Robotisation of production processes: step by step to effective automation

Estimated reading time: approx. 10 minutes

TL;DR:

• Robotisation is a response to rising labour costs and the need for high quality products
• It is worth starting with the processes repetitive and most vulnerable to human error
• The key stages are auditrobot selection, design, testing and team training
• With the right integration and service, it is possible to rapid return on investment (ROI)
• Robotisation provides scalabilitysafety and stable production efficiency

Table of contents

• Introduction
• Why is robotisation of production processes becoming essential?
• Needs analysis and selection of the process to be robotised
• Next steps in implementing manufacturing robotisation
• Examples of applications of robotic production processes
• Success factors in process robotisation
• How do you calculate the potential return on investment (ROI)?
• Examples of robotisation implementation strategies
• Support Michale Automation in the robotisation of your plant
• Internal linking - developing the theme of automation
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Robotisation of production processes is gaining in popularity year on year - especially in the face of rising labour costs, staffing challenges and the need to maintain high product quality. A number of studies (including IFR reports published in recent years) show that companies investing in automation and robotisation significantly improve their efficiency and reduce the impact of potential downtime on production flow. In this article, we will show you step-by-step how to prepare for the implementation of robotisation in your plant, what to pay attention to and what practical benefits you can gain. You will also learn how Michale Automatika can help you robotise selected stages of your production, as well as how - being an official distributor of the SIASUN robots - we provide comprehensive technical and service support.

Why is robotisation of production processes becoming essential?

The robotisation of production processes is not a fad - it is a response to the specific challenges of modern industry. In an era when customers expect ever higher quality, faster lead times and the ability to personalise orders, companies need solutions that ensure stable productivity.

Key benefits of a robot in the company

• Improving repeatability and quality: Robots run processes with a precision that is difficult to achieve when operating manually, eliminating human error.
• Improving worker safety: Robotised workstations take over monotonous and dangerous tasks and require only supervision and periodic servicing.
• Lower costs in the long term: Although the investment in an industrial robot may seem high at the outset, the rapid return on investment (ROI) is due to the reduction in labour costs, the reduction in production shortages and the elimination of so-called quality downtime.
• Scalability and flexibility: Robotisation allows us to respond more quickly to increases in demand, changes in customer specifications or the need to introduce new products into the range.

Market trends according to reports

According to the latest reports from international organisations (e.g. IFR), it is particularly noticeable that investment in automation and robotics solutions in the countries of Central and Eastern Europe is increasing rapidly. The region's industrial recovery is translating directly into the number of robots being installed. Companies are increasingly opting for the full integration of vision systems, the use of cobots (collaborative robots) and the integration of artificial intelligence into real-time analysis of production data.

Needs analysis and selection of the process to be robotised

Preparation for the implementation of robotisation should start with a thorough analysis of production processes. Not everything is worth automating at the same time. There are areas where robotisation will have a quick and visible effect, and areas that may require complex integration and are better left for a later stage.

Which processes are worth robotising in the first place?

• Repetitive and monotonous processes: Examples include packaging, palletising or feeding components to the assembly line.
• Operations subject to human error: Grinding, painting, nocturnal welding - wherever repeatability and precision determine product quality.
• Hazardous activities: Any workshop or workplace with a higher risk of injury (e.g. welding in an awkward position) can be automated, improving human safety.
• Time-critical operations: If the production bottleneck lies in manual packaging or component preparation, automation will eliminate this bottleneck.

Examples of questions to ask yourself

• Is the process stable enough and can it be standardised?
• Do we have figures on errors, downtime, costs?
• How quickly do we want to recoup our investment (ROI assessment)?
• How have costs within a process changed over the years (material costs, employee costs)?
• Are we planning to expand our product range in the near future and therefore need to provide a flexible layout?

Next steps in implementing manufacturing robotisation

1. Consultation and audit of processes

In the first stage, it is important to consult an integrator company such as Michale Automation, which specialises in the construction of machines and production lines and the implementation of robotic workstations. During the audit, the specialists check, among other things:

• which levels of production can be automated relatively easily,
• whether line modifications will be necessary,
• what range of movement and lifting capacity the robot should have,
• which security systems to implement,
• whether integration with an ERP/MES system is needed to track data in real time.

2. selecting the right robot and components

Based on the analysis, specific hardware solutions are selected. Much depends on:

• type of tasks (welding, painting, packaging, etc.),
• the reach of the robot arm and the necessary load-bearing capacity,
• required precision and speed,
• available space in the plant,
• the company's development plans (whether the position will need to be expanded in the future).

Michale Automation as official distributor SIASUN robots uses a wide range of industrial equipment. Examples include robot SIASUN SR25A-12-2-01. This model features high precision and flexibility in configuration, making it suitable for a wide range of industries.

3. stand design and integration with existing line

The next step is the comprehensive design of the robot workstation, taking into account, among other things, the fast motion path of the manipulator, the ergonomics of the supervisors and the safety of the entire workstation. During the design phase, layouts, 3D models and simulations are developed to anticipate possible collisions or suboptimal movements.

4 Testing and commissioning

Before the workstation is put into permanent operation, a series of tests are performed, e.g. quality tests, performance tests or simulations of various production scenarios. Only after it is ensured that all parameters meet expectations does installation in the plant take place.

5. staff training and performance monitoring

Crews need to be trained in the use of the new solutions, and key personnel need to acquire the competence to monitor performance. The automated workstation should also be subject to ongoing analysis of indicators (e.g. OEE). The spread of data, such as the number of parts processed, the number of quality rejections or service downtime, makes it possible to continuously optimise the robot's performance.

Examples of applications of robotic production processes

Robotisation of welding

Welding is one of the most frequently robotised processes - mainly due to the significant impact of the quality of the welds on the safety of the final products. Examples of industries: automotive, metallurgy, steel structure manufacturing. If you would like to learn more about the possibilities and benefits of robotisation of welding, we invite you to take a look at the details.

Robotisation of packaging and palletising

Companies in the FMCG (fast moving consumer goods) sector, e-commerce or logistics operators are increasingly relying on automated solutions for packaging and preparing goods for transport. Robotisation of packaging enables high productivity, flexible assortment changes and minimises the risk of picking errors.

Vision systems and quality control

Advances in vision systems mean that a robot can not only move objects from point A to point B, but also carry out precise quality control on the fly. The use of 2D, 3D cameras or deep learning technology makes it possible to detect defects that are not visible to the naked eye.

Flexible assembly stations

The dynamic market necessitates frequent changes in the production model, which in turn favours the implementation of modular robot workstations. These enable a company to quickly adapt robots to assemble a new product or a different variant within the same product.

Success factors in process robotisation

Working with an experienced integrator

The basis for a successful implementation is close cooperation with an experienced integrator company that will identify best practices, solve technical problems and ensure compliance with safety standards. Michale Automatics provides support at every stage of the project.

Comprehensive service and maintenance

One of the key aspects is to regularly inspect sites and check key components. Neglecting maintenance can quickly reverberate into weeks of downtime and repair costs. If you would like to know more about the range of support we provide following the implementation of robotic workstations, we recommend the following servicing and maintenance of stations.

Continuous process improvement and software updates

Robotisation is not a one-off project. Once a job has proven itself, plans can be made to automate further processes. Changing technologies and robot software (e.g. in the area of AI) offer more and more possibilities, such as automated optimisation of movement trajectories.

How do you calculate the potential return on investment (ROI)?

One of the main questions that is asked during the robotics planning phase is "when will we start making money?". In reality, ROI depends on several elements:

• the cost of purchasing and installing the robot,
• savings on labour costs (for example, replacing employees for the most repetitive and tiring tasks),
• reducing downtime,
• reduction of quality deficiencies,
• an increase in production with possibly the same employment.

Some industries record a return on investment in as little as 12-18 months. In more complex processes (especially assembly), the ROI can be slightly longer.

Examples of robotisation implementation strategies

Gradual modernisation of the line

Many companies are opting for step-by-step robotisation:

1. They choose one area that will produce the quickest or most tangible results (e.g. packaging).
2. Once the results are positive and the ROI analysed, they extend robotisation to further stages (e.g. welding or quality control).

Complete transformation of the plant

Alternatively, large companies - financially ready to make large investments - are introducing robots into almost all key processes simultaneously, creating a comprehensive automated production ecosystem. Such a strategy, however, requires:

• in-depth knowledge of manufacturing mechanisms,
• a ready-made "plan B" in case of technical problems,
• smooth integration into ERP/MES systems,
• a dedicated project management team.

Support Michale Automation in the robotisation of your plant

Michale Automation specialises in the design and implementation of complete industrial automation solutions. We support companies at every stage of robotisation - from the initial audit, through component selection to final integration and service. We create bespoke workstations tailored to the needs of a specific company, ensuring that they are flexible and can be developed in the future.

• Many years of experience in the construction of machinery and production lines allows us to quickly and reliably assess which processes are worth automating first.
• Individual approach to each project means that the solutions created by Michale Automation actually translate into lower costs and increased production.
• As an official distributor of SIASUN robots we have direct access to a wide range of state-of-the-art industrial robots, which increases the possibilities to match different applications - from lightweight cobots to high-capacity robots.

Internal linking - developing the theme of automation

• If you're thinking about robotic welding, take a look at our page about robotisation of welding.
• Find out how Michale Automation is bringing modern robotisation technologies to manufactories and industrial plants: robotisation.
• Find out the benefits of properly servicing robotic workstations: servicing and maintenance of stations.
• Find out more about the possibilities offered by SIASUN-branded robots in production facilities: SIASUN works.

Practical conclusions and recommendations

Robotisation can give your business the opportunity to:

• Reducing labour costs and increasing productivity: The productivity of robots can be many times higher than traditional solutions.
• Maintaining consistently high quality: Even weld spacing, repeatable material feeding - all of this reduces the number of defects.
• Protecting employees and improving health and safety conditions: By having robots take over hazardous tasks, significant health risks are eliminated.
• Scalability and rapid adaptation to change: If the product is modified, the robotic station can be rearmed without great expense.

Recommendations:

1. Conduct a preliminary process audit - see where the most common errors and stoppages occur.
2. Assess the potential ROI - calculate the costs and compare them with the expected profits.
3. Find a trusted partner - an experienced integrator will help avoid costly mistakes in the selection and implementation of solutions.
4. Plan your training - for the team to be able to work effectively with the robots, control their work and diagnose any problems.
5. Take service and maintenance into account - Regular maintenance will extend the life of the robots and minimise downtime.

Summary

Today, the robotisation of production processes is an indispensable step in the development of companies focused on growth, reducing operating costs and increasing production flexibility. Thanks to the precision of robots, the reduction of human errors and better resource management, it is possible to remain competitive even in the most demanding markets.

If you would like to find out more about how Michale Automation can help you robotise your production line, we encourage you to check out our services and specific offers, such as in the areas of welding, packaging or service. Leave a comment, subscribe to our newsletter or contact our team directly - we'd be happy to help you find the perfect solution for your needs.

With the right planning, a partnership with a qualified integrator and the use of the latest robotics technology, your company will gain an edge in both quality and production efficiency. Robotisation of production processes is a future you can start creating today.

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.