There are many benefits to implementing automation into production processes. Increased productivity, reduced costs, and flexibility to respond to changing market conditions are just some of them. However, implementing new automatic production lines poses several challenges. What considerations do companies planning to automate production need to take into account? How are Industry 4.0 principles related to production lines? What does the process of designing and implementing these lines entail? These and other questions will be answered in the following article by Paweł Małachowski – Senior Design Engineer at Endego.
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The driving force behind the dynamic technological development we are currently experiencing is the idea of Industry 4.0. The implementation of automated production lines is perfectly in line with this revolutionary concept. The use of robots, digitisation, automation, and the systematic collection of data are influencing the innovation of production lines, enabling more efficient, precise, and flexible working.
Here are the key elements of the Industry 4.0 concept that impact modern production line design and optimisation:
Robotics: Industrial robots equipped with sensors and programmable arms are able to perform a variety of tasks that previously had to be performed by humans: from assembly to packaging and sorting.
Artificial Intelligence: Advanced AI algorithms make it possible to monitor, analyse, and optimise production processes. AI systems can also predict failures and prevent interruptions in production.
Internet of Things: IoT devices allow remote monitoring and management of production lines. This makes it possible to react quickly to potential problems and optimise productivity.
Data storage: Data collected from production lines allows areas for optimisation to be identified.
Companies are constantly looking for ways to improve the efficiency of their production processes. One of the key tools to achieve this is the automation of production lines. The advantages that automation brings to manufacturing are primarily:
One of the most important advantages of automatic production lines is the increased productivity and speed of production. Automated processes allow tasks to be performed faster and more reliably, leading to increased production rates. Robots and machines operate continuously, eliminating interruptions caused by human fatigue. In addition, automated production lines are designed to provide a specific time to produce the finished product. This results in faster delivery of goods to the market, which in turn can affect competitive advantage.
Automatization eliminates human mistakes and reduces deviations in production processes. As a result, products are manufactured with more precision, resulting in higher quality products. Complex and repetitive tasks, prone to human errors, can now be executed with precision by advanced production lines. The automation of production processes eliminates the risk of errors due to human factors, such as mistakes, fatigue, or lack of employee focus. Automatic systems operate according to pre-programmed algorithms, which minimises the likelihood of errors.
Automatization helps reduce production costs. Although investing in automatic production lines can be costly initially, it saves money in the long term. Following the initial investment, automated machines yield lower costs compared to human labour performing the same tasks. In addition, the optimisation of production processes and the minimisation of errors translate into reduced costs associated with defective products and reduced material losses.
The COVID-19 pandemic is a prime example of how sudden events can affect the operation of businesses. Automatic production lines, largely independent of human intervention, can continue production even when workers are forced to remain isolated.
Modern production lines are characterised by flexibility, allowing production to change quickly from one type of product to another. This is an important feature in an environment where market trends and customer demand can change rapidly. With flexible production lines, companies can adapt to new requirements without major production interruptions or wasted resources.
Production lines equipped with Industry 4.0 technologies enable monitoring and remote control of production processes. The real-time data collected on them can be analysed, allowing potential failures to be detected early and corrective action to be taken before major problems occur.
The introduction of automatic production lines brings significant benefits, but also comes with some challenges that companies need to address.
One of the main challenges is the need to invest in machinery and technology to enable automated production. Each new type of product may require adaptation or even the purchase of completely new equipment. This comes at a financial cost as well as the time required to implement new technological solutions.
Automatic production lines require new skills from personnel. Employees need to be trained in their use and in managing automated processes.
The introduction of automatic production lines often involves the integration of different systems and technologies. This is a complex process that requires cooperation between different departments of the company.
Automated systems require constant monitoring and maintenance. Keeping the equipment in good working order and responding quickly to any failures are key to maintaining production continuity.
Endego has the knowledge and experience to design production lines for a diverse range of industries. Whether your company is in the automotive, white goods, construction, or other fields, Endego is able to tailor solutions to the specific requirements and needs of your sector. There are many ways in which Endego can support your company in the introduction of automatic production lines, including:
When your company wants to automate production, Endego presents the most cost-effective and efficient solutions. Based on an analysis of the company’s operations, Endego prepares a design and quotation, enabling planning and budgeting based on reliable data.
Using advanced 3D Design tools such as Catia and SolidWorks, our engineers create a detailed design and visualisation of the production lines as well as their technical documentation. Endego has implemented a precisely designed, multi-stage production line design process. Each of its stages aims to ensure that the line is perfectly functional and efficient, and to meet customer expectations by guaranteeing efficient production.
The first stage, the order analysis, is the foundation of the entire process. The priority is to design a line that meets specific requirements, such as CT (‘Cycle Time’) or OEE (machine utilisation rate), etc.
The concept is the second step and is based on the analysis of the order. Here, engineers create various variants of the solution, taking into account technical aspects, ergonomics, and efficiency. In this way, a first framework design is created that will potentially meet the customer’s requirements.
In the next stage, engineers proceed to the detailed design of the production line and the selection of mechanical, electrical, and pneumatic components. Aided by advanced tools such as Catia and SolidWorks, designers create three-dimensional models (Design 3D) to see the line simulated in space. In the machine design and construction phase, our engineers draw on their extensive knowledge and many years of experience. It is at this stage that innovative ideas are born that shape the heart of machines. The result is the creation of production lines that are not only functional but also distinguished by their unique character and innovative potential.
Once the line has been carefully designed, the ordering of components proceeds. The parts are completed and assembled. Although we do not have our own assembly department, we work with reputable external companies that carry out assembly based on Endego’s design and under our supervision. This partnership enables comprehensive project implementation, ensuring high-quality assembly according to design.
The production line is usually installed and pre-started at our department in Gliwice. This is the stage when the equipment is connected and its correct functioning is checked.
After pre-commissioning, test production is carried out to check that the process meets all requirements. Possible imperfections and areas for optimisation are identified and rectified.
If the tests have been successful, the line is transported to the customer’s site. The assembly of equipment, optimization, and on-site commissioning then take place in accordance with the previous assumptions.
The final stage is to carry out operator training. Endego’s specialists teach the customer’s employees how to use the new production line, ensuring that the technology is used effectively.
Endego provides a guarantee on its machines that also includes maintenance of the line throughout, and a fast response to warranty claims is one of the hallmarks of our company.
Automatic production lines bring many benefits but also pose some challenges for companies. Capital expenditure, the need to train employees, and the integration of technology are all factors that need to be taken into account when planning an implementation.
Endego is a partner that can help your company introduce automatic production lines, regardless of the industry you work in. We offer support from the beginning to the end of the process, from conception and design to implementation, line commissioning, warranty, and post-warranty service. Thanks to the professionalism, experience, and knowledge of Endego’s employees, the creation of production lines is a standardised process leading to the delivery of advanced and optimised solutions meeting the highest standards to the customer.
This guide is designed for business owners and decision-makers within manufacturing and production industries who are considering investing in industrial automation.
Here’s what we’ll be discussing:
Let’s get started.
If you’re considering some form of factory automation equipment, it’s very likely you’ll see a lot of case studies from automation companies. What you rarely see is an in-depth description of the industrial automation integration process outside of closed doors. There are good reasons for this:
With those caveats in mind, we’d like to pull back the curtain on our factory automation process. Understanding this simplified outline should improve the quality of your custom machine integration.
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The Automation Assessment is all about narrowing down the targets of the project to something realistic, practical, and financially sound. We identify the best opportunities based on the return on investment (ROI) and risk. Let’s break this step down.
Every Automation Assessment meeting should begin with a risk-free virtual discussion about the project. You should not expect to have to outline parts, machine designs, or other machine specifics. This meeting is simply talking about the process you need to automate. The most productive virtual discussions gather the following pieces of information:
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Your Return on Investment with Your Integrator
Ask your integrator to provide a standard mutual automation NDA to support a fully open discussion. Both sides will want to go further into specific details on products and processes and a mutual NDA can provide the legal protections you need to constructively share information.
This can come after the virtual discussion as that’s more about project viability than sharing critical intellectual property (IP) details. The NDA allows the integrator to share their own IP including any provided proposals. Once NDAs are signed, the Automation Assessment process can go deeper.
After the Virtual Opportunity Discussion, you get an early ROI calculation. This is an estimate, based on the provided process metrics, of how long it will take for your automated solution to make back the investment. For a reasonably sized project, this takes one to four years, but after that point, the machine will provide pure profit.
The ROI calculation covers a comparison of your current business to a potential business estimate from the advanced capabilities of the machine. Not everyone considers the additional opportunities to grow your business in the ROI calculation.
For instance, you can account for the potential profits you can get if you can make three times the products with half the workers, but automators commonly don’t account for the ways those displaced workers can pursue additional sales, take that time to pursue research and development (R&D) or take the time for process improvements.
DEVELOP LLC includes a reverse ROI calculation capable of drilling down into the type of budget you should have available for the type of project you want based on swifter or more gradual project deadlines.
We offer two options for Project Assessment:
Are you interested in learning more about Automatic Production line? Contact us today to secure an expert consultation!
We then assess the specific process discussed in the Virtual Opportunity Discussion but also evaluate the other processes in your production facilities for additional automation opportunities and process improvements.
We strongly recommend this if you’re new to automation. DEVELOP LLC will give a full report on your opportunities in as little as four on and offsite hours, and that report can help you learn about what you can automate.
In a series of follow-up meetings, we collaborate. If multiple opportunities were identified, we provide a scatterplot of project options ranking each of them by capital expenditure, ROI, and risk. We meet with the customer to select one opportunity to build an official Statement of Work.
In the event of a single project, we refine that project into a more specific machine concept that targets the quickest ROI and the largest financial gain. In both cases, we apply details of how it impacts the other lines in the production facility, what kinds of power and labor it needs to run, and how it would support the growth of the business around it.
Next, we hold calls, emails, meetings, and conversations to generate a mutually agreed-upon Statement of Work. This series of discussions provides the following:
The Statement of Work is signed, and the custom automation project begins.
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Your Industrial Machine Design Proposal
This stage remains collaborative. Now that the main scope of the machine and the Factory Acceptance Testing (FAT) requirements are mutually agreed upon, the primary responsibility shifts. These requirements are agreed-upon targets that demonstrate where the final machine is meeting or not meeting the project expectations.
At this point, the bulk of the work is in the hands of the integrator. Their task is to translate these high-level goals into the technical capabilities of the machine.
In this stage, the integrator updates you on progress, giving demos and asking for feedback at distinct stages. While you’re solicited for samples and details specific to the application, a lot happens internally with the integrator.
You may have seen a 3D design in the Statement of Work and wondered, “Doesn’t this represent the final machine design?” True, during the Kickoff Meeting where you signed the Statement of Work, you met with the automation integration team and they went over the full scope of the project, including a 3D Computer-Assisted Design (CAD) model capable of demonstrating a working concept of your machine. The CAD model in the Statement of Work is a working draft, not a final model. There are good reasons for this.
In the Internal Kickoff Meeting, every member of the DEVELOP LLC team comes together to formally plan the project in an internal-only kickoff meeting. The CAD and high-level requirements are presented to the entire team and designated team members are assigned their roles in engineering and design (software engineering, electrical engineering, mechanical engineering, building, technical writing, integration, etc.).
With everyone in the room, the team builds a flow diagram of the entire machine process from beginning to end. Every incremental step, from startup to accepting the first part, to processing, moving, selecting, and finishing is charted.
With our single-source guarantee, each member of the design and engineering team has an open invitation to pause. They can call out missed steps, ask questions about vague or puzzling parts of the design, or flag certain parts of the flow diagram for engineering risk or more information needed.
Complications are anticipated, mitigated, and functionally averted using the draft CAD as a model. Sample parts from the production line are examined and theoretical stress testing trials are laid out for the future (i.e., “If we choose this robot arm, will the gripper still be able to grip when swinging the part at max speed”).
The team then prepares for the Customer Kickoff Meeting. They compile a list of detailed questions for the customer about their product automation.
The team meets with you and presents a more formal introduction to the machine. Roles are explained and finalized. Mutual opportunities are given for Q&As about the process, specifications, and details. The team may show and review multiple design options with customers where preferences play a factor. This is also the point where both teams take one last check for major changes, additional SKUs, or forgotten requirements.
Using the info and feedback in the Internal Kickoff, the entire team is given free rein for Proto CAD design. This stage is concurrent with the Onsite Information Gathering described below.
The best way to design is to start, and our team is given free rein to experiment, draft, change out critical elements, and try solutions with authentic parts selection, software, and schematic design. They review multiple 3D models of the machine to address practical alternatives to the trickier engineering risks of the final machine.
They also review the Human-Machine Interface (HMI) design for aesthetics and functionality. This is another opportunity to consider if there are better engineering choices for a swifter ROI, practical design, and functional engineering. The team wraps up the Proto CAD phase by archiving all their attempts and then restarting the finished design with a committed team-approved vision.
We then outline the Bill of Materials (BOM) and schedule part orders based on lead times. Parts for early prototypes are ordered to make sure an early prototype can mitigate the high-risk aspects of the integration.
The project team goes onsite to the production facility. While there, they verify the footprint of the final machine, consider integration with other machines onsite, and check with operators to confirm that the machine design will meet their needs. The team asks detailed questions of the production team and management while providing updates.
While onsite research may only happen once or twice, back-and-forth information gathering continues throughout the entire engineering process with options to discuss outside of scheduled meetings. The team makes themselves available for questions.
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The team then assembles working prototypes of individual modules, focusing on the areas identified as the highest engineering risk. They collaborate with multiple reviews of a final 3D CAD, completed electrical engineering, and fully scoped software. The final HMI is assembled and refined.
Rigorous cycle time verification studies and Factory Acceptance Testing (FAT) take place to drill any issues and stress test the quality of the machine.
A last internal meeting is then held to confirm that the machine is ready for the client.
The team assembles a potentially complete version of the machine. FAT standards are rigorously tested from beginning to end using raw materials and products from the customer. The customer comes to HQ, confirms the FAT standards have been met, and minor changes are made to accommodate last requests or fine-tuning.
A final review meeting is held at DEVELOP LLC HQ (or virtually based on preference or convenience) between the project team and the client. All the FAT standards are confirmed in demos of the working prototype. All the specifics of the machine, how it works, and how it looks are finalized.
The customer reviews the machine and is given 30 days to approve the transition from prototype to final build. This is the last opportunity to make minor adjustments to the machine before final integration.
Our team disassembles the finished machine at HQ and then ships it to your production facility. In a process that takes days or weeks, depending on the scope of the project, we reassemble and integrate the machine into your production line. We run Site Acceptance Testing (SAT) to make sure it runs just as well in your facility as it did in HQ and there are no regressions. Then, we make sure it works in relation to the footprint, environment, and safety requirements of your facility.
While the build team assembles and integrates the machine, our project managers and trainers work with your operators, managers, and relevant staff to train on the safe operation of the machine, and regular maintenance protocol, and answer any questions about what the custom automation does or doesn’t do.
At DEVELOP LLC we specialize in education and training for self-sufficiency. We distribute physical and digital training materials and our staff make themselves available for any last-minute needs related to the machine.
With the machine rebuilt, and the operators fully trained on the machine, the integration is done. The ROI might be months or years off, but those figures were a snapshot of your old production capability versus what your new machine could do.
You can reap the benefits of your lower facility footprint, your higher production speed, and your higher rate of revenue the second the integration is done. You can redirect any displaced workers to pursue new sales, R&D, or help customers. This will match your enhanced production. A responsibly utilized automated machine positions you to shorten that ROI timeframe with growth opportunities.
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It can be. But these are the things you should consider before moving on from your integrator:
We train for self-sufficiency and the ability to maintain the custom automated machine, but we understand when customers want to settle for nothing less than expert service. We offer a variety of cost-effective maintenance contract packages that allow for onsite and remote troubleshooting of your technology.
Our machines will also have options for data and remote maintenance. Talk with your project manager to set this up ahead of time as part of your onsite training.
If you worked with a responsible automation integrator, then your machine was built anticipating future automated additions to your production capacity. When a low-mix, high-volume machine hits a production floor, the staggering increase in efficiency, speed, quality, consistency, safety, and revenue changes your business.
Suddenly, you’ll realize you can pursue bigger customers, new opportunities, and new product lines. The savings from decreased rework, downtime, labor costs, turnover, and production variability mount quickly. Seizing that growth opportunity with another automated machine is what makes the difference between squandering an advantage and visionary planning.
Now that you’re familiar with the process, the team, and what custom automated machinery means to your growth, you can use that knowledge to inform the next machine. A similar machine targeting the best ROI opportunity has the potential for swifter design, build, integration, and lower cost.
You can even choose to augment your custom machine with additional secondary processing (i.e., adding a pick-and-place packaging and palletizing system to the end of the assembly conveyor).
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We hope this has helped you better understand the automation integration process. A lot of people come up to us at trade shows and say, “We definitely want to automate, but we’re thinking of getting that going two years from now.”
The automation process — from planning and communication to engineering — takes significant time, sometimes extending just to secure board approval for such sizable investments.
If you’re considering automating in two years, the time to start talking with DEVELOP LLC is now. Don’t wait until the last minute. Let us help you prepare for a seamless transition into automation. Start by telling us about your project today, schedule a virtual meeting, or reach out directly at (262)-622- to begin your journey toward custom automated machine integration.
Act now to shape your automation future — contact DEVELOP LLC to learn how to kickstart your custom automation project.
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