How to prepare your company for the implementation of a technology machine - a practical guide

Estimated reading time: 8 minutes

TL;DR

• Define business objectives clearly and identify the processes most beneficial for automation.
• Analyse options for future expansion and available funding sources.
• Include the installation schedule, staff training and acceptance testing.
• Don't forget regular service and maintenance to avoid downtime.
• Consider combining process machinery with robotisation to increase production flexibility.

Table of contents

• Introduction
• What is a technology machine and why it matters
• When to consider implementing a new technological machine
• Key steps in preparing a company for the implementation of a technological machine
• The role of robotisation in the context of process machinery
• The most common challenges in implementing a new technological machine
• ROI and efficiency of technology machine investment
• Case studies - practical implementation examples
• Combine the technology machine with other solutions
• Service and maintenance - a step not to be forgotten
• Quality control and operational safety
• Practical advice and conclusions
• Summary
• FAQ

Introduction

A process machine is one of the key elements of modern manufacturing. The term encompasses both advanced industrial equipment operating in a fully automated cycle and multifunctional machines that can be easily integrated into existing production lines. In an era of increasing competition and the need to increase productivity, more and more companies are considering investing in this type of solution. But how do you professionally prepare for this?

In this article, we provide a detailed step-by-step roadmap of what to look out for in order to fully and safely implement a technology machine in your company. You will learn about the most important technical and organisational aspects, when to consider automation, and how to choose the right supplier and integration partner. After reading the entire article, you will gain not only knowledge, but also implementation tips to help your plant avoid unnecessary downtime and additional costs.

What is a technology machine and why it matters

A process machine is a device designed to carry out a specific manufacturing process - from simple tasks such as forming material, to advanced operations involving welding, painting, packaging or even operating production lines in an automated manner. In today's economic reality, companies are looking for solutions that allow:

• Reduce the costs of running production, especially labour costs.
• Increase flexibility and speed of adaptation to market changes.
• Maintain high quality and repeatability of products.
• Optimise processes to minimise material and time losses.

The purchase of a new process machine is often defined as the first step towards comprehensive automation. It can form the foundation for further robotisation of the plant or complement the existing process line, taking over the most cumbersome or repetitive production steps.

When to consider implementing a new technological machine

The decision to implement a technological machine in a company requires sound analysis. The most common reasons for such an investment are:

Growing demand for products

If your company is experiencing an increase in orders and your existing production lines are no longer able to meet the needs of the market, an expansion of your machinery fleet or an upgrade of your existing solutions may be inevitable.

Staff shortages and high labour costs

When it is difficult to find skilled workers to perform repetitive activities, a technology machine can be an excellent alternative. This solution is particularly beneficial in industries suffering from a shortage of staff or in regions where employment costs are high.

Willingness to improve quality and repeatability

Performing many operations manually is fraught with the risk of errors and quality fluctuations. With automation, a consistent level of quality can be ensured, resulting in increased customer satisfaction and an improved corporate image.

Process optimisation

Modern machines, especially those integrated with control systems or equipped with industrial robots, allow cycle times to be reduced, material losses to be eliminated or process parameters to be controlled more precisely.

Key steps in preparing a company for the implementation of a technological machine

The implementation of a technological machine should be preceded by multifaceted analysis and planning. The most important stages are discussed below:

1. Definition of business objectives

Before doing anything, it is important to define what you want to achieve with your investment in a process machine. Is the priority higher productivity, reducing labour costs or perhaps increasing production flexibility? Precise formulation of the objective facilitates further selection of potential solutions.

2. analysis of production processes

Before deciding on a particular machine, look at your company's process map. Identify those areas where a technology machine will bring the greatest benefit. Evaluate the processes in terms of:

• Repeatability - The more repetitive the task, the clearer the gain from automation.
• Time-consuming - the long time it takes to perform a given operation manually can be costly.
• Risks of errors and downtime - automation reduces the likelihood of human error.

3. choice of machine type

Not every process machine will be suitable for a given plant. There are many types of machines: from simple, single-purpose machines (e.g. for painting or cutting) to highly specialised machines with integrated safety systems, sensors and robotic modules. The choice should depend on:

• Type of product and material.
• Expected performance.
• Space available on the production floor.
• Potential for future expansion.

4. consultation with automation specialists

It is a good idea to consult a company that specialises in machine building and automation system integration. Michale Automation has experience in designing and implementing machines for various industries, as well as integrating industrial robots into existing production lines. It is important to plan at an early stage how the machine will communicate with other equipment or the production management system (e.g. ERP/MES).

5. verification of available funding sources

The purchase of a new technological machine is a major expense, especially for small and medium-sized companies. It is worth looking for subsidies, grants or favourable leases. Operational programmes are also sometimes available to support investment in technological innovation, which can reduce initial costs.

6. Planning the implementation schedule

Often the purchase of the machine itself is only the beginning. Assembly, configuration and commissioning may require additional work, such as:

• Preparation of foundations or reinforced floors.
• Adaptation of electrical supply and safety systems.
• Operator training.
• Acceptance testing and technical acceptance.

Scheduling these tasks in time will avoid chaos and delays.

The role of robotisation in the context of process machinery

Although technological machinery is associated with traditional automation, industrial robots are increasingly becoming an integral part of it. This is particularly relevant for companies that want to increase production flexibility or improve ergonomics.

Robotic workplaces - when is it worth implementing them?

A robotic workstation often combines a process machine (e.g. a specialised press, welding machine or packaging system) with a robot taking over the operator's tasks. This approach has several advantages:

• Higher precision and repeatability of the process.
• Ability to work in harsh environments (e.g. high temperatures, dust).
• Reducing the risk of accidents and reducing health and safety costs.

At Michale Automatika, we not only design and build machines, but also implement robotic workstations tailored to the specifics of each industry. In addition, we are an official distributor of robots from SIASUN, one of the leaders in industrial robotics.

The most common challenges in implementing a new technological machine

As with any investment project, obstacles can also arise. Here are some of them and tips on how to counter them.

1. Underestimated budget

There is more to installing a machine than just the cost of buying it. You have to take into account the costs of transport, installation, employee training and often the adaptation of the plant infrastructure. In addition, service and future maintenance must be taken into account.

2. lack of competence within the team

Implementing new technologies requires the right skills. If you do not have people in your company who are familiar with systems integration or robot programming, you will need to organise training or hire external companies.

3. production downtime

Downtime is possible in an existing process until the new machine is fully operational. This is why it is important to agree a timetable in advance with the supplier and the production department to limit losses associated with line stoppages.

ROI and efficiency of technology machine investment

Investment in a process machine, especially when robotisation is involved, often involves high initial costs. Over time, however, it brings real savings:

• Lower raw material consumption due to higher precision.
• Reduction in the time needed to produce a product.
• Risk of human error reduced to a minimum.

Many companies recover their financial outlay within 1-2 years of implementing a technology machine. It is worth making your own calculations or using the online tools available, e.g. ROI calculator for welding robotisation - even if this does not apply directly to welding, the methodology for counting the return may itself be similar.

Case studies - practical implementation examples

Although each company has its own specificities, there are many examples showing how a well-prepared implementation of a technological machine can change the face of production.

Example 1: Packaging line in a food company

The owner of a small food facility decided to purchase a specialised process machine for product packaging. An integrated palletising robot additionally picks up the finished packages and transports them to the storage area. Results:

• Reducing packaging time by 30%.
• Reducing mislabelling errors.
• Ease of future line expansion.

Example 2: Robotisation of the welding process

A company in the metal sector has implemented a new process machine suitable for machining parts of varying shapes. The SIASUN robot is responsible for precisely maintaining the welding position, and the control is closely integrated into the production line and ERP system. The result:

• Savings in the order of tens of thousands per year in labour costs.
• Improved weld quality and reduced claims by more than 40%.

In both cases, the key to success was the careful tailoring of the equipment and the appropriate training of the crew.

Combine the technology machine with other solutions

The modern factory is not just one machine - it is an integrated ecosystem of equipment, control systems and robots.

You may choose to integrate a cobot (collaborative robot) to assist operators with manual tasks, such as grinding products. See more: Robotisation of grinding.
If you are interested in automating your packaging processes, a modular packaging line that is easy to expand and adapt to changing market requirements may be the solution. Check out our offer in the area of Robotisation of packaging.
For repetitive processes (e.g. palletisation of identical loads), a system can be implemented robotisation dedicated to repetitive productionwhich will definitely improve logistics on the shop floor.

By properly integrating process machinery with robots and management systems, companies are able to maximise line efficiency, reaping the benefits of end-to-end automation.

Service and maintenance - a step not to be forgotten

Even the most advanced process machine requires regular service. Ensuring proper maintenance is key to avoiding costly downtime and keeping the machine in optimum condition. You should:

• Carry out periodic technical inspections (e.g. every 6 or 12 months).
• Replace consumable parts in accordance with the manufacturer's recommendations.
• Monitor machine performance indicators (e.g. temperature, vibration, oil level).

Michale Automation offers Service and maintenance of stationswhich helps companies to extend the life of their machinery and to make the necessary technical improvements.

Quality control and operational safety

After the implementation phase comes the time for daily operation. It is worth ensuring that:

• The process machine met safety standards (e.g. European CE standards).
• The workers had been trained in the use of the equipment and were familiar with health and safety regulations.
• The company had control procedures in place to check compliance with production parameters.

Practical advice and conclusions

Below is a list of the most important points to bear in mind in order to maximise the benefits of implementing a technology machine:

1. Carefully define the business objectives of the investment - whether you want to increase productivity, reduce costs or reduce error rates.
2. Examine your production processes and see where automation has the greatest potential for return.
3. Consider robotisation, especially in processes that require high precision or are carried out in harsh environments.
4. Remember the implementation schedule - plan assembly, training and testing to avoid chaos in production.
5. Take into account available forms of financing, such as grants or leasing, which make it easier to cover initial costs.
6. Schedule service and maintenance - regular maintenance prevents breakdowns and unplanned downtime.
7. Make sound ROI calculations to have a clear picture of the profitability of your investment.

Summary

Implementing a process machine is a step towards modern, efficient and business-supporting production. Although the investment may seem costly, a proper analysis of the needs and benefits (such as reduction in production time or labour costs) proves that in most cases it is a solution with high payback potential.

If you are looking for support in preparing your company for the implementation of a technological machine, we invite you to contact the experts at Michale Automatics. With many years of experience in the construction of machines and production lines and an in-depth knowledge of industrial automation, we will help you select and implement a solution tailored to your specific needs.

We also encourage you to take a look at our other blog articles, in which we cover topics related to robotisation, efficient systems integration and technological innovations resulting from our partnership with SIASUN. Together with us, you can take the next step towards Industry 4.0 - the future starts here and now.

Do you have questions? Do you want to implement a process machine or are wondering which type of automation will be most beneficial for your plant? Contact us and join the ranks of companies that are already reaping real benefits from investments in modern technology.

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.