The automation process in manufacturing companies: a comprehensive step-by-step guide

Estimated reading time: approx. 10 minutes

TL;DR

• Automated production lines significantly improve productivity and reduce costs
• Lack of skilled workers and rising labour costs are the main motivations for deployments
• A cost-effectiveness calculation and a precise plan is the foundation of successful robotisation
• Employees should receive training and support to take full advantage of new technologies
• Monitoring of key indicators and continuous improvement provide competitive advantage

Table of contents

• Introduction
• Why is the automation process inevitable in modern manufacturing?
• Rising labour costs and shortage of skilled workers
• Improving quality and eliminating errors
• Scalability and flexibility
• Planning the automation process: from analysis to strategy
• Step 1 - Identification of processes to be improved
• Step 2 - Analysis of costs and potential ROI
• Step 3 - Consultation with experts and choice of technology
• Step 4 - Staff implementation and training
• How to organise the automation process step by step?
• Timetabling and change management
• Integration of new machines into existing systems
• Example of automation of selected production steps
• Packaging automation
• Robotisation of welding
• Monitoring and optimisation - how to develop the automation process after the first implementation?
• Continuous improvement
• Service and maintenance of machines
• Trends in automation - what's worth keeping an eye on?
• Artificial intelligence and learning systems
• The Internet of Things (IoT) and Industry 4.0
• Collaborative robots (cobots)
• The most common challenges and mistakes when implementing automation
• Lack of precise guidelines as to the scope of the project
• Skipping the testing and prototyping phase
• Underdeveloped training and lack of communication within the team
• Practical conclusions
• Summary
• FAQ

Introduction

The automation process is today one of the key factors influencing the competitiveness of manufacturing companies. It can not only increase productivity and reduce costs, but also improve product quality and reduce errors due to the human factor. In this article, I explain why automation is gaining importance and what a step-by-step implementation looks like in organisations of all sizes. You will also learn what to look out for when planning automation, what trends are shaping the field and which solutions can support your business most effectively.

From the perspective of Michale Automation, a company specialising in the design and construction of automated production lines, machine brigades and industrial robots, the automation process is a daily practice. As official distributor of SIASUN robots we have access to the latest technologies that help businesses in a variety of industries improve efficiency and reduce operating costs. If you are planning to implement automation solutions at your premises - I invite you to read on.

Why is the automation process inevitable in modern manufacturing?

Automation has become fundamental to the development of companies. According to a number of industry reports, companies that have opted for robotic solutions report significant improvements in product quality indicators and productivity gains. Below you will find the main reasons why this is happening.

Rising labour costs and shortage of skilled workers

Many companies are facing a shortage of skilled candidates who can perform repetitive or precise tasks with consistent accuracy. Rising wages and rising recruitment costs are making the cost-effectiveness of automation ever greater. Industrial robots and intelligent machines do not need interruptions, do not make fatigue-related errors and can work continuously.

Improving quality and eliminating errors

Quality deficiencies, resulting from manual monotonous tasks, pose a serious threat to profitability. Automated processes can significantly reduce the number of defective products. In the welding industry, for example, a well-programmed robot maintains a consistent welding path and the correct parameters, leading to a significantly lower risk of defects compared to manual work.

Scalability and flexibility

Properly implemented automation significantly facilitates the scaling of a company. Expanding a production line with additional modules or robotic stations is sometimes much simpler than re-training more employees or moving production to another location. This allows the company to react quickly to market changes.

Planning the automation process: from analysis to strategy

Comprehensive plant automation starts with a precise plan. This is the moment when the company should answer questions about its business objectives, available resources and expectations from the implementation of new technologies.

Step 1 - Identification of processes to be improved

The first stage of planning is to diagnose the current processes. It is worth looking at all areas of production and picking out where:

• Most errors and corrections occur.
• Employees are involved in extremely repetitive tasks.
• Performance lags behind market demand.

It is also worth considering whether automation should cover the entire process or only certain stages. In small production facilities, it does not always make sense to invest in comprehensive robotic lines; sometimes it is sufficient to automate only a specific module, such as packaging or quality control.

Step 2 - Analysis of costs and potential ROI

A concrete financial plan is the key to avoiding disappointment after implementing automation. Accurate estimation of expenditure (initial outlay, energy, maintenance and supervisory personnel costs) versus potential gain (reduction in scrap, increased productivity, reduced downtime) allows a rational view of the automation project.

A good tool to pre-calculate the cost-effectiveness of robot deployment is the ROI calculator for welding robotisationwhich takes into account the number of shifts, active machine hours or energy requirements. In our company Michale Automation We often recommend testing such tools to pre-verify the effectiveness of the investment.

Step 3 - Consultation with experts and choice of technology

The possibilities in the field of industrial automation are now very broad. Depending on the industry, you can benefit from:

• Industrial robots operating fully autonomously (e.g. SIASUN robots),
• Collaborative robots (cobots),
• Specialised equipment for processes such as grinding, packaging, welding or painting.

Companies like Michale Automation offer full implementation support - from process audits to the installation and integration of all production line components into existing systems. As official distributor of SIASUN robots, we help you select the hardware and software to meet the needs of your specific application.

Step 4 - Staff implementation and training

The automation process does not end with the purchase and installation of machinery. Proper personnel preparation is crucial. Operators and engineering staff must learn how to work in an automated environment, how to interpret data from vision systems or how to manage digital line documentation.

A particularly important stage is to test run the automated line and make adjustments to the hardware or software configuration. This makes it possible to catch possible faults or problems with the flow of goods and eliminate them quickly.

How to organise the automation process step by step?

Implementing automation can sometimes be a major organisational undertaking. However, there are proven methods of project work that can streamline the entire process and minimise downtime.

Timetabling and change management

Any implementation work is best carried out according to a set timetable and budget. It can be helpful to use project management methodologies (e.g. Agile or PRINCE2), which allow the project to be broken down into smaller stages. Change management within the organisation should also not be overlooked. Employees need to know why the next action is being taken, how it will affect their day-to-day work and how results will be measured.

Integration of new machines into existing systems

One of the most common challenges is the adaptation of modern solutions to existing machines, IT systems or databases. Sometimes the implementation of appropriate communication protocols (e.g. OPC UA) or the modernisation of electrical and pneumatic systems is required. At this stage, it is worth considering cooperation with companies specialising in systems integration. If we are introducing advanced vision systems or integrating robots with ERP software, this process may require time and additional testing.

Example of automation of selected production steps

To illustrate how the automation process works in practice, let's take a look at examples of the production steps where robots or modern automated lines are most commonly used.

Packaging automation

The packaging process, especially in the food or logistics industry, requires high speed and accuracy. By directing robots or equipment to automatically stack products in cartons, labour costs and human error can be significantly reduced. In addition, vision systems can detect defects or incorrect positioning of goods before packing.

If you are specifically interested in automating such activities, check out the offer for the robotisation of packaging. There you will find detailed information on dedicated solutions for fast and error-free packaging of products of different sizes.

Robotisation of welding

Welding is one of the most popular areas of fully automated production. A welding robot can work without interruption, maintaining repeatable precision for hours. What's more, special sensor systems and algorithms that supervise the welding path avoid defects at an early stage of production.

If you are considering automation in the area of welding, you may want to take a look at our welding robotisation offer. With the right robots and expert integration, many companies achieve significant reductions in cycle times and improvements in the quality of the finished product.

Monitoring and optimisation - how to develop the automation process after the first implementation?

Automation is usually invested in with an eye to the future. Therefore, particular attention should be paid to the post-implementation monitoring of KPIs, followed by downstream improvements.

Continuous improvement

Stabilised production lines are only the starting point for further improvements. Analysis of the data collected (e.g. number of units produced, downtime due to breakdowns, clocking times) allows bottlenecks to be diagnosed. In the next step, they can be eliminated - either by simply adjusting machine parameters or by extending the line with additional stations.

Service and maintenance of machines

No robotic line will run smoothly without regular service and maintenance. If neglected, production downtime can become longer and more costly. It is worth defining maintenance standards and frequency from the outset. Some companies opt for service contracts with specialist companies. For example, Michale Automation also offers servicing and maintenance of stationsto ensure safe and continuous operation of the equipment.

Trends in automation - what's worth keeping an eye on?

Automation is not standing still. New technologies are emerging at an ever-increasing rate and machine manufacturers are outdoing each other with solutions that further reduce labour costs and increase the flexibility of industrial systems.

Artificial intelligence and learning systems

AI algorithms support robots in learning how to respond to unforeseen situations. Machines can recognise patterns, such as changes in line conditions, and dynamically adjust the parameters of their operation. For manufacturing companies, this means less downtime and reducing the role of operators to overseeing rather than intervening in every detail of the process.

The Internet of Things (IoT) and Industry 4.0

By networking the machines, it has been possible to introduce a new level of remote monitoring and management. Production results are controlled in real time and the systems are able to automatically implement corrections if they are outside the norm. This data analysis is the next level in continuous improvement, which increases scalability and process insight.

Collaborative robots (cobots)

Cobots, devices capable of safely collaborating with a human in a single work area, are revolutionising small and medium-sized companies in particular. They do not require large enclosures and have simple, intuitive interfaces, so they can be adapted to process changes without months of programming. Whether in the cosmetics or food industry, cobots can provide a rapid return on investment and flexibility in operations.

The most common challenges and mistakes when implementing automation

Even the best plan can fail if certain aspects of implementation are overlooked. Here are the most common mistakes to avoid.

Lack of precise guidelines as to the scope of the project

Sometimes a company focuses on the general slogan 'we are increasing automation', but does not define specific success indicators. As a result, it is not clear whether the investment in robotisation has had the desired result. To prevent this, it is useful to set a clear target - such as a 20% reduction in scrap or a 30% increase in productivity in six months.

Skipping the testing and prototyping phase

Without testing pilot-scale operating scenarios, it is very easy to overlook functional limitations of machines or inadequacies of the line to the nature of the product. Testing and prototyping reduce the risk of major failures and revert production to a manual version.

Underdeveloped training and lack of communication within the team

Automation often raises concerns among employees about their jobs. Skipping training and insufficient communication can lead to staff resistance and sabotage of new solutions. Ensuring that the team is engaged will not only reduce the risk of conflict, but will actually ensure better automation outcomes.

Practical conclusions

• Define business objectives before implementation - define what you want to achieve and what you will measure success by (e.g. cost reductions, productivity gains).
• Examine your processes - identify the areas where errors and repetition are greatest, as this is where automation will yield the quickest return.
• Accurately calculate cost-effectiveness - use tools such as ROI calculatorto avoid disappointment in the future.
• Provide support and training - automation is also about changing the work culture; the better informed and trained the team, the higher the chance of success.
• Remember to continuously improve - monitor effects, make adjustments and improvements. Automation is a process that evolves with the market and technological advances.

Summary

The automation process is the key to increasing the competitiveness of today's manufacturing companies, regardless of their size. From the analysis and initial definition of objectives, to the selection of appropriate technologies and solutions, to testing and employee training - every step is important for the final success. Industrial automation implementations achieve higher productivity, better product quality and reduced operating costs.

With the rise of artificial intelligence and the Internet of Things, companies need to bear in mind that automation is not a one-off investment, but an ongoing process - continually improved through further hardware upgrades, software enhancements and production data analysis. From the perspective of companies such as Michale Automation The holistic nature of the implementations is paramount - automation involves integrating various systems, adapting the line to new products and training the workforce to fully exploit the potential of the new technology.

If you want to implement similar solutions in your organisation, I encourage you to read our section Services and take note of robotisation. Also consider consulting with advisors who can help you create a precise automation investment plan. Please do not hesitate to contact us if you have any questions - automation can be an excellent starting point for developing the potential of your business.

Thank you for reading the article. If you would like to share your experiences or have any further questions, I encourage you to leave a comment and follow up with further posts on industrial innovation.

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.