not always have to include robotisation, modern technologies are increasingly being taken into account already at the design stage. As the official distributor of SIASUN robots in Poland, Michale Automatyka offers a wide range of solutions to improve the operation of production halls and lines.

• Multi-axis industrial robots. Depending on demand, welding, packaging or sorting tasks can be automated.
• Cobots (collaborative robots). They are ideal for applications that require operator assistance and enhance safety in the production environment.
• Diagnostics and analytics in the cloud. A wide range of sensors and mobile apps allow managers to make decisions based on reliable data.

The role of the integrator in the mechanical engineering process

The process of building production machinery is not just a purely engineering issue - proper project management and cooperation between the many participants in the process is crucial. The role of the integrator is to bring all the elements together into a coherent whole.

• Conceptual design. The integrator is responsible for creating the system concept and tailoring it to the client's needs.
• Coordination of suppliers. When different modules and components need to be ordered for a single project, the integrator ensures their timely delivery and compatibility testing.
• Support in testing and implementation. A key task is to carry out technical acceptance and staff training.

Examples of applications in various industries

Manufacturing machine building is not limited to one sector. Automated solutions and robotics are encroaching virtually everywhere, providing higher production efficiency and safety.

1. Food industry
   Machines designed for shredding, packaging or labelling food products must meet the highest standards of hygiene and sterility.
2. Automotive sector
   Robotised assembly lines perform repetitive tasks such as welding or painting. This requires sophisticated automation and precision control.
3. Cosmetics and pharmaceuticals industry
   The various dispensing equipment and packaging sealing systems must be characterised by rapid batch-to-batch transition and attention to the highest quality.

Would you like to explore more detailed examples of robotisation of your chosen process? You will find comfortable solutions in sections of our services.

Practical conclusions and recommendations

To summarise all the steps and solutions presented, the construction of production machinery is a complex undertaking that can be simplified with the professional support of an experienced integrator. Below are the key recommendations:

• Carefully plan the conceptual phase. This is the moment to review financial and technological assumptions - even a minor mistake at the start can generate significant costs in the future.
• Invest in prototyping and testing. This avoids duplicating mistakes on the production line.
• Think long term. Consider how the machine affects the entire production chain and whether it could easily be expanded with new technologies (e.g. robots, vision systems).
• Remember the service. Regular maintenance and inspections are essential to keep machines running efficiently and without unplanned downtime.
• Consider robotisation in areas of repetitive activity. These are the areas where the investment usually pays off the fastest, as ROI analyses confirm.

Summary

The construction of production machinery is a multi-phase process that begins with a sound needs analysis and ends with final testing, taking into account safety and quality. In each of these phases, proper planning and knowledge of the latest trends in industrial automation, as well as cooperation with qualified specialists, become crucial.

We encourage you to follow our upcoming articles, in which we introduce you to aspects of robotisation, the integration of vision systems or the implementation of advanced production analytics. At Michale Automatyka, we focus on comprehensive support - from the design of machines and production lines to their full integration and service.

Share this article and visit our blog to keep up to date with the latest implementations in the world of industrial automation. If you have questions or would like to consult on your project, feel free to contact us. We will be happy to help you create tailor-made solutions and equip your company with modern, efficient and scalable production machines.

FAQ

How long does it take to build a production machine?
Time depends on the complexity of the project. For simpler machines, a few weeks are sufficient, while for more complex lines with robotics and automation elements, it can take up to several months.

Is it possible to retrofit an existing production line?
Yes. In many cases, instead of building new machines from scratch, it is more cost-effective to introduce retrofitting and robotisation of workstations already in operation. This reduces downtime and costs.

How to assess the potential savings from automation?
You can use dedicated tools such as our ROI calculator. You will get an estimate of your return on investment, taking into account factors such as cycle time, labour costs and risk of downtime.