What the process of implementing robotisation in a company looks like

TL;DR:

• Needs analysis: meetings with key people, setting of objectives, identification of processes to be optimised.
• Audit: measurement of cycles, manual operations, costs; report with bottlenecks and potential savings.
• Process selection criteria: repeatability, precision, error reduction, high volume, ROI analysis, technology flexibility.
• Technology selection: process fit, precision, scalability, integration, safety, type of robot depending on tasks.
• Implementation plan: stages - analysis, design, prototype, testing, implementation, optimisation; training and IT integration.
• Infrastructure: power supply, networks, test environment.
• Training: operation, health and safety, data analysis; practical workshops.
• Change management: clear communication, Ambassadors for change.
• Monitoring: real-time data analysis, KPIs - productivity, OEE, downtime, costs.
• Continuous improvement: quarterly audits, updates, testing of new solutions.

The robotisation of production does not start with the purchase of a robot, but with a thorough needs analysis. In our work, we see that companies that prepare this stage well achieve a faster return on investment.
The robotisation implementation process is not a single action, but a coherent plan - from process audit to team training and optimisation.
In this article, we show you step-by-step what this looks like in practice.

What is the analysis of the company's needs before implementing robotisation?

The first step before investing in robotisation is to understand exactly which processes in the company need to be optimised and which can be automated to deliver a real return on investment.
At Michal, the process starts with meetings with key people in the organisation to establish the business objectives and issues to be addressed. This provides a coherent picture of the current situation and identifies areas with the greatest potential for improvement. Many companies opt for an initial consultation to understand what opportunities are available to them robotisation and how it will affect their production.

How do you audit a company's business processes?

The audit involves reviewing all key production steps and supporting processes for repeatability, time-consumption and error-proneness. The analysis establishes cycle times, the number of manual operations and the costs associated with each stage.
Before implementation, it is best to carry out an audit. Using measurement tools that will record data from the production line, which will give an objective picture of performance. The result of the audit is a report indicating which processes are bottlenecks and the potential savings after the implementation of robotisation.

How do you identify processes for robotisation and assess their potential?

The processes selected for robotisation are those that are repeatable, require high precision or generate losses due to human error. Production volume, available space, quality requirements and possible financial benefits are assessed.
Our clients are recommended to carry out an ROI analysis to see how long it will take before the investment starts to pay off. The flexibility of the technology is also taken into account to ensure that it can adapt to future changes in production. This ensures that the selection of processes for robotisation is based on data and real benefits, rather than purely on intuition.

How to select the technology and plan the process automation steps?

Selecting the right technology and precisely planning the automation steps are the two pillars of a successful robotisation implementation. The process should always start with a clear definition of business objectives and translating them into specific technical requirements. Only then is it possible to select tools that will realistically increase productivity and improve the quality of production, while being compatible with the plant's capabilities and infrastructure.

What criteria should determine the choice of robotic technology?

The most important criterion is to match the technology to the specifics of the process - the robot must be able to complete the task in the required time, with the right precision and within the established production cycle.
It is also important that the solution is scalable and allows easy integration with existing lines and control systems. Available space, the type of materials to be processed and safety requirements play an important role.
In many cases the use of collaborative robots works well, but in processes requiring high payloads or complex movements, multi-axis robots, such as SIASUN SR25A-12-2-01. It is also important that the supplier has experience in integration and can provide full service support.

How to effectively plan a robotisation implementation schedule?

Effective planning starts with breaking down the project into clear stages: needs analysis, conceptual design, prototyping, pilot testing, full implementation and optimisation.
Each phase should be assigned technical and human resources and a realistic deadline for completion. The schedule must include time for staff training, infrastructure modifications and IT systems integration.
The best results are achieved when a pilot implementation precedes a full implementation - this allows potential problems to be detected before they affect the operation of the entire production line.

What does step-by-step RPA implementation look like in practice?

The implementation of RPA in a production facility starts with careful planning of each step and a clear definition of the objectives to be achieved.
The process includes analysis of selected operations, selection of appropriate technological solutions, preparation of the infrastructure and full integration with the existing IT and machine environment.
In our practice, implementation is always carried out in such a way as to minimise downtime while allowing the team to quickly master the new tools. A detailed description of the stages can be found on the page dedicated to robotisation.

How to prepare the technical infrastructure and test environment?

Preparing the technical infrastructure involves adapting production lines and workstations to the requirements of the new equipment. This includes the installation of additional power points, the installation of communication networks and the provision of suitable conditions for stable robot operation.
In many cases, it is also necessary to prepare a separate test environment in which the system can be tested without risk. This allows potential problems to be detected and rectified even before integration into the main production line.

What is the integration with current systems during implementation?

Integration with current systems involves linking robots to the company's software, PLCs and production management systems.
When implementing new solutions, it is essential to ensure full compatibility and real-time synchronisation of data exchange. Only then will automation have the desired effect of increasing productivity and reducing errors.
Our experience shows that integration works best when the implementation team works directly with the IT and maintenance department, even at the system design stage.

How to train employees and manage change in robotisation?

The effective implementation of robotisation in a company requires not only the installation of equipment, but also the preparation of the team to work in the new environment. The success of a project depends largely on how well employees understand the new technology, can handle it and feel included in the change process.
Training and change management are two equal pillars that determine whether an investment will have the desired effect. Technologies such as industrial robots and automation systems require new skills and mindsets from employees, so the approach to education and adaptation must be planned as carefully as the installation of the equipment itself.

What elements should be included in the training for the robot team?

Training should cover three main areas: robot maintenance, safety procedures and data analysis and process quality control skills.
In the first part, the team learns how to program and configure robots, diagnose faults and perform basic maintenance.
In the second, he learns about health and safety standards and emergency response procedures.
The third area involves the use of data generated by automation systems to optimise production efficiency and quality.
In our company, training is delivered in the form of practical workshops so that participants can work directly on the equipment and immediately consolidate the skills they have acquired.

How to deal with employee resistance to the introduction of robotisation?

Resistance to change is a natural phenomenon, especially when employees fear losing their jobs or having difficulty adapting to new tasks. Successful change management requires clear communication, demonstrating the benefits to the team and involving employees in the implementation process from the outset.
Prior to the implementation of robotisation, we recommend holding briefings that present the objectives of robotisation, the projected effects and the opportunities for the development of digital competences.
The next stage is to create a group of change ambassadors. Individuals from the workforce who are the first to receive training and support the others in adapting.
This allows employees to see that new technologies are not a threat, but an opportunity to develop and improve their working conditions.

How to monitor and optimise processes after implementing robotics with Michale Automation?

Monitoring processes after the implementation of robotisation is essential to ensure that the investment works as intended and delivers the planned benefits.
This process involves constantly analysing robot data, comparing results with baseline values and reacting quickly to any deviations. We use real-time reporting systems to assess the performance of the workstations and identify elements for improvement. This makes it possible not only to maintain, but also to increase the efficiency of robots and entire production lines.

What KPIs should be used to assess the effectiveness of robotisation?

The most commonly used KPIs are productivity (number of units produced per hour), cycle time, OEE (Overall Equipment Effectiveness) and number of downtimes.
These indicators allow us to objectively assess whether robotisation is delivering the expected return on investment. In our company, we also frequently analyse production error rates and unit costs, as these data clearly show the impact of automation on quality and production profitability.
In the case of advanced positions, those using, among other things the SIASUN SR25A robot, monitoring can include additional parameters such as energy consumption or axle load.

How to ensure continuous process improvement after implementation?

Continuous improvement requires cyclical analysis of operational data, implementation of minor modifications and testing of new solutions under production conditions.
We recommend quarterly audits to our clients, during which we verify the effects of the robots, talk to the operators and look for improvements.
Keeping the control software up to date and adapting algorithms to changing production requirements is also key.
This approach not only maintains high efficiency, but also prepares systems for future expansion or a change in production profile.

Summary

From the text above, you learned that the needs analysis should be the starting point for selecting the processes with the greatest potential for robotisation.
We then discussed the criteria for selecting the technology and creating an implementation plan. The next step was to show how to carry out the robotisation process itself and train the team effectively.
Finally, ways of monitoring performance, evaluating ROI and continuous process improvement are described.
Our experience shows that a well-thought-out plan, the right technology and attention to the team are the keys to sustainable robotisation results.