Line production: how to plan and implement successfully

Estimated reading time: 10 minutes

TL;DR

• Planning: carry out a thorough needs analysis and set clear objectives.
• Design and simulations: use tools to detect bottlenecks before investment.
• Automation: Consider industrial robots or cobots, especially in repetitive processes.
• Service and training: invest in regular reviews and develop the team's competences.
• Monitoring: analyse OEE indicators and data in real time.

Table of contents

• Why is line production so important?
• Steps in setting up a process line
• Automation and robotisation strategy for process lines
• Intelligent control systems and line production
• The role of a qualified partner - support from Michale Automatics
• Internal linking - where to look for additional information?
• Quality and safety assurance methods
• Trends in line production
• How do you calculate the profitability of producing a process line?
• Challenges and problems in implementation
• Practical applications - step by step
• Summary

Introduction

The production of process lines is a key step in the development of modern industrial companies. In an era of global competition, every minute counts and the efficient implementation of a new line can reduce labour costs, improve product quality and increase company flexibility. At the same time, market demands are increasing - customers want tailor-made solutions and maximum efficiency. In this article, we will discuss how to take a comprehensive approach to line production, what stages it consists of and what to look out for when implementing automation. You will also learn how Michale Automation (hereafter referred to as Michale Automation) can assist in the design and integration process of advanced solutions, including robotic workstations and dedicated machines.

Why is line production so important?

The production of process lines involves the creation of a consistent and reliable sequence of tasks, enabling specific products to be manufactured in a reproducible and as trouble-free manner as possible. Today, these lines are increasingly equipped with industrial automation solutions and robotic workstations.

Key benefits of a modern processing line

• Increasing productivity: Automation and robotisation allow you to operate without downtime and reduce production cycle times.
• Quality improvement: Precise, repeatable processes reduce errors and eliminate defects due to human factors.
• Occupational safety: The use of modern safety systems (e.g. safety barriers, sensors) protects staff from mechanical hazards and ergonomically improves working conditions.
• Scalability: Process lines can be expanded - adding more modules, robots, assembly stations - as the company grows.

Thanks to the increasing availability of advanced electronic solutions, sensors, control systems and robots (e.g. SIASUN robots, of which Michale Automatika is the official distributor), line management becomes transparent and easier to modify in the event of changing needs.

Steps in setting up a process line

The production of process lines is not a one-off event. In practice, it is a complex project requiring knowledge from different areas: from mechanics and pneumatics, to PLC control, to robotics and vision systems.

Analysis of needs and requirements

• Preliminary audit of the company's processes: Identifying which tasks in the production process need to be streamlined or automated.
• Defining key parameters: Production batch size, type of materials, required safety standards, investment budget.
• Identify development opportunities: Consider whether the designed process line is to be flexible (e.g. easily modifiable) or rather geared towards maximum efficiency for one type of product.

Design and simulation

• Technical design: Detailed machine drawings, electrical schematics, pneumatic diagrams and control concepts are produced at this stage. If the line includes industrial robots, their movement trajectories and operator workstations are also defined.
• Component selection: Choosing the right type of motors, PLCs, sensors, vision systems and - very often - robots (e.g. the SIASUN SR25A robot, available from Michale Automatyka).
• Performance analysis: Creating simulations allows potential bottlenecks to be predicted, line performance to be examined and cycle times to be realistically estimated.

Construction and integration into existing machinery

• Mechanical assembly: Realisation of physical construction, assembly of components and mechanical connections.
• Wiring and control implementation: Installation of sensors, connection to industrial networks (e.g. Ethernet) and configuration of the control system.
• Factory tests (so-called FAT): Running parts of the line under factory conditions is intended to confirm that the entire system is working as intended.

On-site installation and commissioning

• Transport and installation: Placement of the process line in the target production hall.
• SAT (Site Acceptance Test): Re-checking the operation of the system under real conditions.
• Training of operators and maintenance staff: Imparting the necessary knowledge of operation and maintenance.

Optimisation and service

• Analysis of operational data: After a few weeks or months, it is worth conducting an in-depth analysis and making any adjustments to the line parameters.
• Service agreement: Regular inspection and maintenance often is a requirement to keep the machine running at maximum efficiency.
• Scaling up and modernising: Further modules can be added, additional steps can be robotised or the system can be integrated with ERP/MES.

Automation and robotisation strategy for process lines

The use of various automation methods speeds up work and increases repeatability. At the same time, the question arises: should we rely on classic industrial automation or implement industrial robots or cobots (collaborative robots)?

Selection of robots and control systems

• Industrial robot vs cobot: Industrial robots excel at tasks requiring high speed, while cobots are easily adapted to work around people, which can be important in smaller halls.
• Integration with additional systems: Among others, vision systems (for detecting workpiece alignment or for quality control), automatic feeders, measuring systems.
• Official distribution of SIASUN robots: Availability of spare parts, service support and ongoing updates are assets that can significantly speed up implementation work.

Examples of robotisation applications

• Robotic packaging stations - Thanks to vision-based shape recognition systems, robots deposit products in the carton in an organised and repeatable manner.
• Robotisation of steel and aluminium welding - robots equipped with the right accessories can maintain a constant welding speed and angle, positively influencing the quality and safety of the work.
• Detail painting and varnishing - The robotic spray gun provides even, streak-free coatings while protecting human health from chemical fumes.

Intelligent control systems and line production

Modern process lines are not just an arrangement of machines responsible for individual tasks, but also - and perhaps above all - an extensive control system. Increasingly, integrations with production management systems (ERP/MES) are being implemented to:

• Real-time production tracking: Information on the condition of the machines, quantities produced or OEE (Overall Equipment Effectiveness) indicators enables a rapid response to errors.
• Cost optimisation: Consumption of energy, tools and human labour can be monitored and compared with projections.
• Data-driven decision-making: Automatic failure reports and trend analysis help to plan maintenance in advance.

In practice, Industry 4.0 solutions are increasingly being used - implementing the combination of machines, sensors, robots and IT systems into a single network, so that the whole works like an integrated ecosystem.

The role of a qualified partner - support from Michale Automatics

The process of creating a technology line can be lengthy and challenging, which is why many companies opt for the support of external experts. By working with an experienced integrator, you reduce the time it takes to achieve the desired result and gain confidence that your company's internal resources will not be overwhelmed.

Michale Automatika is a company with many years of experience in the implementation of automation and robotisation projects, including the construction of machines to specific customer requirements. As an official distributor of SIASUN robots, the company is able to complete and integrate the entire turnkey production system - from analysis to the finished solution.

Internal linking - where to look for additional information?

When planning your own process line, it is worthwhile to familiarise yourself with the services that Michale Automation offers. Here are some useful links to expand your knowledge:

• If you want to see the full range of industrial automation services, check it out: Automation services
• Looking to learn more about how the robotisation of various production processes is taking place? Take a look here: Robotisation
• Welding steel, aluminium or other plastic - you may be interested: Robotisation of welding
• Curious about one of SIASUN's popular robot models? Browse through: SIASUN SR25A robot

Quality and safety assurance methods

Quality and safety are the two pillars of any process line operation. In practice, this means carefully conducted tests, quality control and measures to minimise risks to people.

Implementation of ISO and industry standards

• Stabilisation of process parameters is easier when the line follows well-defined procedures.
• Compliance with EN standards (e.g. for electrical equipment, machinery) avoids accidents and financial penalties.

Safety of operators and maintainers

• Use of light barriers, presence detectors and E-Stop systems (emergency stops).
• Appropriate labelling of danger zones, ergonomic height of workstations.
• Periodic machine inspections - provide assurance that the control system and mechanical components are working correctly.

Trends in line production

The production of process lines is becoming more and more oriented towards the implementation of Industry 4.0 concepts. Here are some current trends that can facilitate companies' competitive advantage:

• Internet of Things (IoT) and Big Data - systems that collect real-time data allow anomalies to be detected early and failures to be predicted.
• Video system integration - efficient visual quality control at the production stage minimises problems at a later stage.
• Robotisation of workplaces - stationary or mobile robots, crowded in guards or cooperating, can perform monotonous and repetitive heavy processes.
• Modularity and scalability - the growing popularity of flexible lines, which can easily be converted from the production of one product to another.

How do you calculate the profitability of producing a process line?

Investment in a new line generally needs a sound financial justification. A key indicator is the ROI (Return on Investment), or profit-to-cost ratio.

Costs to consider

• Purchase and installation of machinery - including design, construction, robots and control systems.
• Implementation and training costs - including PLC programming, infrastructure adaptation, staff training.
• Operating costs - energy, consumables, oils, lubricants, filters and possible replacement components in the robots.

Expected profits

• Reduction in labour costs for jobs that have been automated.
• Reduced production rejects (improved quality) and overall increased productivity.
• Gains from literal higher production or from services (in the case of companies offering spare capacity).

With more advanced systems, it is also worth considering an overall improvement in reputation - a modern company is more attractive to contractors and potential employees.

Challenges and problems in implementation

Despite its many advantages, line production also runs the risk of a misguided investment if certain issues are not taken into account.

• Competency gaps within the team: The maintenance department or operators may need new skills to operate robotic workstations.
• Adaptation too slow: Any modification of the production process can cause disruption, especially at the beginning.
• Integration with other systems: Not all older machines and IT solutions will easily work with the new control system.
• Excessive investment cost: If the line concept is excessive, it can strongly extend the original budget.

Practical applications - step by step

To summarise the key steps and advice involved in the production of process lines, it is useful to reach for a list of priorities:

1. Assess the current state: Investigate which processes in your production really need automation.
2. Define clear objectives: Specify target parameters, e.g. productivity, number of operators per shift, energy savings.
3. Take advantage of the simulation: Line simulation programmes allow bottlenecks to be detected even before investment.
4. Plan the integration well: Check that the new line will work with existing machinery and systems.
5. Prepare operators and staff: Training removes resistance to new technology and teaches the effective use of robots.
6. Determine the service model: Regular maintenance extends the life of the equipment and prevents serious breakdowns.
7. Measure effects: Gather data (e.g. OEE indicator) to inform decisions on process improvement.

Summary

The production of process lines is the foundation of modern industry and is the key to efficiency, competitiveness and high quality. A comprehensive approach - from needs audit, design, simulation to control system integration and the popularisation of robotisation - allows companies to better respond to market challenges.

We hope that after reading this article you now know how to plan the next steps to equip your company with an innovative and efficient process line. If you need support in building bespoke machines, implementing SIASUN robots or other industrial automation solutions, contact Michale Automation.

You will gain a reliable partner who will guide you through the entire process: from the first analysis to the final optimisation. Today's market demands not only quality and efficiency, but also flexibility and a vision for the future. With a modern technology line, your company is one step ahead of the competition.

Practical tips

• Think about integrating vision systems as early as the design stage - this enables better quality control and protects against errors at a later stage.
• Keep communication open with all departments - this ensures a more efficient exchange of information and a quicker response to any problems.
• Don't forget regular training - even experienced staff need continuous development, especially when new technologies and robots are being implemented.

Thank you for reading our guide. If you would like to learn more about robotisation, see concrete examples of the use of SIASUN robots or check out other completed projects by Michale Automatyki, please use the internal links above and browse through the range of solutions available. We wish you the best of luck with your new process line - may it be the start of a successful industrial transformation!

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 rely on retraining and professional development for the team.

Does robotisation only pay off for large companies?
Today, more and more small and medium-sized companies are embracing robotisation. Declining equipment costs and flexible solutions make it possible to achieve a favourable return on investment even for smaller operations.