Work automation - how to implement robotisation in your company step by step

Estimated reading time: approx. 7 minutes

TL;DR:

• Automation is a key element of development in industry and business.
• Needs analysis allows you to select suitable areas for robotisation.
• Choice of technology and implementing partner influences the success of the project.
• Planning and testing minimise the risk of errors and prolonged downtime.
• Team training ensures effective use of new developments.

Table of contents

• Introduction
• Why is work automation so important?
• Step 1: Analysis of needs and definition of objectives
• Step 2: Selection of technology and implementing partner
• Step 3: Project planning - schedule and resources
• Step 4: Integration into existing systems and pre-testing
• Step 5: Staff training and practical implementation
• The most common challenges and how to solve them
• Practical conclusions and recommendations
• Summary
• FAQ

Introduction

Workplace automation is an increasingly important topic in the industrial and business world. Increasing competition, pressure to reduce costs and the need to maintain high product quality are causing businesses to look for ways to streamline production processes. One of the most effective solutions is the introduction of industrial robots or robotic workstations.

Why is it worth taking an interest in robotic automation right now? Firstly, because the widespread development of technology (e.g. artificial intelligence or vision systems) makes it relatively easy to integrate robots into existing production lines. Secondly, the dynamics of the labour market in Poland encourage cost optimisation and efficient use of personnel.

In this article, we will present step by step how to prepare a company for the implementation of work automation, what are the key decision areas and what to pay attention to during the whole process. We will focus on practical tips and solutions used by Michale Automation, which specialises in machine building, production line integration and the implementation of robotic workstations.

Why is work automation so important?

The automation of work, i.e. the introduction of robots and systems to streamline production processes, has become an indispensable part of the development of many companies. According to data from the International Federation of Robotics (IFR), global sales of industrial robots are growing by several per cent year-on-year, demonstrating growing business confidence in this form of innovation.

Benefits of work automation:

• Reduction in operating costs. Robots and robotic workstations can operate 24/7, reducing labour costs and increasing productivity.
• Quality improvement. Roboticised processes are repeatable and less prone to human error.
• Production flexibility. Thanks to modern solutions - such as collaborative robots (so-called cobots) - you can easily adapt workstations to new products or changing production volumes.
• Safety and ergonomics. Robots can take over tasks that are dangerous or strenuous for workers, improving working conditions and reducing the risk of accidents.

Michale Automation is an official distributor of robots from SIASUN, a world leader in the field of automation and robotisation, and therefore has a wide range of solutions to suit the needs of plants of all sizes - from small companies to large enterprises.

Step 1: Analysis of needs and definition of objectives

The first and most important step in implementing work automation is a sound analysis of the company's needs. Without this, it is difficult to determine in which areas robotisation will bring the greatest benefits. At this stage, it is worth involving various departments within the company - production, logistics, human resources management and even sales.

Several questions need to be answered:

• Which processes are the most time-consuming and costly?
• In which areas do the most common errors, complaints or quality losses occur?
• What benefits does management expect? Cost reduction, increased safety, or perhaps scaling up production?
• Are there processes in the company that, from an ergonomic point of view, endanger the health of employees?

Once this information has been collected, it should be analysed and the main objectives for the automation project should be identified. Depending on the company's profile, these could be to reduce labour costs by 10-15%, increase the productivity of a given line by 20%, reduce waste or shorten the production cycle time.

Step 2: Selection of technology and implementing partner

On the technology side, it is crucial to choose the right equipment (robot, cobot or whole workstation) and software that will enable full integration with ERP or MES systems. It is also important to pay attention to the availability of service support and the possibility of further expansion of the machine park in the future.

The selection of the implementing partner should be based on criteria such as:

• Industry experience and the ability to provide a complete solution (design, installation and integration).
• Access to modern, proven technology (e.g. robots from reputable brands such as SIASUN).
• Flexibility and ability to adapt the design to specific production requirements.

Michale Automation offers not only robot integration services, but also full consultancy and turnkey solution design. Some companies start by automating repetitive processes, but it is worth remembering that robotisation has a wider range of possibilities - it can include welding, packaging, palletising, CNC machine operation and much more.

If you would like to see how we take a comprehensive approach to implementing robots on the shop floor, visit our services page Robotics at Michale Automation.

Step 3: Project planning - schedule and resources

Planning the implementation of work automation is the point at which - based on the defined needs and the chosen solution - you develop a detailed schedule and budget. Take into account:

• Scope of design work. What elements need to be designed from scratch and what can be integrated into the existing infrastructure?
• Scope of engineering and installation work. Will there be a need to redesign the production line layout? What safety issues need to be addressed?
• Task phases and their deadlines. Which works can be carried out in parallel and which must be carried out sequentially?
• Budget for each phase of implementation. Does the company have a buffer reserve if unforeseen complications arise?

In large production facilities, preparing a plan can take several weeks. In smaller companies taking their first steps in work automation, the process is usually shorter, but it requires well-considered decisions each time.

Step 4: Integration into existing systems and pre-testing

In addition to the installation of the robots themselves, it is crucial to connect the new equipment to other IT systems, such as:

• Vision systems (e.g. for quality control).
• ERP/MES systems to track all production data in real time.
• Other peripherals, including sensors and safety components.

Prior to the start of main production, preliminary tests should be carried out. These are designed to check that the robots work correctly with the rest of the line and that the results (e.g. productivity, quality and safety) meet initial assumptions. It is worth remembering that even the best design can still be fine-tuned in the test implementation phase before releasing the finished line into full production.

Want to find out more about how we can help with further robotic workstations? Take a look here: Service and maintenance stands.

Step 5: Staff training and practical implementation

Even the best designed and tested solution will not deliver its full benefits if the team is not properly prepared to operate it. Training includes:

• Operating and programming the robot - at a basic or advanced level, depending on the profile of the employees.
• Maintenance and minor repairs, reducing the risk of downtime.
• Safety procedures, especially important in systems where robots collaborate with humans (cobots).

Employees often fear that robots may replace them. In practice, however, the implementation of work automation increases the capabilities of the company and creates additional positions, such as those related to quality control or managing the entire production line. Good internal communication is crucial in this context.

The most common challenges and how to solve them

Most common challenges:

1. Fear of change among the crew.
2. Imprecisely defined project objectives.
3. Delays and costs in excess of original assumptions.
4. Difficulties with systems and software integration.
5. Deficiencies in technical infrastructure (e.g. insufficient production space).

Possible solutions:

• Early involvement of employees in the decision-making process, e.g. training and presentations on robot capabilities.
• Clear definition of KPIs (Key Performance Indicators) to be achieved.
• Regular monitoring of project progress and a flexible approach to modifying the plan.
• Selecting an experienced integrator who is familiar with a variety of systems and communication protocols.
• Planning the upgrade of the production hall well in advance.

At Automation Michale, we analyse the client's space and systems at the initial consultation stage, which helps avoid many problems.

If you are interested in automating repetitive production so as to increase its volume and quality, see our offer Robotisation of repetitive production.

Practical conclusions and recommendations

- Prepare for a mental shift. Automation of work may require a change in organisational culture, openness to new technologies and processes.
- Match the scale of the project to real needs. It is not always worth starting a transformation across the whole plant at once. Sometimes it is better to robotise a single station, test it and gain experience.
- Include ROI (Return on Investment). If you are wondering how to translate automation into financial benefits in practice, we recommend using dedicated tools - such as ROI calculators to help you estimate your return on investment.
- Count on comprehensive service support. This will reduce the risk of downtime and extend the life of the machines.

Find out how to calculate the ROI of your welding automation investment using our proprietary tool ROI calculator - welding robotisation.

Summary

Workplace automation is a process that brings tangible benefits to businesses wishing to grow in an efficient and modern way. Even if it seems challenging at first - especially in terms of cost - well-designed and executed robotisation enables significant savings and a competitive advantage in the long term.

The key element is a detailed analysis of needs and objectives, a thoughtful choice of technology and a solid implementation plan that takes into account both technical issues and staff competence. It is also worth remembering the role of an experienced integrator, who will not only select the best solution, but will also ensure that it is fully customised to the individual needs of the company.

We encourage you to consider working with Automatika Michale - a company with extensive experience in building machines and production lines and implementing complex robotic workstations in the manufacturing industry. Thanks to being an official distributor of SIASUN robots, Automatika Michale offers proven and innovative solutions to support work automation in both small and large plants.

If you want to deepen your knowledge of robotics and automation, we also recommend using our other materials available on the company website. There, we share implementation examples, report data and practical advice to help you prepare your company for the next step into the future of Industry 4.0.

We hope the article has cleared up your doubts and shown you the great potential of workflow automation. If you need help with planning and implementation, feel free to contact us. Benefit from the knowledge and experience of our robotisation specialists and you will soon see your production line enter a higher level of productivity and quality.

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.