Workstations - how to design and prepare them for modern automation

Estimated reading time: approx. 8 minutes

TL;DR

• Appropriately designed workstations increase efficiency and provide higher quality production
• Modern modernisation integrates workspace, industrial robots i IT systems
• Audit of current processes and ergonomic planning is the key to success
• Choosing the right robots, peripheral equipment i security systems enables safe and efficient working
• Regular staff training i monitoring of ROI help you carry out implementations smoothly and benefit from automation

Table of contents

- Introduction
- Why is it important to modernise workstations?
- Step 1 - Audit and analysis of the company's needs
- Step 2 - Design and ergonomics of new workstations
- Step 3 - Choosing the right robot and peripherals
- Step 4 - Employee safety and training
- Step 5 - Integration with IT systems and process optimisation
- Step 6 - Calculation of profitability and ROI (Return on Investment)
- Mistakes to avoid when upgrading workstations
- Examples of robotic workstation applications
- Summary of main content - key conclusions
- Recommendations and practical guidance
- Summary
- FAQ

Introduction

Modern industry is moving towards ever-higher levels of automation and robotisation, and workstations are its foundation. It is on properly selected, designed and implemented workstation solutions that the scalability of production, the quality of manufactured products and the safety of employees depends. At Michale Automatics, we are noticing a growing interest from entrepreneurs who want not only to speed up their production processes, but also to ensure innovation and competitiveness in the market.

In this article you will learn:

• How to plan workstations in the context of automation and robotisation.
• What benefits can you expect from upgrading your workstations in the spirit of Industry 4.0.
• How to avoid common mistakes during deployments and what to look out for when training staff.

You will gain practical tips that will allow you to design or upgrade workstations to increase the efficiency and safety of production.

Why is it important to upgrade workstations?

Industrial development and the role of jobs
Until recently, workstations were mainly associated with a simple place for an employee to carry out his or her daily tasks. However, with the development of technology, industrial robots and IT systems that monitor production in real time (e.g. ERP or MES), the range of functionalities of workstations has changed dramatically. Today, the workstation is largely:

• A space that integrates the work of humans, machines and robots.
• A place where data from sensors and vision systems are processed in real time.
• An area where ergonomics and safety are playing an increasingly important role - especially in the context of collaborative robots (so-called cobots).

At Michale Automation, we recognise that the right job configuration combined with automation not only increases productivity, but also helps to maintain repeatable quality. According to OECD data, up to 14% traditional jobs in developed countries could disappear by 2030 due to automation. This means that many manual tasks will sooner or later be automated. It is therefore worth preparing processes and personnel in advance so that these areas do not become a barrier to development.

Step 1 - Audit and analysis of the company's needs

Identification of processes to be automated
Before you start designing upgraded or completely new workstations, carry out a thorough analysis of your existing production processes. It is worth paying particular attention to activities:

• Repetitive and monotonous.
• With a relatively high proportion of manual work.
• Subject to a high risk of human error.
• Associated with heavy loads or exposure to harmful agents (high temperatures, chemicals).

Only after identifying such areas do you decide which ones can be improved through robotisation and which ones only require modification (e.g. better layout of equipment or introduction of new tools).

Infrastructure assessment
The next stage is to assess the state of your current infrastructure. Consider whether your production hall or assembly line has sufficient space and adequate connections (for pneumatics, electrics, etc.). Make sure that all components meet safety standards and that any expansion will not exceed your investment budget.

Step 2 - Design and ergonomics of new workstations

The 3W principle - Convenience, Efficiency, Collaboration
When creating robotic workstations, pay attention to ergonomics and worker safety. The increase in efficiency and quality of work depends largely on whether humans and robots can interact seamlessly. When designing workstations, we think of the so-called 3W principle:

1. Convenience - posts must be planned so that operators do not risk injury or unnecessary strain.
2. Performance - the layout of machinery and tools should minimise the loss of time and travel distances of semi-finished products.
3. Cooperation - a common operating area for humans and robots requires the use of safeguards (e.g. light curtains) and the development of safety procedures.

Use of the latest technology
Although ergonomics still mainly associated with adapting workstations to human convenience, in modern industry there is also the aspect of integrating digital solutions. Vision systems can enable robots to recognise workpieces with precision, and MES (Manufacturing Execution System) software transmits data to the cloud in real time. All this means that workstations cease to be static points and become part of an intelligent industrial ecosystem.

Step 3 - Choosing the right robot and peripherals

Types of industrial robots and cobots
There are many types of industrial robots on the market: from classic multi-axis assembly equipment to so-called cobots (collaborative robots). As an official distributor of SIASUN robots, we at Michal Automatika have a wealth of experience in selecting a specific model to suit your needs. The key questions to ask yourself are:

• How high is the weight of the item to be handled?
• What is the maximum production speed?
• Will the robot interact directly with a human (cobot) or rather work in a specially designated area?

Peripheral equipment
Workstation performance is also affected by components such as grippers, feeders, vision systems and all control automation. Ensure that each of these components is compatible and provides the necessary precision. Also think about whether you plan to expand the workstation in the future (e.g. with additional axes, new functions). It is better to anticipate this possibility at the design stage than to carry out costly upgrades after a few months.

Step 4 - Employee safety and training

Risk assessment and implementation of safeguards
Both in the design and implementation of automated and robotic workstations, safety must not be forgotten. In the case of industrial robots, suitable enclosures, guards or safety scanners are often necessary. If we are talking about collaborative robots (cobots), assembly work or quality control can be carried out together with a human in one zone. In such an arrangement, it is necessary:

• Conduct a risk assessment taking into account ISO standards, e.g. ISO 10218.
• Provision of security systems (light curtains, presence detectors).
• Rethinking emergency scenarios, e.g. in the event of power loss.

Training and reskilling
Automation and robotisation do not necessarily mean a decline in employment. Reports from international organisations (e.g. ILO) show that in many cases new positions are being created, e.g. to supervise the operation of machines, to analyse production data or to maintain automation. For this to happen, it is important to ensure that staff are competent. Employees should receive training in robot operation, programming basics or data interpretation. Simply introducing robots without proper staff preparation can result in complications and even reluctance towards new technologies.

Step 5 - Integration with IT systems and process optimisation

Linking production control to workstations
One of the major trends in the area of automation is the integration of workstations with IT systems. In practice, this means designing a flow of information such that engineers, production managers and assembly line operators have a constant overview:

• Overall Equipment Effectiveness (OEE) data.
• Alerts on possible faults or quality errors.
• Operating status of individual robots and machines.

This makes it possible to react quickly to process deviations and even predict possible failures using predictive analytics algorithms. This reduces service costs and keeps production flowing.

Practical monitoring tools
Cloud platforms for collecting data from sensors mounted within workstations are becoming increasingly common. Many solutions offer so-called dashboards that show real-time information on work cycles, equipment temperature or even power consumption levels. Depending on how much you care about detailed analysis, you can choose tools that integrate with ERP or MES systems.
At Michale Automation, we design complete lines that combine SIASUN robots with software to continuously evaluate process performance. If you would like to find out more about Robotics in practice - Michale Automation services, it is worth exploring the topic in greater depth in terms of possible applications.

Step 6 - Calculation of profitability and ROI (Return on Investment)

How do you calculate the return on investment?
Automation and robotisation of workstations involve some financial outlay - sometimes considerable. The key to making a good business decision is a sound cost-effectiveness analysis. Consider:

1. Costs of purchasing robots, hardware and software.
2. Infrastructure expenditure (e.g. bringing in power, installing covers).
3. Costs of training and possible external support.
4. Projected decrease in the number of quality deficiencies.
5. Time saved by staff on manual activities that could be used differently.

Possible funding (EU or national) can also be taken into account, which shortens the payback period. If you are interested in simulating the profitability of implementing a robot, you can use our ROI calculator - welding robotisation.

Many of our customers have found that with the right choice of robots, ROI can be as high as 1.5-2 years. This is shorter than in many other production investments (e.g. in a new assembly line with a traditional design).

Mistakes to avoid when upgrading workstations

Unclear vision of objectives and plan
A common mistake is to introduce robotisation 'for applause' or just because competitors are starting to implement automation. It is always important to have a clear objective, the implementation of which will bring tangible benefits in the form of improved quality, increased productivity or cost optimisation.

No safety analysis
Ignoring risk analyses can result in accidents, increased risk of downtime or the need for subsequent costly modifications (e.g. adding guards, replacing sensors). If workstations are to be highly robotic, safe human-machine interaction should be a priority.

Insufficient staff training
The belief that the purchase of a state-of-the-art robot alone will solve all the ills of production is sometimes illusory. Advanced technology also requires properly prepared employees. At Michale Automatika, we always recommend extensive training for operators, maintenance departments and managers.

Overlooking the aspect of easy maintenance
The daily operation of automated workstations involves maintenance, inspection and possible repairs to the equipment. It is advisable to plan service and spare parts availability in advance to avoid prolonged downtime. Our maintenance offer.

Examples of robotic workstation applications

Welding in the metal industry
Robotic welding is a classic example of a workplace where an industrial robot performs brilliantly. We achieve higher weld repeatability, eliminate human error and protect workers from prolonged exposure to welding fumes. Details can be found in our welding robotisation offers.

Packaging and palletising
Workstations dedicated to product packaging often combine cobot operation with vision systems that recognise the shape and position of items. This allows the line to be adapted instantly to different packaging formats or changes in assortment.

Quality control
In the automotive or electronics industry, fast and precise quality control plays a huge role. A robotised workstation with vision cameras and artificial intelligence algorithms makes it possible to assess hundreds of details in a matter of minutes. Tasks previously performed manually are verified faster and the risk of mistakes due to operator fatigue is eliminated.

Summary of main content - key conclusions

• Workstations today are the interface between the operator, the robot and complex IT systems such as ERP or MES.
• Well-designed and robotic workstations translate into higher productivity, stable product quality and a lower risk of accidents.
• Automation does not just mean job cuts - with the right approach, new roles are emerging in the company, requiring upskilling (reskilling).
• Planning is the key to success: from process audit and infrastructure analysis, to selecting the right robot and peripherals, to staff training and integration with IT systems.
• Investments in robotisation often pay for themselves within 1.5-2 years, especially in industries that expose workers to strenuous, repetitive tasks.

Recommendations and practical guidance

1. Consider a smaller scale pilot
   Before you automate the entire line, you may want to rely on smaller pilot projects to assess efficiency and see if staff feel confident in their new role.
2. Set clear KPIs
   Performance indicators such as OEE or MTTR will help you to reliably assess the effectiveness of the robotisation of your workplaces. This will make it easier for you to convince management or investors of your next development steps.
3. Plan service and maintenance
   Constant monitoring of the technical condition of robots and equipment is a guarantee of keeping production flowing. It is worth implementing preventive maintenance. If necessary, you can make use of our servicing and maintenance of stations.
4. Invest in developing the team's competence
   Don't leave employees without support. Provide access to training, manuals and even videos. Case studies from other plants where similar implementations have been successful can be instructive.
5. Act comprehensively
   Modernising workstations is a process that requires a consistent approach: from planning to implementation to maintenance and continuous improvement. If you design high automation in one place and in another place workers still struggle with poor ergonomics and inadequate equipment, the results will be limited.

Summary

Implementing modern robotic workstations in a company is a strategic decision that has a real impact on the company's growth potential, its competitiveness and the safety of its people. With the current market dynamics, it is worth betting on future-proof solutions with a view to the years to come.

If you are considering modernising or implementing robotisation in your facility, we encourage you to contact the Michale Automation team. We will be happy to analyse your needs, advise you on the selection of robots and peripherals and help you design ergonomic and safe workstations. Also check out our offer for more details: Robotisation in practice - Michale Automation services.

If you are curious about other articles from our blog, such as ROI calculations or cost optimisation, be sure to sign up for our newsletter and keep up to date with the latest news in the automation industry.

Thanks for reading and feel free to discuss - share your experiences in the comments. Share the text on social media if you find it useful. Together, we can create an increasingly efficient and safe industry, where the underlying workstations are ideally suited to the needs of modern technology and workers.

FAQ

How long does it take to implement a robotic workstation?
Implementation time depends on the complexity of the solution being designed. Simpler workstations can be up and running in a few weeks, but extensive lines and extensive integration with IT systems may require several months of preparation.

Does robotisation mean redundancies?
Not necessarily. Many companies are retraining employees so that people previously doing monotonous or dangerous tasks can go into handling new technology, quality control or data analysis.

What IT technologies are worth integrating into workstations?
The most commonly used systems are MES and ERP, which allow the entire production process to be monitored in real time and quick decisions to be made based on reliable data. Predictive analytics and vision systems have also been growing in importance in recent years.