Integration of robots in manufacturing industries - how to effectively combine modern automation with existing processes?

Estimated reading time: approx. 8 minutes

TL;DR:

• Robot integration is becoming crucial in manufacturing industries due to increasing demands and pressure on productivity.
• Step by step: define business goals, select robots, plan integration and test deployments, take care of training.
• Industries such as automotive, food and beverage, FMCG and electronics are benefiting particularly strongly from automation.
• The biggest challenges are compatibility of existing lines, health and safety issues and appropriate ROI calculations.
• Michale Automation supports the comprehensive selection and implementation of SIASUN robots, providing advice and service.

Table of contents

• Introduction
• What is robot integration in manufacturing industries?
• Step by step - how to prepare for the implementation of robot integration?
• The most popular areas for robot deployment in manufacturing industries
• Michale automation support for robot integration
• Key challenges in integration - what to look out for?
• Practical tips - how to start integration step by step
• What are the business benefits of robot integration?
• Summary - Integration of robots in manufacturing industries as an investment in the future
• Practical conclusions and recommendations
• FAQ

Introduction

Manufacturing industries are currently facing a number of challenges: customer expectations are rising, a rapid response to fluctuations in demand is needed, and labour and raw material costs continue to rise. In such a situation, automation and robot integration are key to remaining competitive and achieving higher productivity. In the following article, we explain what robot integration is in manufacturing industries, the benefits it brings and why it is worth introducing to modernise industrial processes. We look at both the specific implementation steps and the issues involved in selecting the right machines and systems.

After reading this text you will learn, among other things:
- Why robot integration is so important in most manufacturing industries today.
- What the step-by-step interaction of robots with existing process lines looks like.
- What to look out for when planning automation and how to carry it out optimally.
- How automation company Michale helps entrepreneurs with complex robot integration and service.

What is robot integration in manufacturing industries?

Robot integration in manufacturing industries involves the implementation and integration of industrial robots, cobots or other forms of automation into an existing production environment so as to maximise the benefits of the new solutions. This typically includes:

• Assembly and configuration of robots and peripheral equipment (e.g. vision systems, sensors).
• Integration of robots into existing production software (e.g. ERP, MES).
• Adjusting the process accordingly so that the robot can support humans in daily tasks or fully replace them where possible and cost-effective.

The use of robotic solutions allows:

• Relieving workers from monotonous or dangerous activities.
• Significantly accelerate production, especially where high repeatability, precision and speed are required.
• Reducing costs and reducing the risk of human error.

The importance of integration in the context of modern trends

According to industry estimates (e.g. from reports by the IFR - International Federation of Robotics), the rate of robot deployment in various sectors is accelerating worldwide. Many companies are systematically expanding their machine parks with new types of robots (e.g. delta robots, SCARA, cobots or mobile manipulators - so-called MoMas) in order to respond effectively to market pressures and increasing consumer demands.

Increasingly, companies, especially in industries such as food, automotive, packaging or electronics, are making full use of the capabilities of collaborative robots (cobots), which can operate safely alongside workers. This fusion of people and machines increases production flexibility, while also promoting higher health and safety standards.

Step by step - how to prepare for the implementation of robot integration?

Implementing robots in an existing factory or plant is a process that requires a proper plan and a balanced approach. Below are the main steps that typically need to be gone through before a new system is put in place.

1. diagnosis of business needs
- Defining the objective - is it key to increase productivity, reduce labour costs, improve quality or perhaps develop new services?
- Process analysis - identifying bottlenecks and tasks that are most worthwhile to automate.

2. choosing the right kind of robots
- Articulated robots - ideal for welding, painting or handling heavier components.
- Delta robots - great for when you need tremendous speed and precision when working with small objects.
- Cobots (cobots) - suited to working directly with people and are favoured in industries with high task variability.
- Mobile manipulators (MoMas) - combine an autonomous transport platform with a robotic arm, thereby increasing transport and assembly flexibility.

3 Integration of software and systems
- Combining robots with ERP or MES systems enables real-time production tracking and data fusion in a consistent manner.
- The additional implementation of IoT solutions or vision systems makes it possible to conduct advanced quality analyses or machine condition monitoring.

4. tests, simulations and virtual launch
- The creation of virtual twins (Digital Twin) enables potential problems to be analysed before changes are made on the shop floor.
- The simulations show where bottlenecks can occur and how much the production line will be able to accommodate higher loads.

5. employee training
- At the same time as installing the robots, it is worth taking care of qualified personnel.
- Trained workers gain the ability to operate and make minor adjustments to equipment themselves, reducing downtime and increasing crew safety.

6 Commissioning and further support
- After physical deployment, it becomes crucial to provide continuous service and monitor the activities of the robotic workstation to make any optimisation adjustments.
- For more extensive robotic solutions, the option for quick maintenance, service and software updates for changing needs will be extremely important.

The most popular areas for robot deployment in manufacturing industries

Every manufacturing sector can benefit from robotisation, but a particularly large increase in demand is seen in:

Automotive and engineering industry

- Due to the intensive repetitive work (e.g. welding or handling components), robots can speed up production and increase the precision of assembly.
- Articulated robots are considered standard here for bodybuilding, and new test benches are increasingly equipped with mobile manipulators.

Food and FMCG industry

- The integration of robots in packaging, labelling and even quality control processes helps to speed up the line and eliminate many human errors.
- With vision-based identification systems, robots can segregate products by shape or colour, resulting in less waste and easier assortment management.

Electronics and white goods

- Assembly of high-precision components (e.g. PCBs) requires a very high degree of accuracy, which is effectively achieved by SCARA or delta robots.
- Automation in the electronics industry prevents damage to sensitive components and maintains the quality of final products.

Metal working and specialised welding

- Robotised workstations are particularly suited where the continuity of the welding process is crucial and the working conditions can be arduous or dangerous for people.
- The design and implementation of robotic welding systems is one of the specialisations of Michale Automation, which is also the official distributor of SIASUN robots.

Michale automation support for robot integration

Michale Automation (often referred to as Michale Automation) specialises in the construction of machines, production lines and the implementation of robotic workstations in various plants. As the official distributor of SIASUN in Poland, we offer comprehensive support for single robots as well as entire turnkey solutions.

We deal with:
- Technical advice on choosing the right robot (e.g. for welding, painting, packaging).
- Design preparation and simulation work using virtual commissioning.
- Installation and configuration of robots, including necessary accessories.
- Integration with ERP/MES systems, as well as vision and AI systems.
- Staff training and full lifetime service.

If you are interested in welding robotics in particular, we encourage you to learn more about Michale Automation - find out more about welding implementations by visiting
robotisation of welding.

Key challenges in integration - what to look out for?

Extensive and heterogeneous environment

In some plants, the problem lies with older process lines that are difficult to fully adapt to work with modern robots. This is why it is important to analyse the compatibility of protocols, safety solutions and possible upgrades in advance, before the actual installation begins.

Employee safety

Although robots can operate in areas that are inaccessible to humans, it is important for cobots to provide adequate protection measures (e.g. sensors that stop the robot's movement when a collision is detected). In plants where there are still people operating machinery in the vicinity of robots, developing health and safety procedures that take into account the new technology is a priority.

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