How to combine robotics and automation with an ERP system to track production in real time

Estimated reading time: approx. 8 minutes

TL;DR:

• ERP integration with robots provides a complete overview of production data in real time
• Automatic reports and analyses facilitate resource planning and reduce errors
• Effective implementation requires a well thought-out architecture, testing and staff training
• Gradual introduction of automation minimises the risk of downtime and errors
• ROI analysis assess the profitability and gain support for the investment

Table of contents

• Introduction
• Importance of ERP integration with robotics and automation
• Benefits of integration
  • Ongoing tracking of performance indicators
  • Optimisation of resource use
  • Automatic generation of reports and analyses
• How to integrate robotisation into ERP step by step
  • Planning stage and needs analysis
  • Selection of suitable hardware and software solutions
  • Implementation and testing
  • Staff training and involvement
• Examples of areas of integration
• Challenges in integration and how to overcome them
• Practical tips and good practices
• Summary

Introduction

Robotisation and process automation are an increasingly common choice for manufacturing companies looking to improve productivity, quality and speed of order fulfilment. Properly designed lines, robotic workstations and integration with IT systems can bring tangible benefits in the form of cost savings and better control over the manufacturing process. However, only full integration with an ERP (Enterprise Resource Planning) system allows effective real-time production tracking and business decisions based on up-to-date data.

In this article, we will answer the question of how to combine robotisation and automation with an ERP system in order to fully exploit the potential of the collected production data. We will also suggest what to look for in the planning and implementation stages of new solutions. This will give you a comprehensive view of both technology and business that can help your company make the most of its resources.

If you operate in the industrial sector and are considering implementing advanced solutions to support manufacturing processes, this guide is for you. After reading it, you will know what specifically the combination of robotisation with an ERP system offers and how to avoid the most common mistakes during implementation.

Importance of ERP integration with robotics and automation

One of the most important aspects of robotisation and automation of production processes is optimisation - both in terms of cost, time and quality of final products. Undoubtedly, quick access to data and its correct interpretation are of key importance here. The ERP system is responsible for collecting and processing information on orders, stock levels, machine performance and production schedules.

However, if robots and machines operate in isolation from the ERP system, databases may be incomplete or outdated. Without real-time production tracking, it is more difficult to respond to changing market demands, process downtime or even minor operator errors. Integration allows machines and people to be fully coordinated and therefore increases the company's ability to make quick decisions.

At Michale Automatyka, we are noticing an increasing demand for projects that take into account both the physical construction of the production line and advanced integration solutions with IT systems - including ERP. As an official distributor of SIASUN industrial robots, we help companies to design and implement complete solutions that, on the one hand, ensure stable, automated production and, on the other hand, extend the functions of the ERP system with a complete view of data from the individual stages of manufacturing.

Benefits of integration

The basic rule of thumb is: only an integrated ecosystem - from robots to production workstations to ERP - enables you to extract the real-time information you need to manage your business efficiently. Let's look at the key benefits of such integration.

Ongoing tracking of performance indicators

With robots equipped with sensors and systems that monitor operating parameters (e.g. speed of operations, arm load, temperatures), companies can collect data on the progress of the manufacturing process. When integrated with an ERP system, this data gains business context - it can be cross-referenced with order information, the amount of raw material in stock or even the sales plan for the following weeks.

Immediate access to key indicators (e.g. OEE - Overall Equipment Effectiveness, line efficiency, downtime) enables a rapid response to undesirable situations. As a result, production managers know whether the implementation of the plan is going according to plan and can take corrective decisions if deviations are detected.

Optimisation of resource use

By acting on the current data provided by the robots and collected in the ERP system, the company can plan logistical operations (procurement, transport, warehousing) more efficiently, as well as the distribution of work between departments. If the system indicates that a certain part of production will be over-performing, resources can be redirected immediately to more priority tasks.

This flexibility reduces the risk of bottlenecks and congestion on the line, which often result from poorly planned, manual processes. What's more, a consistent data exchange platform also minimises the costs associated with potentially over-ordering raw materials or holding large reserves.

Automatic generation of reports and analyses

Data from robotic lines can be instantly recalculated and presented in integrated applications, showing quality indicators, the real cost of production or the need for specific materials at any given time. This type of automation of report generation significantly reduces the number of errors that occur when data is entered manually.

Instead of wasting time tediously collating information from various databases, managers have it at their fingertips, ready for further analysis and interpretation. This saves time and allows them to focus on more strategic activities, such as developing new products or entering new markets.

How to integrate robotisation into ERP step by step

Full integration of robots and machines into an ERP system requires a clearly planned process. Below is a suggested path forward based on Michale Automatics' project experience.

Planning stage and needs analysis

The first step is to define the project objectives and the scope of activities. At this stage, it is important to ask what we want to measure, what reports will be needed and in which areas we will make the most use of production data. It is worth including not only the production department, but also representatives from logistics, sales and IT in the discussions.

• Determine whether you need full integration or only selected functionalities (e.g. real-time scheduling, material consumption reports).
• Analyse the workflow in the factoryto identify the key points at which robots transfer relevant data to the ERP system (e.g. packaging robots, quality control stations).

Selection of suitable hardware and software solutions

Not every production line or robot has built-in communication modules that support the most common data transfer protocols (OPC UA, MQTT, Profinet). It is therefore worth determining at the outset whether the current machines enable such connections or whether they will need to be upgraded. In the case of the industrial robots from SIASUN that we offer at Michal Automatyka, you have a wide range of communication options adapted to ERP standards.

Implementation and testing

The implementation of a system integrating robotisation and automation with ERP should be carried out in a phased manner to minimise disruption to ongoing production. Typically, one workstation or a selected process is integrated first, testing is carried out and only when this is complete does the project expand into further areas.

• Ensure data is mapped correctly - e.g. parameters from robot sensors have counterparts in the ERP database.
• Introduce alerts and notifications (push) in the ERP system that inform of possible anomalies during robot operation.

Staff training and involvement

Even the best-designed solution will be of no benefit if the team does not use it or know how to interpret the data. This is why it is so important to provide training for operators and the IT department, as well as ongoing after-sales support. At Michale Automatika, we often create dedicated manuals, organise workshops on the production floor, and provide for a cyclical audit of the condition of the machines.

Examples of areas of integration

Each industry can benefit differently from combining robotisation and automation with ERP. Below are examples where integration brings exceptionally large improvements.

Monitoring and control of packaging robots

Handling finished products, preparing individual parcels or stacking goods on pallets are activities that are often carried out by robots. If these robots work together with an ERP system, it is possible to automatically update the stock after packaging is completed. For example, in the event of increased demand for certain products, the system updates material requirements and automatically generates orders for raw materials.

If your company is considering investing in similar solutions, we invite you to learn more about robotisation of packaging.

Real-time quality control

The integration of the vision system with the robot and ERP provides the ability to automatically catch production errors and immediately flag parts or batches as defective. When too many deviations are detected, the system can suggest stopping the process and performing a line overhaul, in effect protecting the company from incurring losses.

Many of our customers opt for modular quality monitoring solutions, linked to ERP databases that store detailed information on the entire batch of products produced. This approach not only creates a basis for further analysis, but also facilitates the possible introduction of continuous improvement processes (Continuous Improvement).

Challenges in integration and how to overcome them

While the potential and benefits of integrating robotics and automation with ERP systems are huge, one should not forget the challenges that may arise along the way.

Technological complexity

Linking robots, PLCs, analytics software and an ERP system is no small task. Each device and application may have different requirements in terms of communication, protocols, data security. The solution? Thorough planning of the system architecture, working with an experienced integrator and testing the individual components before implementation on the target line.

Data security

Sharing production data between ERP and robots opens up additional communication channels. Any security vulnerability could lead to the leakage of sensitive production process information. Encrypted transmission protocols, regular security audits and network segmentation are therefore recommended. From a data management point of view, it is worthwhile for a company to implement clear procedures for granting and revoking access rights.

Ongoing maintenance and upkeep costs

The integrated system requires regular monitoring and servicing on both the machine (robot) side and the software layer. Minor updates to the ERP system can affect communication, and changing a module in a robot or sensor also requires checking that everything continues to interact with the ERP. Therefore, it is important to plan an adequate budget and resources for the maintenance of such a system in the long term.

At Michale Automatics, we provide after-sales support, servicing and maintenance of stations. In this way, customers can be assured that integrated production remains efficient and resistant to downtime.

Practical tips and good practices

The right approach to implementing the integration of robotisation and automation with ERP requires not only technical competence, but also change management skills within the company. Below are some proven tips:

Investment in training

Companies that plan to integrate robotic workstations with ERP need to ensure that employees understand why we are doing this and what the benefits will be. It is also the role of managers to explain that robots do not replace humans 'automatically', but help eliminate highly repetitive or ergonomically burdensome tasks.

Gradual implementation

Even if the plan is to integrate the entire factory, it is a good idea to start with a smaller pilot project. This will allow you to work out procedures, test key functionalities and make adjustments where unforeseen difficulties arise.

Return on investment analysis

Implementing robots and an extensive ERP system represents a major expense. As in any optimisation project, it is worth calculating potential savings and efficiency gains. When calculating the ROI from robotisation, it helps (if only approximately) to have a convenient ROI calculator. Although this tool focuses mainly on the welding process, the mechanics of the calculation are universal and can be the starting point for creating your own calculation model.

Summary

Combining robotisation and automation with an ERP system is a step that can elevate the competitiveness of a manufacturing company to a whole new level. The ability to monitor processes in real time, automatically generate reports or respond immediately to changes in demand translates into greater flexibility and efficiency.

If you are considering such an implementation, it will be crucial to have a good understanding of the needs of all departments, meticulously design the data flow, and provide support and training for all staff involved in the process. With thoughtful integration, you will not only avoid downtime and errors, but also realistically reduce production costs, increase efficiency and gain the necessary data insights to make decisions faster.

We encourage you to familiarise yourself with our robotisation services, as well as with the other offerings available at Michal Automation, where you will find comprehensive solutions tailored to your business needs. If you have any questions, please get in touch or check out our other blog articles. Stay in touch with us so you don't miss out on the latest trends and tips for the robotics and industrial automation industry.

We hope that you now know how to effectively combine robotics with an ERP system to track production in real time. Good luck in modernising your processes and increasing your competitive edge!

FAQ

How long does it take to implement a system that integrates robotics with ERP?
The implementation time depends on the scale of the project, the complexity of the production processes and the readiness of the IT infrastructure. This can range from a few weeks for small-scale implementations to many months for complex projects.

Does the integration of ERP with robots mean that the current infrastructure has to be completely replaced?
Not necessarily. In many cases, upgrading machines and adapting them to support standard communication protocols is sufficient. Instead, it is crucial to check the compatibility of robots and PLCs with the ERP system.

Is robotisation putting people out of work?
Robotisation often takes over tasks that are monotonous and have a high risk of error or injury. Employees are then redirected to other tasks that require higher value-added skills. Usually, this is an opportunity to develop and re-profile competences rather than downsizing.