Technology and assembly automation - a practical step-by-step guide

Estimated reading time: approx. 7 minutes

TL;DR

• Automated assembly reduces costs and minimises errors
• The key to implementation is a thorough analysis of production processes
• Choosing the right robots and sensors determines the success of the investment
• Staff training ensures effective interaction with new systems
• Constant monitoring and optimisation keep performance high

Table of contents

• Introduction
• Why invest in assembly automation?
• Step 1 - Analysis of needs and processes in the assembly area
• Step 2 - Selection of technology and automation solutions
• Step 3 - Design and integration of assembly systems
• Step 4 - Training and implementation of assembly automation systems
• Step 5 - Monitoring and optimisation
• Practical examples and conclusions
• Summary
• FAQ

Introduction

Technology and assembly automation are becoming increasingly important in almost every manufacturing sector. In an era of rising labour costs and the need to maintain high product quality, more and more companies are choosing to streamline their assembly processes. In this article, we suggest how to implement step-by-step advanced technological solutions in the area of assembly in order to increase production efficiency, optimise costs and remain flexible in the face of changing market requirements. After reading, you will learn what to pay special attention to when planning your investment, how to choose the right systems or plan employee training.

Why invest in assembly automation?

The automation - including robotisation - of assembly processes is one of the key development paths of modern manufacturing. According to the International Federation of Robotics (IFR), the global market for industrial robots is growing by an average of several to tens of per cent per year. Assembly is one of the areas where advanced technologies can significantly improve the flow of operations and reduce quality errors.

• Reducing labour costs and minimising errors: Robots can work continuously around the clock, reducing the risk of errors due to human indisposition, fatigue or routine.
• Increased productivity of assembly lines: The use of vision systems, sensors and artificial intelligence algorithms allows components and assemblies to be identified quickly, making assembly processes faster and more efficient.
• Improving worker safety: In many industries, especially heavy industry, automation eliminates the hazards of operating machinery in harsh environments.
• Scalability of production: Dynamic market changes require flexible and scalable solutions. Robots and automated assembly lines can be adapted to fluctuations in volume or product type in much less time than with traditional methods.

At Michale Automatika (also often referred to as Michale Automatika), we have been providing solutions for machine and production line construction for years, as well as implementing robotic workstations - including the official distribution of SIASUN robots. As a result, our customers can count on comprehensive technological services and support in the design, implementation and service phases.

Step 1 - Analysis of needs and processes in the assembly area

The first step in implementing assembly technology and automation is a thorough analysis of the company's needs. This is the stage where it is determined which assembly processes cause the most difficulties or generate the greatest costs and where the greatest improvements can be made.

Identification of key assembly tasks

Before moving on to specific technical solutions, it is useful to make a detailed list of all the assembly steps. This could be:

• Retrieving components from storage.
• Selection and completion of individual components.
• Tightening screws or riveting parts.
• Quality control and packaging for onward transportation.

During this analysis, there are often many items that are repetitive and time-consuming, but could very easily be robotised. Once we have identified such tasks, we can assess the potential for automation in specific areas.

Selection of areas for automation

Not every step of the assembly process needs to be fully robotic - in some cases it will be more cost-effective to use simple assistive devices (e.g. positioning systems) and in others to use full robotic systems equipped with artificial intelligence. The key is to select the tasks that will provide the fastest return on investment or clearly greater process stability.

Step 2 - Selection of technology and automation solutions

Once you know which areas of production need to be improved, it is time to choose specific solutions. It is worth paying attention to:

• Type of robots: In some processes, articulated robots (e.g. for precise assembly of parts) are better suited, while in others, SCARA-type robots designed for handling light parts are more suitable. Cobots (collaborative robots) are also gaining popularity, allowing them to work together with a human during complex operations.
• Sensors and vision systems: Many modern assembly lines use camera and image recognition systems to select the right components or control their quality.
• Integration with existing IT infrastructure: If a company uses an ERP or MES system, integrating the planned automation with these solutions should be a priority. This allows real-time monitoring and optimisation of production, as well as rapid response to any irregularities.

In the context of technology and assembly automation, it is worth exploring the wider range of solutions our company offers. On the Services - Robotisation you will find a discussion of different automation approaches and implementation examples. Thanks to Michale Automation's extensive experience in building machines and production lines, we are able to configure a tailor-made system, taking into account both technical aspects and software integration possibilities.

Step 3 - Design and integration of assembly systems

Once the appropriate technologies have been selected, it is time to create the concept for the robotic workstations and their integration into the existing production line.

Development of layout and technical specifications

At this stage, designers prepare the so-called layout of the workstation: the layout of machines, robots, additional sensors or safety systems. A detailed technical specification is also established - including the power output of the equipment, power requirements, compressed air requirements, supports and guards to protect people from accidentally entering the robot's working area.

Simulation tests and proof of concept

An important point is the verification of the concept through computer simulations or small-scale prototyping. This allows a preliminary estimate to be made:

• The clock time that will be achieved through robotisation.
• The number of robots and other equipment required to handle the planned volume of production.
• Adverse events or critical points that can generate downtime.

At Michale Automation, we also assist clients with the drafting of project documentation, which facilitates the subsequent implementation of solutions and their acceptance by health and safety services or supervisory inspectors.

Step 4 - Training and implementation of assembly automation systems

Even the most modern robot or assembly line will not work efficiently if the team is not properly trained.

• Operator training: Staff operating the system should learn how to interact with the robots safely and effectively, how to respond to alarm signals or perform basic diagnostics.
• Programming and technology training: Those in the maintenance department or process engineers need to gain knowledge of robot programming, trajectory optimisation or the configuration of vision systems.
• Providing after-sales support: The automation solution provider should guarantee access to fast service, spare parts and software updates.

At the same time, it is worth calculating the potential return on investment (ROI) that assembly automation brings. Even if the main problem is not cost but lack of manpower, a thorough financial analysis allows you to better plan further improvements. For a quick ROI calculation for processes that can be robotised, you can use our interactive Calculator. Although it was created with robotic welding in mind, it gives an indicative scale of savings and provides an understanding of how such an approach might translate into other phases of production, including assembly.

Step 5 - Monitoring and optimisation

After the first weeks of operation of a new system, it is time to evaluate its performance. Both management and engineering departments should monitor:

• Cycle time (cycle time) compared to before.
• Failure rate and possible downtime due to equipment errors.
• Quality indicators, i.e. the number of defective products produced in a given period.
• Feedback from operators and staff in the immediate vicinity of the line - whether tasks are easy to handle and the system safe enough.

If actual results cannot be achieved, it may be necessary to further fine-tune robot parameters, replace tools (e.g. grippers) or redesign parts of the layout. Optimisation is an ongoing process - as market needs change or new products are introduced, assembly lines need to be flexibly modified.

Practical examples and conclusions

When it comes to technology and assembly automation, each company may have different priorities and concerns. For some, operational costs and limited budgets will be key, for others, employee safety or increased productivity. Whatever the main objective, the implementation of automated assembly lines can bring tangible benefits within the first 6-12 months of operation.

For example, in the furniture industry, the use of robotic workstations has allowed one of our customers to reduce cabinet assembly time by 30% and the number of errors (mis-matched components) to be reduced almost to zero. In the food industry, where maintaining food hygiene and safety is a priority, automated sorting or packaging lines significantly reduce the risk of product damage, as well as contact with external agents.

If you are also looking to automate other processes in your company, it is worth reviewing our overview of services, where you will find more information about which areas of our robotisation and production line modernisation activities we cover. You can also take a look at our offer robotisation of repetitive productionbecause many of the solutions implemented in series production also work well in repetitive assembly tasks.

A summary of the key findings and recommendations follows:

• Invest time in a detailed analysis of your assembly processes. This will allow you to more accurately select the most cost-effective areas for robotisation.
• Match the type of robots (collaborative, articulated, SCARA) to the specific tasks. Not all processes require full robotisation.
• Ensure the integration of new systems with your existing IT environment (ERP, MES). This will give you full control over the production cycle.
• Conduct sound training for operators and technical staff so that the new system is used to its full potential.
• Regularly monitor performance indicators and carry out modifications if results deviate from expectations.

Summary

Technology and assembly automation offer tremendous opportunities to increase a company's competitiveness while helping to improve the quality, safety and flexibility of production. With state-of-the-art solutions such as industrial robots adapted to a variety of assembly processes, vision systems or advanced AI solutions, key elements of product manufacturing can be significantly improved.

If you'd like to learn more about the latest developments in robotics and ways to reduce costs and improve quality in a short space of time, I encourage you to check out our other blog articles. Or get in touch with the experts at Michale Automation - together we can discuss the details and help you choose the best solutions for your industry.

Thank you for reading the article. If you found the information helpful, please consider sharing it on social media or sending the link to your colleagues. We believe that through continuous development in the area of modern technology and assembly automation, Polish companies can compete even more effectively in global markets.

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.