Manufacturing robot - how to integrate it into an existing production line?

Estimated reading time: 10 minutes

TL;DR:

• Integrating a robot into an existing production line increases a company's competitiveness
• A thorough analysis of processes and technical requirements is necessary
• Properly planned implementation ensures cost optimisation and higher product quality
• Staff training and safety are key
• The success of deployments in various industries demonstrates the flexibility of robotic solutions

Table of contents

- Introduction
- Potential for integration of a production robot into an existing line
- First steps: needs assessment and process analysis
- Integration stages
- Examples of use in various industries
- Key integration challenges
- Practical tips and tools to support integration
- Example of integration of a SIASUN robot into a production line
- Conclusions and recommendations
- Summary

Introduction

Today, the production robot plays a key role in industrial automation, often determining a company's competitiveness in the market. More and more companies are looking for ways to effectively integrate a robot into their existing production lines in order to increase production capacity, reduce costs and improve product quality. In this article, we discuss the most important aspects and steps of integrating a production robot into a company's existing infrastructure. We explain step-by-step what to look out for and provide practical tips to avoid costly mistakes. Using this information will make it easier for your company to move smoothly through the process of robotising your production lines and bring you closer to the benefits of implementing modern solutions.

Potential for integration of a production robot into an existing line

In an era of industrial technological revolutions and a continuous rise in market expectations, the efficient use of robotic equipment can significantly increase production efficiency and product quality. The introduction of a production robot into an already operating plant infrastructure in many cases means:

• Cost optimisation and reduction of errors,
• Improving staff safety,
• A more stable, automated workflow,
• Ability to adapt quickly to changing needs (e.g. order volumes).

At Michale Automatyka - a company dedicated to industrial automation and the implementation of robotic workstations in manufacturing companies - we have repeatedly encountered situations where the proper integration of a robot into an existing line has been a breakthrough, allowing companies to gain a significant competitive advantage. Such a process can range from optimising existing machines to retrofitting the line with new equipment and coordinating software.

Why is retrofitting for robotisation so important?
In today's economy, where human labour costs and market pressures are increasing year on year, any innovation in production efficiency translates directly into profits. Automating lines with a production robot not only ensures a more efficient work rate, but also allows for more effective management of raw material resources and optimisation of material flow (so-called intralogistics). As a result, processes become more sustainable, less error-prone and more stable in the long term.

First steps: needs assessment and process analysis

Diagnosis of production needs

Before you start selecting a specific robot and planning the integration, it is necessary to diagnose the current needs of the company in detail. It is worth dissecting step-by-step what tasks are to be automated and why. Is it about handling heavy parts, welding or perhaps packaging the final product?

Definition of key line parameters

• Line capacity in cycles per hour,
• The types of products produced on the line,
• Production space available,
• The expected speed and quality of the final product.

Establishing the technical and business requirements early on will allow the right robot model and integration method to be tailored. This is the key to a smooth transition to the next stages.

Integration stages

Design and planning

At the initial stage, an integration design is created. Among other things, the layout of the existing line, the arrangement of machines and people, and the transport paths for raw materials and finished products must be taken into account. When creating a new robotic station, it is also crucial to plan safety areas such as cages, light barriers or vision sensors.

Software engineering and simulation testing

Once the design has been created, it moves on to software preparation and simulation testing. This makes it possible to anticipate possible collisions or downtime associated with an inefficient robot path. Simulations allow the robot parameters, line routing and machine configurations to be modified in real time, without the costs incurred during actual production.

Installation and implementation

Once the design and simulation tests are approved, installation can begin. The production robot is installed on the shop floor - usually in a specially prepared area connected to existing equipment. At this stage, the interaction between the plant's maintenance department and specialists from the integrating company (in this case a company such as Michale Automation) is crucial. This is followed by a commissioning test phase to verify compliance with the design objectives under real-world conditions.

Optimisation, monitoring and maintenance

Once the robotic line is up and running, it is time to optimise and monitor key indicators (productivity, downtime, product quality). Typically, the first post-implementation period is an intensive period of minor adjustments, including teaching the robot additional motion paths, corrections in sensor software or integration with ERP/MES systems.

• Regular maintenance: it is important to keep a schedule of inspections, maintenance and replacement of operating parts.
• Real-time monitoring: systems to analyse performance and collect data on downtime.

Examples of use in various industries

Food industry

Due to the need to maintain high sanitary and quality standards, robotic production stations in the food industry are often responsible for packaging, sorting or labelling products. The robot is able to work under refrigerated conditions and in constant contact with vision systems to catch sub-standard products. In addition, it is easily adaptable to changing product lines.

Metal and engineering industry

For tasks such as welding, grinding or painting, robots adapted to work in harsh, dusty environments are ideal. Examples include robotised welding or robotised grinding, where the repeatability and precision of the robot's work significantly exceeds that of a human and increases operator safety.

Chemical and cosmetics industry

When deploying a robot in the chemical industry, it is particularly important to meet safety standards and accurately dispense substances. Very similar challenges arise in companies dealing with cosmetic products, where precise work in areas exposed to high humidity, varying temperatures or contact with viscous substances is often necessary.

Key integration challenges

Safety and health standards

Any implementation of a manufacturing robot should take into account:

• Health and safety standards for robotic equipment,
• The need for safety barriers, guards and interlocks,
• Training of the crew in the operation of the machine.

Alignment with existing ERP/MES systems

Integration should not just be limited to physically integrating the robot into the line. It is also important to configure IT systems (e.g. ERP, MES) in such a way that they can collect performance data in real time and ultimately adjust the production plan in real time. The more extensive the existing IT systems are, the more work may be required for full automation and digitalisation.

Staff training and team approval

Humans always remain an important part of the production process, despite the robots being introduced. Successful integration depends to a large extent on employees being properly trained in the use, maintenance and programming of the robot, as well as on building a positive organisational culture around the idea of automation. Openness to change and willingness to work with the robot in many plants is proving to be a key success factor.

Practical tips and tools to support integration

The role of industrial automation and vision systems

- Vision sensors scanning the shape and position of components together with image analysis software can steer the robot in real time.
- Advanced force or torque sensors allow processes that require subtle pressure (e.g. assembly of delicate components).

Additional accessories and peripherals

Often robots require specialised tools for their work, so-called end-of-arm tooling: grippers, welding torches or grinding heads. An integrator, such as Michale Automatics, selects these based on product characteristics and line specifics. Equally important are conveyors, rotary tables or vision systems that ensure work continuity and synchronisation with other production stages.

Example of integration of a SIASUN robot into a production line

Michale Automatics is the official distributor of SIASUN robots - advanced machines with high precision, robustness and flexibility. One model of particular interest to our customers is the SIASUN SR25A-12-2-01 robot.

Characteristics of the SIASUN production robot

- High payload and arm reach,
- Speed of movement to achieve high production rates,
- Stable construction, resistant to external influences,
- State-of-the-art software for easy integration into vision and ERP/MES systems.

Key benefits of implementation

- Reduction in manual operations and downtime,
- Precise repetition of the same steps, resulting in a higher quality product,
- Reducing the risk of errors and material losses,
- Easy expansion with additional workstations in the future.

If you are wondering which robot will fit your company's needs, we encourage you to browse the
SIASUN Robot SR25A-12-2-01 on our website.

Conclusions and recommendations

Key lessons from integration
1 Detailed analysis before implementation is crucial. An ill-fitting production robot or poorly designed workstation can lead to inefficiencies and generate unnecessary costs.
2 It is worthwhile to ensure adequate training and service support. Every production line changes over time, so operators need to be able to make small software modifications themselves and take care of ongoing maintenance.
3 Universal systems and the ability to change over quickly allow the plant to develop towards further robotisation.

How to prepare for further robotisation?
- Invest in growing staff competence: training, workshops, certification programmes.
- Plan next steps for improvement, e.g. robotisation of welding, packaging or grinding - we offer dedicated solutions such as
robotisation of packaging or robotisation of welding.
- Remember to regularly service and maintain your robotic workstations to ensure their longevity and reliability (you can read more about this in the
servicing and maintenance of stations).
- If you are planning further investments, pay attention to the potential for ROI calculations to accurately estimate the payback of robotisation.

Summary

Integrating a production robot into an already operating line requires meticulous analysis, concretisation of objectives and close cooperation between developer and integrator. Thoughtful implementation, taking into account security, communication flow with IT systems and staff training, results in cost optimisation, increased productivity and improved quality control. To achieve the best results, it is worthwhile:

• Approach the project holistically: take into account the current infrastructure, IT systems, the nature of production and future growth of the company.
• Bet on a reliable partner: who will lead the turnkey integration. At Michale Automation, we specialise in the comprehensive implementation of robotisation projects - from initial analysis to post-launch support.
• Consider successive, phased expansion: starting from a single robotic station to a highly automated 4.0 line.

Automation and robotics are constantly evolving. Sometimes all it takes is one robotic workstation to revolutionise processes and pave the way for further improvements. Read more about our
robotisation services in various production areas and find out how a robot can improve work in your facility too. If you would like to share your experiences, ask questions or find out more, please do not hesitate to contact us - we will be happy to advise and assist you on your path to effective robotisation.

We also encourage you to check out the other articles in our section
automation services, and if you need additional information, get back to us! Follow our blog to keep up to date with industry trends. Share this article with your friends and colleagues - let the knowledge of effective manufacturing robot integration reach everyone who wants to develop modern companies.

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.