How to implement step-by-step robotisation of production processes and prepare your company for the future

Estimated reading time: approx. 9 minutes

TL;DR

• Robotisation of production processes increases productivity and reduces costs
• Select the repetitive and most time-consuming processes to automate
• Identify business priorities and analyse return on investment (ROI) indicators
• Adequate communication and training reduce staff concerns
• Cooperation with an experienced integrator guarantees smooth implementation

Table of contents

• Why robotisation of production processes is the future of industry
• How to prepare your company for the implementation of robotic production processes
• Step by step: what the implementation of process robotisation looks like in practice
• Examples of areas of robotisation of production processes in factories
• The most common concerns related to the robotisation of production processes
• Practical conclusions and recommendations
• Summary

Introduction

Robotisation of manufacturing processes is no longer just a futuristic vision, but a viable solution that allows companies to increase efficiency, reduce costs and build a competitive advantage. In this article, we will explain why robotisation is becoming increasingly important in industry, what to consider before implementing automation, and practical tips on what steps to take to start this transformation and avoid unnecessary costs. You will also learn how Michale Automation, which specialises in machine building, production lines and industrial automation, can support the implementation of robotic workstations in both small, medium and large companies.

Why robotisation of production processes is the future of industry

Robotisation of production processes has become one of the most important industrial trends of the 21st century. According to market analyses, the greatest benefits of this change are primarily:

• Higher productivity and precision - robots can work continuously, achieving the desired quality in less time.
• Reducing costs and minimising errors - by eliminating repetitive, monotonous human tasks, rates of production shortages and accidents related to the human factor fall.
• Scalability of production - it is easier to implement changes in production cycles, introduce new products and increase flexibility without overstaffing.
• Quality maintenance and standardisation - robots are able to perform tasks according to a repeatable pattern, resulting in a higher quality final product.
• Worker safety - robots can take over dangerous tasks, reducing the risk of accidents on site.

In Poland, there is growing interest in both cobots (collaborative robots) and industrial robots designed for specific processes such as welding, packaging or assembly. Even small and medium-sized companies are increasingly considering investing in robotic workstations, as the benefits of robotising production processes are tangible enough to justify the costs incurred.

How to prepare your company for the implementation of robotic production processes

Here are some key steps to go through before introducing robots into everyday industrial operations.

Define your business goals

The first step should be to find out what you want from robotisation. Do you care about:

• Increased productivity and faster order processing?
• Reducing labour costs and downtime?
• Improving quality and reducing quality errors?
• Ensuring employee safety?

It is worth conducting a brief analysis to select priorities. For smaller companies, where budget pressures are particularly acute, cost containment and ensuring production continuity with variable staff availability will often be key motivations.

Choose the processes worth robotising

Even in highly automated plants, not all tasks are carried out by robots. It is best to start with processes:

• Repeaters - needing consistent, identical quality.
• Tiresome or hazardous to the individual (e.g. working at high temperatures or with harmful substances).
• With high human labour costs and a relatively low risk of product change in the near future.

An example of a process that is often robotised is welding, as it requires precision and can be a health hazard. Michale Automation offers, among other things, robotisation of welding in various industries. In a similar way, it is possible to robotise packaging or robotise repetitive assembly operations.

Determine budget and analyse ROI

Robotising production processes is an investment, but it is worth remembering that it also brings long-term savings. In modern production lines, robots operate continuously 24/7, reducing the need for additional operators. It is also possible to almost completely eliminate downtime due to employee indisposition.

• Costs include the purchase of the robot, integration with the existing system, staff training and possibly the purchase of additional peripherals (e.g. vision systems).
• Key indicators: time to return on investment (ROI), total cost of ownership (TCO).
• In the calculation, it is worthwhile to additionally take into account the potential gains from increased workmanship and better repeatability.

If you want an initial look at how quickly a welding robot or other manufacturing robot can pay for itself, you can use the
ROI calculator (welding).

Prepare your team

The company's transformation towards greater automation can raise concerns among employees about the reduced need for human labour. To address concerns, it is worthwhile:

• Communicate clearly the goals and benefits of robotisation.
• Invest in training and competence development - machine operators will be able to deal with more advanced tasks and staff will have the opportunity to develop new skills.
• Encourage employee involvement in the implementation process - this will help them adapt more quickly to change, and often provides invaluable knowledge of the specifics of the production line.

Choose an experienced systems integrator

The implementation of robotic systems requires specialist knowledge and experience. This includes the selection of robot types, their parameterisation, as well as integration with existing vision systems or MES/ERP modules. Michale Automatyka (notably as an official distributor of SIASUN robots) deals with the comprehensive construction of machines and production lines and the implementation of robotic workstations. You can find examples of services worth reading about at
Robotics on offer from Michale Automation.

Step by step: what the implementation of process robotisation looks like in practice

Analysis of the current state

The first task is to understand your processes, needs and constraints. The analysis of the current state takes into account:

• Type and number of production lines.
• Level of automation to date.
• Product types and product range variability.
• Key issues and pain points (e.g. bottlenecks, machine breakdowns, staff shortages).

At this stage, it is also important to diagnose whether the company has the right infrastructure, such as a stable power supply, adapted workstations and a maintenance department capable of working with robots.

Solution design

After the analysis, the integrator develops the robotisation concept together with you. The following are determined:

• The extent of automation - whether it includes only machine operation or also inter-process transport and quality testing.
• Type of robots and attachments - for example, six-axis robots, cobots, heavy-duty robots (such as SIASUN SR models and others).
• Line modifications needed (e.g. feeders, turntables, safety curtains).

Construction and tests working "offline"

In the next step, the integrator - that is, in our case, Michale Automatics - prepares the actual solution, usually in its engineering centre. There, the workstations are built and programmed, and the machines undergo testing to minimise the risk of faults and downtime in your plant.

Installation and commissioning on site

When the workstations are ready, installation at the target location takes place. Implementation includes:

• Installation of equipment and its integration with existing lines and other systems.
• Configuration of sensors, vision systems, as well as safety tests.
• Carrying out technical acceptance.

Training and handover to users

Once the testing and commissioning phase is successfully completed, line operators, maintenance engineers and management staff are trained to operate the robots, make basic changes and respond in the event of a system alarm.

Service and maintenance

The first few weeks after deployment may require service support for any adjustments to robot performance. Thereafter, it is important to keep all the components of the workstation in good condition. To ensure many years of trouble-free operation, it is worth familiarising yourself with
Service and maintenance stands.

Examples of areas of robotisation of production processes in factories

Robotisation of welding

Welding is an extremely demanding process that involves changing conditions and the need to maintain high precision. The implementation of a welding robot makes it possible:

• Standardise weld quality and reduce errors.
• Significant acceleration of the pace of work.
• Increased safety, especially with large aluminium and steel components.

Many factories are choosing to robotise welding primarily to meet their customers' high weld requirements while reducing production costs.

Robotisation of packaging and palletising

In some companies, the most time-consuming part of the production process is packing products and preparing them for shipping. Packaging and palletising robots can work very quickly and with fewer errors than humans, resulting in higher productivity. In addition, maintaining stable hygienic conditions in the food industry becomes easier when some of the work is done by machines.

Robotisation in machining, grinding and painting

Some tasks, such as sanding, painting or applying protective coatings, present a high physical workload and potential health risks. The use of robots in these ranges is the answer:

• Ensuring repeatable movements and high quality workmanship (e.g. in the even application of paint).
• Protecting workers from dust, welding fumes or toxic substances.

The most common concerns related to the robotisation of production processes

Will robots take jobs away from humans?

This is probably the most popular question that arises on the subject of automation. The answer is that in the short term, some of the simple tasks may be taken over by robots, but at the same time, new jobs requiring more advanced skills are being created. Machine operators, robot programmers, maintenance engineers and quality specialists become even more necessary.

Is it really going to pay off?

The investment costs for industrial robots can be high, but looking at the long term, the ROI (return on investment) often turns out to be very favourable - especially in the face of rising human labour costs. In many plants, the payback is within 1.5 to 2 years. It is also worth considering the quality and safety benefits of the work.

Is integration into an existing line too difficult?

In modern systems, robots are designed to be able to interact with other devices. Standardised communication protocols (e.g. Ethernet/IP, Profinet) are often used. An integrator company (such as Michale Automatyka) is responsible for the correct 'alignment' of the hardware with the vision system and ERP/MES systems, so the risk of problems can be significantly minimised.

Practical conclusions and recommendations

1. Make a list of the processes that cause the most problems: repetitive, time-consuming, putting workers at risk.
2. Prioritise - choose those areas where automation will bring the quickest or greatest benefit.
3. Set realistic business goals with both short-term improvements and long-term growth in mind.
4. Plan training and internal communication so that the team feels prepared for organisational change.
5. Benefit from the professional support of experienced integrators who will propose the right solution and help you implement it successfully.
6. Don't forget to service and regularly maintain your robots - this is key to maintaining stable production quality for many years.

Summary

The robotisation of production processes is increasingly available and brings noticeable benefits to companies in terms of both cost reduction and increased growth opportunities. Whether you manage a furniture factory, a steel processing plant or a small food manufacturing business, it is worth considering whether and to what extent robotisation will be profitable for you.

If you are looking for a proven partner to expertly assess your needs, design and implement state-of-the-art production workstations, Michale Automatika's offering could be the ideal solution. Due to their experience in the construction of production lines, industrial automation and the installation of SIASUN robots, the specialists at Michale Automatika will guide you through the entire process - from the initial concept to the final implementation and service.

We encourage you to visit
Automation and robotics services, to find out more about robotisation opportunities. If you feel it's time for the next step in your company's development, study the tips above and see how robotisation can improve the profitability, safety and stability of your production. If you have any questions or concerns, contact Michale Automation - the experts will help you choose the solutions best suited to your industry and specific needs.

Thank you for reading the article! If you would like to learn more about specific robot applications in selected industries or check out additional tips, please continue reading on Michale Automation's blog.

FAQ

How long does it take to implement robotisation in a company?
The implementation time depends on the complexity of the processes and available resources. It can range from a few weeks for simpler solutions to several months for more extensive projects.

Does robotisation mean redundancies?
It doesn't have to be this way. Automation allows employees to focus on more creative and strategic tasks, while freeing them from monotonous tasks. Many companies are using the process 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. Investment costs are falling and flexible solutions can deliver a favourable return on investment even for smaller operations.