Robotisation vs automation - discover the key differences and use them in modern manufacturing

Estimated reading time: approx. 10 minutes

TL;DR:

• Automation is about streamlining repetitive processes, robotisation gives greater flexibility in complex tasks
• Industrial robots allow faster implementation of new products and frequent product range changes
• Robotisation costs are higher initially, but potentially more than pay for themselves
• The right choice (automation vs robot) depends on the type and number of tasks in the process
• Michale Automation offers comprehensive implementation of robotic lines and modernization of the machine park

Table of contents

• Robotisation versus automation - definitions and meaning
• Key differences - from simple tasks to scalable solutions
• Do you always need robotisation? Examples of applications
• Integration of robotics and automation - what does it look like in practice?
• How do companies calculate the return on investment of industrial robots?
• Examples of industries and benefits - case studies
• Challenges in implementing robotisation and automation
• How do you prepare your company for implementation? Practical tips
• Summary of key differences and recommendations
• How can Michale Automation help you?
• Summary

Introduction

In an era of increasing demands on the quality and efficiency of production processes, the question is often asked as to what is better to implement: robotisation or automation. Both trends are revolutionising the industry and bring with them a range of benefits, but they differ in their scope, extent of investment and impact on company growth. In this article, we comprehensively discuss what robotisation and automation actually are, what makes them different and in which situations each works best. We will also show you how Michale Automatics approaches projects involving the construction of robotic lines and the modernisation of machine fleets. After reading, you will find out what to look for when choosing the right solutions and learn about examples of practical applications of robots and automation systems in modern plants.

Robotisation versus automation - definitions and meaning

The first step in understanding the differences between robotisation and automation is to clearly define the two terms. Although they are sometimes used interchangeably in colloquial language, they reflect slightly different approaches to improving industrial processes.

What is automation?

Automation is the implementation of tools, machines and systems that perform specific tasks without the need for constant human supervision. It can involve a single step (for example, product testing) or an entire process line. Examples include:

• lines transporting material between stations in a synchronised manner,
• machine control software for autonomous execution of the subsequent steps (e.g. dosing, cutting, sorting),
• machine control systems that automatically adjust process parameters (pressure, temperature, speed) on the basis of predefined algorithms.

Through automation, it is possible to achieve:

• repeatability - the machine always maintains a certain standard of performance,
• reduction in human error - reducing problems with the so-called "human factor,"
• cost stability - precisely planned cycles of operations and predictable expenditure.

What is robotisation?

Robotisation, on the other hand, is a form of automation in which robots capable of performing complex movements and tasks play a key role. Industrial robots (such as six-axis manipulators) are able to manipulate workpieces, move and assemble components or perform technological processes. The essence of robotisation is high flexibility - a robot can be rearmed or reprogrammed for other tasks, which is occasionally more difficult with classical automation systems. Robotisation is commonly used in:

• welding of structural components,
• packaging and palletisation,
• treatment (grinding, painting, polishing),
• detail assembly in equipment or components (e.g. automotive industry).

Michale Automatika - as an official distributor of SIASUN robots - is seeing an increasing demand for flexible cobots and robots capable of working non-stop while maintaining high quality and minimising production waste.

Key differences - from simple tasks to scalable solutions

Robotisation and automation have quite a lot in common, while the key differences are revealed in aspects such as cost, flexibility, level of complexity and the type of processes to which the implementation is dedicated.

Implementation costs

• Automation: depending on the scope, it can be less costly, especially when it comes to simple process lines or typical mechanisms (conveyor belts, quality control stations).
• Robotisation: although the price of industrial robots is falling, it still involves a higher initial investment and safety modifications to the line. In the long term, robotisation can bring significant savings through reduced labour costs and fewer defective products.

Flexibility and complexity of tasks

• Automation: mainly concerns repetitive operations in a well-defined process, requires relatively stable production conditions (cube, dimensions, technological parameters).
• RobotisationThe robots are suitable for complex, multi-step operations and are easily reprogrammed for new tasks, which is why they are the choice of companies with a frequently changing product range.

Speed of action

• Automation: the systems will operate very quickly and efficiently under strictly defined conditions, minimising human intervention.
• Robotisation: robots can perform complex movements and handle workpieces of different shapes; moreover, they can react quickly to changes in programmed processes.

Industry context

• Automation: popular in mass production, sectors where repeatability is a priority - e.g. food lines, pouring and packaging lines, sorting plants.
• RobotisationIt is widely used in the automotive, electronics and precision welding sectors (e.g. robotisation of welding) and assembly tasks.

Do you always need robotisation? Examples of applications

The implementation of robotisation is not always necessary or cost-effective. The choice between classic automation and full robotisation sometimes depends on the nature of production, financial possibilities, business objectives and the number of product series to be handled.

When is automation enough?

• When the process is simple and does not require complicated movements - for example, automatic sorting of cartons with identical dimensions.
• When a production stage does not require variability in equipment configuration or rapid changeover to another production variant.
• When the main objective is only to stabilise quality and increase speed, and not necessarily flexibility.

Examples of processes requiring robotisation

• Repetitive but precise operations (e.g. robotisation of painting), where stability and accuracy are crucial at all times.
• Variable production conditions: frequent change of details, different sizes, introduction of new models at short intervals.
• Need to integrate with vision systems (shape recognition, orientation, product quality) - the robot can dynamically adapt to each item.

Integration of robotics and automation - what does it look like in practice?

Often it is not an either-or choice, but a harmonious combination of robotics and automation. Michale Automation specialises in complex implementations where robots work with existing transport systems, CNC machines and production lines already equipped with industrial automation.

Planning and needs analysis

Before implementing robotisation, it is worth analysing:

• Level of automation to date - can machines be upgraded or supplemented with collaborative robots (cobots)?
• Scalability - will the robotisation only support one type of detail or are you planning a wider range of products in the future?
• Human interaction - in today's projects we are planning not only autonomy, but also safe interaction between workers and robots (security systems, area scanners).

Typical integration steps

1. Process audit and ROI (return on investment) analysis.
2. Selection of solutions - choice of robot type (e.g. SIASUN SR25A robot), development of control system.
3. Station design - adaptation of existing lines or construction of dedicated ones.
4. Programming and testing - from simple movements and sequences to performance testing under simulation conditions.
5. Implementation and training - preparing the team to operate robots or automated lines.

How do companies calculate the return on investment of industrial robots?

The 'automate or robotise' dilemma often comes down to numbers. A high initial investment may scare you, but in a few years' time robotisation can be very cost-effective, especially with staff shortages and rising human labour costs.

Key factors influencing ROI

• Labour costs: replacing or assisting a human being in a monotonous or difficult task.
• Reducing the number of deficiencies: robots ensure consistent precision.
• Cycle time: reducing the time it takes to manufacture a single product or an entire batch.
• Lower staff turnover: in strenuous and dangerous work, robotisation protects against crew burnout or injury.

For these reasons, some plants recover their costs in as little as 1-2 years - just look at our ROI calculator welding robotisationto get an idea of how savings are calculated in practice.

Examples of industries and benefits - case studies

Automotive sector

In the automotive sector, the robotisation of welding and assembly processes has been going on for years. Robots perform repetitive tasks with a speed and precision that is difficult for humans to achieve. As a result:

• The number of faulty welds is reduced,
• The lead time for a given type of component is reduced,
• Safety is increasing - we are reducing staff involvement in difficult processes.

Food industry

In the food industry, cleanliness and repeatability are key. Robotisation is invaluable in tasks such as robotisation of packaging and sorting of fragile or hygienically demanding products. Examples of benefits:

• No risk of contamination from employees,
• Minimising raw material waste,
• Flexibility of robots to handle a variety of sizes and shapes.

Furniture and fittings industry

Here, the surface treatment in particular matters. Robotisation of grinding and polishing produces a reproducible result with minimal dust in the workplace. This reduces turnaround times and eliminates the need for the worker to wear protective clothing much of the time.

Challenges in implementing robotisation and automation

Despite the undeniable benefits, some companies are still wary of introducing advanced solutions. Below, we list the most common difficulties that arise and how Michale Automation helps to overcome them.

Lack of knowledge and experience

- Problem: The team does not have enough knowledge about robotisation management, robot programming, service.
- Solution: Michale Automation offers comprehensive training and support during the implementation period, as well as servicing and maintenance of stations.

Fear of high costs

- Problem: Need to invest in works and line upgrades (e.g. PLC replacement).
- Solution: Accurate ROI calculations, case studies from similar industries, advice on equipment selection and funding sources (e.g. leasing, grants).

Integration into existing infrastructure

- Problem: Difficulties in combining new solutions with existing vision, MES or ERP systems.
- Solution: An experienced engineering team can develop an integration strategy, often creating dedicated communication interfaces.

How do you prepare your company for implementation? Practical tips

Both automation and robotisation require good planning. Implementation should be based on cool analyses, taking into account not only costs but also potential risks.

Step by step

1. Make a list of the company's processes and identify the steps most prone to errors or bottlenecks slowing down production.
2. Creation of preliminary budget assumptions, both for the version with classic automation and the version extended with robots.
3. Consultation with an integrator (such as Michale Automatics), who will verify which solutions will pass the test in a given type of production.
4. ROI analysis with a variant that takes into account not only the cost of the robot, but also servicing, possible training and long-term profitability (uptime, stable quality).
5. Pilot testing - it is sometimes worth considering a robotic test bed where staff will learn how to work with the robot and the company will gain confidence in its investment decision.

Safety issues and standards

• When implementing robotisation, it is important to ensure that safeguards are in place to protect workers (safety curtains, fences, alarm systems).
• In the case of so-called human-adapted cobots, it is necessary to comply with safety standards and a thorough risk assessment before the workstation is finally put into operation.

Summary of key differences and recommendations

Here are the key lessons to remember:

Automation:

• Ideal for simple, repetitive processes.
• Cheaper in the initial implementation phase.
• Limited flexibility - mainly intended for tasks that will not change dynamically.

Robotisation:

• Higher flexibility and ability to handle complex movements.
• Longer investment path, but potentially higher returns in the long term.
• Accelerates the implementation of new products and models.

Recommendations:
- Conduct a company-wide process diagnosis to determine which stage is best to automate and which to robotise.
- Take into account the overall cost of implementation and maintenance.
- Do not underestimate the increase in motivation of a team that is given the tools to eliminate tedious and risky tasks.
- Work with an experienced integrator: choosing the right robot, engineering support and advice on safety issues are crucial.

How can Michale Automation help you?

Michale Automation is a team of specialists who have been designing and manufacturing dedicated workstations, production lines and robotic installations for industry for years. As an official distributor of robots from the renowned company SIASUN, we offer robots with a diverse range of payloads and reach - from small models for human collaboration to large robotic systems supporting complex logistical processes. We can prepare an individual cost-effectiveness analysis, perform full job integration and provide long-term service.

We support clients in:

• Selection of machines and industrial lines for a specific process,
• Extension of existing automation systems with robotic modules (including Siasun SR25A robot),
• Crew training - so that staff feel comfortable in operating and programming the robots,
• Service and maintenance of stations after the end of the guarantee.

Summary

Robotisation and automation are the future of manufacturing: they address cost pressures, increase productivity and enable the business to scale seamlessly. However, to choose well, it is helpful to understand the essence of both concepts. Automation focuses on the use of machines and control systems to streamline repetitive line steps, while robotisation places a strong emphasis on flexibility and the ability to respond dynamically to change.

We encourage you to read the other articles on the Michale Automation blog to better understand the potential of advanced technologies in manufacturing. If you need a customised analysis or would like to discuss the possibilities of implementation in your company - contact us and together we will work out the best solution for your industry.

Thank you for reading and we hope that the knowledge from this article will help you to make prudent investment decisions. Think about which production steps can be accelerated and improved with classic automation and where it is worth reaching for industrial robots - and take the first step towards modern, efficient production!

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.

What safety aspects should be taken into account when implementing robots?
Above all, risk assessments, appropriate fences and safety curtains or the deployment of cobots, which have built-in systems to prevent collisions with humans.