Automation service - how to keep machines and robot workstations running reliably

Estimated reading time: approx. 7 minutes

TL;DR:

• Regular maintenance of machines minimises the risk of downtime and breakdowns.
• The automation service ranges from repairs to preventive measures and upgrades.
• Proper diagnosis and rapid response reduce downtime.
• Planning the maintenance schedule avoids unexpected costs.
• Documentation and data analysis help to improve service processes.

Table of contents

• Introduction
• Industrial automation service - what does the term mean?
• Why is regular maintenance so important?
• The most common challenges in servicing robotic machines and workstations
• Steps for proper automation service
• Modernisation versus automation service - why go the extra mile?
• Service costs - is it worth investing in professional support?
• How do you prepare a company for an automation service?
• Safety and ecology in automation service
• What forms of service cooperation does Michale Automation offer?
• Case study - modernisation of a robotic station
• Internal linking and additional resources
• Summary - how to implement an effective automation service in your company?

Introduction

Automation service is a key factor affecting the stability of production lines in companies of all sizes. In an era of intensifying competition, even the slightest downtime or error in machine operation can generate large costs. Therefore, it is worth taking a closer look at how to organise industrial automation service properly to ensure continuous production operations, higher product quality and employee safety.

The following article will show you why automation service plays such an important role in modern industry. You will learn how to plan maintenance and how to ensure the highest level of technical support in the event of a breakdown. Finally, you will receive practical tips on how to implement best service practices in your company.

Industrial automation service - what does the term mean?

Industrial automation service is a set of activities aimed at maintaining, repairing and modernising control systems and machines in production plants. We are talking here about advanced industrial robots, as well as sensors, controllers, drives and often even entire process lines working with MES or ERP software.

In today's reality, when companies decide to implement robotic workstations, 'automation service' is rarely just about one piece of equipment. Often, it is a service that ranges from fault diagnosis, replacement of faulty or worn components, to regular maintenance that can prevent future failures.

For companies such as Michale Automatyka (also often referred to as Michale Automation), which specialise in machine building, production lines and robot integration, the automation service completes the entire implementation process. In our case, it is comprehensive support in maintaining the highest quality and safety in production.

Why is regular maintenance so important?

Regular maintenance, which is part of the broader automation service, includes not only emergency repairs, but also preventive measures. In many cases, such preventive maintenance makes it possible to detect minor faults early on, which, if disregarded, can lead to a major breakdown generating large costs.

Here are some of the key benefits of regular maintenance:

• Less production downtime - rapid service and replacement of components at an early stage of wear minimise unplanned stoppages.
• Longer equipment life - Adequate lubrication, cleaning and control of wearing parts keep robots and machines running at optimum performance for much longer.
• Stability of production quality - An efficient automation system reduces the risk of errors and loss of process repeatability.
• Lower operating costs - Reducing the risk of a major failure in practice means spending less, while increasing the confidence of customers and business partners.

According to some industry reports, up to 70% of equipment failures are due to irregular or poorly managed maintenance. Therefore, professionally planned automation maintenance can significantly increase the profitability of a company in the long term.

The most common challenges in servicing robotic machines and workstations

Failures due to intensive use

In fast-paced industries - for example, food, automotive or metalworking - robots can operate 24/7. High workloads are associated with accelerated wear and tear of mechanical and electronic parts. Although today's robots are designed for high resistance to working conditions, intensive use requires more frequent maintenance and replacement of parts.

Problems with integration of new solutions

Sometimes a company will invest in a new technology or production line without considering compatibility with its existing machine base. In such a situation, even the best robot can be a source of faulty duty cycles if it is not properly matched to the physical and programming requirements of the plant.

Lack of adequate service personnel

One of the major challenges is the shortage of skilled professionals familiar with servicing automation and robotics. Seeking outside help on an emergency basis can be costly and sometimes involves additional downtime. The best solution is to establish a long-term partnership with a service company that reviews the customer's needs and offers a personalised maintenance schedule.

Steps for proper automation service

Error diagnostics

Every professional industrial automation service starts with a precise diagnostic. This is the point at which service engineers check the key operating parameters of the equipment. In practice, they use, among other things, specialised diagnostic programmes and analysis tools. This allows them to locate areas of excessive friction, elevated temperatures or communication instability in the industrial network.

Repair and replacement of components

Once a malfunction has been detected, there is a stage to rectify the problem. Whether it is malfunctioning sensors, electronic components or damaged mechanical components, the speed of response and availability of spare parts is crucial. When we schedule service in collaboration with Michale Automation, we can always count on the support of a fast service, which keeps downtime to a minimum.

Calibration and optimisation of operation

After replacing faulty components, it is worth recalibrating the robot or the entire line. Precise settings help to improve the repeatability of production operations and increase the safety of people and machines. It is also possible to implement micro-optimisations at this stage, such as reducing cycle times or using better sensor settings.

Documentation and lessons learned for the future

A professional service should always be completed with a protocol including:

• Description of activities performed.
• A list of the parts listed.
• Recommendations for further operation.

Such documentation helps to plan subsequent maintenance and possible machine upgrades. It is also a great reference point for engineers when similar problems arise in the future.

Modernisation versus automation service - why go the extra mile?

In many cases, periodic servicing of machines and robots is not just about fixing faults, but also the perfect time to make additional productivity-enhancing modifications. For example, if a company is producing increasingly diverse workpieces, one might consider changing the control software, replacing grippers or vision sensors.

Breakdown and maintenance can therefore turn into an investment that will translate into:

• Better alignment of robotic workstations with current company needs.
• Increased safety (e.g. implementation of new health and safety standards).
• Greater production flexibility (e.g. faster changeovers thanks to modern control systems).

Service costs - is it worth investing in professional support?

Automation service costs are sometimes seen as an 'unnecessary expense', especially in smaller companies. However, experience shows that a lack of proper maintenance and response to minor faults not infrequently ends in the costly replacement of entire control modules, motors or mechanical components.

An additional perspective is the so-called opportunity cost: how much does the company lose during production downtime? Depending on the industry, each unproductive hour is a loss of up to several tens of thousands of zlotys.

According to a report by the International Federation of Robotics (IFR), robots that are properly serviced are able to operate without failure for up to 10-15 years, which in the long term significantly increases the return on investment in automated processes.

If you are interested in how you can assess the profitability of investing in robots and process automation (also in terms of service costs), it is worth using dedicated tools. An example is the one available on our website ROI calculator welding robotisation, which, although focused on welding processes, can serve as a reference for initial analysis.

How do you prepare a company for an automation service?

Definition of the scope of work

The most important thing is to define what we specifically need. From minor overhauls of robotic workstations to complex repairs of entire lines. This list of priorities allows the service team to prepare accordingly for the work and estimate the time required for maintenance.

Setting deadlines and timetable

Timeliness is key. When developing a schedule, take into account the volume of production and your maintenance policy. Proper scheduling of downtime (or maintaining partial line operation) will significantly reduce the risk of unnecessary logistical losses.

Provide access to documentation and failure history

It is good practice to share previous inspection reports and possible repairs with service technicians. This way, the specialists know what to pay particular attention to and can efficiently suggest appropriate improvements.

Safety and ecology in automation service

The implementation of robotic solutions and automation is increasingly starting to meet strict health and safety standards and environmental requirements. During maintenance work:

• The condition of guards, barriers and safety sensors is checked.
• It takes care of the correct earthing and the correct condition of the cables to minimise the risk of electrocution.
• Attention is paid to whether machines emit excessive noise.
• In some cases, emissions measurements are carried out.

From an ecological point of view, correctly functioning industrial automation often translates into lower consumption of energy and raw materials. Regular maintenance maintains the energy efficiency of the equipment, which in the long term is not only good for the environment, but also for the company budget.

What forms of service cooperation does Michale Automation offer?

Michale Automatika provides comprehensive support in the area of both the implementation of robotic workstations and the subsequent servicing of entire production lines. In practice, this can mean one-off ad hoc repairs or long-term service contracts with a fixed maintenance schedule.

As part of its maintenance services, the company offers, among other things:

• Diagnosis and repair of a variety of faults, from mechanical to electronic.
• Upgrading components to bring older machines up to new control and safety standards.
• Technical support, including remote consultation and assistance in crisis moments.
• Ability to order spare parts quickly from trusted suppliers.

If you would like to find out more about how the servicing process for robotic workstations works, please see Service and maintenance stands. There you will find a lot of information about how we take care of maintenance in manufacturing companies.

Case study - retrofitting a robotic station in a medium-sized manufacturing plant

To better illustrate what an automation service looks like in practice, it is worth looking at an example implementation at a medium-sized company operating in the metal industry.

• Issue: Regular occurrence of failures in the operation of the welding robot. The robot began to generate inaccurate welds, leading to significant waste of material and time.
• Service action: In the first stage, an overhaul of all components was carried out. Several worn components in the drive system were replaced, the welding control software was updated and the welding gripper was calibrated.
• Effect: The machine has regained operational stability, reducing deficiencies by 40%. A new preventive maintenance schedule every six months has also been implemented.

In addition, as part of the modernisation, Michale Automatics proposed upgrading the control board to make it easier to integrate the system with other machines in the future. Operators were also trained, further minimising the risk of errors.

Internal linking and additional resources

Are you looking not only to service your machinery, but also to expand and modernise your company's processes? Check out our offer for robotisation, where we show how to combine modern machines with IT systems.

Our services also cover other areas of production process automation. Examples can be found under Services.

If, on the other hand, you are looking for practical tips on how your company can transform itself by implementing innovative technologies, be sure to take a look at the solutions we provide for regular maintenance and job modifications. Effective maintenance is a solid basis for further development and optimisation.

Summary - how to implement an effective automation service in your company?

- Plan ahead: Implementing a maintenance schedule will help you avoid mounting problems and the high cost of unplanned breakdowns.
- Regular calibration: It will help you maintain the precision and repeatability of your processes, which will translate into higher quality products.
- Upgrade when needed: Repairing faults is not enough. It is worth taking the opportunity to bet on modernisation to improve efficiency and safety.
- Hire the professionals: Choosing an experienced automation company, such as Michale Automatics, gives you a guarantee of fast response and availability of spare parts.
- Analyse the data and draw conclusions: Maintenance records make it easier to implement optimisation and cost planning.

A properly organised automation service is one of the most important pillars of modern production. Machines and robots that receive regular technical support run more stably and longer, guaranteeing higher quality and lower operating costs. This is particularly important at a time when technological innovation is setting the pace for many companies.

By implementing effective maintenance and upgrade plans, productivity can be increased while maintaining the highest standards of operational safety. As a result, companies can consistently improve their processes without worrying about repeated breakdowns or rising repair costs.

If you are interested in professional support in the field of automation service or are considering investing in new robotisation solutions, contact the experts at Automation Michale. We will be happy to help you select the best technological solutions and ensure that all elements of your production line function smoothly. We also provide ROI analysis tools for investment in process automation, allowing you to comprehensively plan the development of your business.

We hope that, through this reading, you recognise the important role that automation maintenance plays in keeping production running and profitable. Plan your maintenance activities today and don't wait for unpleasant surprises! We encourage you to subscribe to our blog and take a look at our full offer service and maintenance of posts - to ensure that your machinery is always ready for use.

FAQ

How often should maintenance checks be carried out at the production site?
The frequency of maintenance depends on the type of machinery and the intensity of its use. A minimum of one inspection per year is recommended as standard, but for 24/7 continuous operation it is worth considering shorter intervals.

Does increasing levels of automation mean more complex failures?
Automation requires specialised care, but it reduces the risk of human error. With proper maintenance and staff training, failures can occur less frequently than with semi-automated systems.

How quickly can you get support in an emergency?
This depends on the cooperation model. With long-term service contracts, the service company usually guarantees a priority response, even within a few hours. In the case of ad hoc assistance, the waiting time may be longer.

Does the modernisation of machinery always involve a long downtime?
Typically, upgrades are planned in consultation with the customer to minimise the impact on production continuity. A modern approach to servicing often allows some of the work to be carried out gradually or outside of main production hours.