Who is an industrial automation integrator?

Manufacturing is undergoing rapid change, driven by the growing need for automation and process optimization. One of the key elements of this transformation is the industrial automation integrator. With their support, companies can efficiently implement modern technological solutions, increasing production efficiency and safety. In this article, we explain the role of the industrial automation integrator, discuss the challenges and benefits of automation, and outline the skills and tools required in this profession.

Who is an industrial automation integrator?

An industrial automation integrator is a specialist company that designs, implements, and maintains automation systems in manufacturing plants. Its role is not limited to installing the right equipment and software. It also ensures proper operation and integration with existing systems.

With broad expertise in industrial automation, mechanics, electronics, and programming, the integrator can deliver comprehensive solutions tailored to the specific needs of a given company.

Industrial automation and the challenges of modern manufacturing

Industrial automation plays a key role in modern industry, addressing growing demands for production efficiency, quality, and safety. Implementing advanced automation systems makes it possible to significantly improve operational efficiency, reduce production costs, and minimize the risk of human error. As a result, companies are increasingly investing in modern automation technologies that provide full control over production processes.

One of the main challenges companies face is integrating different systems and devices into one coherent whole. This is exactly where the industrial automation integrator plays a critical role, bringing the knowledge and experience needed to connect individual system elements effectively.

In addition, the integrator must stay up to date with the latest trends and technologies, such as Industry 4.0, including the Internet of Things (IoT), data analytics, and artificial intelligence.

Industrial automation integrator: What do they do?

Industrial automation integrator plays a key role in implementing and maintaining automation systems in manufacturing plants. Their work covers a wide range of activities essential to ensuring the efficient and safe operation of automated systems. The main areas of responsibility of an industrial automation integrator are outlined below:

1. Automation system design: The integrator develops automation system diagrams and models tailored to the specific needs of a given manufacturing plant. This includes mechanical, electrical, and software design.
2. Equipment installation and configuration: This process includes installing automation equipment and configuring networks and control systems. The integrator is responsible for ensuring that all components are installed correctly and operate in full synchronization.
3. System integration: The integrator combines different automation systems into one coherent whole, ensuring they work together properly. This often includes integrating new systems with existing ones, which requires advanced technical knowledge and experience.
4. PLC programming: Writing and optimizing control software for programmable logic controllers (PLCs) is one of the integrator’s key tasks. This ensures effective control and automation of production processes.
5. Staff training: The integrator provides training for personnel in the operation and maintenance of new automation systems. This enables employees to use the implemented solutions effectively and safely.
6. Monitoring and maintenance: Ongoing system monitoring, along with regular inspections and repairs, is essential to ensure the continuity and reliability of production operations.
7. CE certification: The integrator prepares technical documentation and carries out certification procedures in line with European Union directives. This includes conformity assessment processes and CE marking, which confirms compliance with European safety standards.
8. Risk analysis: Carrying out a detailed risk analysis according to EN ISO 12100 is essential for identifying potential hazards and implementing preventive measures. This analysis helps minimize the risks associated with the use of automated systems.

Thanks to this broad scope of work, the industrial automation integrator plays a key role in modernizing and automating production processes, ensuring efficiency, safety, and compliance with applicable standards.

Industrial automation integrator: The role of the design office

The design office is an integral part of a company involved in industrial automation integration. Its role is to design mechanical solutions that work together with automation systems. As a result, the industrial automation integrator can deliver complete, consistent solutions that are precisely matched to the client’s specific needs.

Within the design office, various analyses and calculations are carried out, such as strength calculations (finite element analysis), which enable accurate planning and implementation of new solutions. Design office staff work closely with other company departments to ensure that all system components are compatible and perform as intended.

The design office also plays a key role in the process of CE certification for machinery, designing solutions that meet all applicable standards and directives. This allows the integrator to ensure that all implemented systems are safe and compliant with current regulations.

CE certification for machinery: What are the requirements?

CE certification is an essential part of the process of implementing new machines and systems in industry. It ensures that products meet the safety, health, and environmental protection requirements set out in European Union legislation. The industrial automation integrator plays a key role in this process by ensuring that all integrated systems and machines meet these requirements.

One of the integrator’s main tasks is to combine multiple partly completed machines and individual modules into a complete production line. Such an integrator must anticipate all safety-related risks in accordance with the Machinery Directive 2006/42/EC. This process includes:

• Hazard identification: Understanding and documenting all potential hazards associated with machine operation.
• Risk assessment: Carrying out a risk analysis in accordance with EN ISO 12100:2012, which helps assess the level of risk and define appropriate control measures.
• Implementation of preventive measures: Putting in place the necessary technical and organizational measures to minimize risk.
• Technical documentation: Preparing complete technical documentation, including the operating instructions, electrical schematics, and emergency plans.

Once the integration and risk assessment process is complete, the integrator prepares the EC declaration of conformity and places the CE mark on the machine, confirming compliance with the requirements of EU directives.

Industrial automation integrator and adapting machines to minimum requirements

Bringing machines into line with minimum requirements is a key process that ensures older machines, which were not originally designed to modern safety standards, can still be used safely and in compliance with regulations. The industrial automation integrator plays a key role here, helping employers meet their obligations under the Use of Work Equipment Directive.

For machines placed on the market before Poland joined the European Union, it is possible to adapt them to minimum requirements rather than essential requirements. This process includes:

• Safety audit: Carrying out a detailed audit of existing machines to identify areas that do not meet current safety requirements.
• Design and implementation of solutions: The integrator’s design office develops and implements the necessary modifications, such as installing guards, interlocking systems, or upgrading control systems.
• Training and documentation: Preparing the appropriate operating instructions and providing employee training on the safe operation of modified machines.

With this approach, the integrator ensures that all machines in the production plant comply with applicable regulations, minimizing the risk of accidents and improving overall workplace safety.

Structural calculations (FEA) in the integrator’s day-to-day work

Structural calculations (FEA) are an integral part of the design office’s work in a company involved in industrial automation integration. FEA (Finite Element Analysis) enables accurate modelling and structural analysis of the solutions being designed, which is essential to ensure their strength and safety.

In the day-to-day work of an industrial automation integrator, FEA calculations are used at various stages of designing and implementing new systems:

• Mechanical design: The design office uses FEA calculations to design mechanical components that must withstand specified loads during operation.
• Deformation and stress analysis: FEA calculations make it possible to predict how individual components will behave under load, allowing their design to be optimized.
• Assessment of durability and reliability: Structural analysis helps assess the durability and reliability of the solutions being designed, which is essential for ensuring long-term, trouble-free operation of automation systems.

By using advanced FEA tools, the industrial automation integrator can deliver solutions that not only meet all safety requirements, but also offer high quality and durability.

Engineering outsourcing: Benefits and challenges

Engineering outsourcing is becoming increasingly common in industry, especially in the field of industrial automation. Working with external specialists gives companies flexible resource management and access to the latest expertise and technologies. However, like any business strategy, outsourcing brings both benefits and challenges.

Benefits of engineering outsourcing:

• Access to specialist expertise: External engineers often have experience in specific fields, enabling rapid implementation of new technologies and solutions.
• Flexibility: Outsourcing allows companies to manage resources flexibly, which is particularly important for projects with fluctuating workloads.
• Cost reduction: Hiring external specialists can be more cost-effective than building and maintaining in-house engineering teams.

Challenges of engineering outsourcing:

• Coordination and communication: Effective cooperation with external engineers requires good coordination and communication to ensure consistency and avoid misunderstandings.
• Data security: Sharing confidential information and technologies with external parties involves data security risks.
• Quality control: Ensuring that external engineers work in line with the company’s quality requirements and standards can be challenging.

When choosing outsourcing, the industrial automation integrator must carefully consider these aspects and implement appropriate procedures to maximize the benefits and minimize potential risks.

Industrial automation integrator: Machine design

Machine design is one of the most important stages in the industrial automation process. The quality of the design affects not only production efficiency, but also machine safety and durability. The industrial automation integrator plays a key role in this process, combining expertise from different fields such as mechanics, electronics, and programming.

Key aspects of machine design:

1. Requirements analysis: The first step in machine design is a thorough analysis of the customer’s requirements. The integrator must understand the specifics of the production process, the expected technical parameters, and the budget and schedule constraints.
2. Technology selection: Based on the requirements analysis, the integrator selects the appropriate technologies and solutions. This may include choosing mechanical components, control systems, and automation software.
3. Concept and preliminary design: Developing the concept and preliminary design, including diagrams, technical drawings, and 3D models. At this stage, structural calculations (finite element analysis) are often used to assess whether the designed components will withstand the planned loads.
4. Prototyping and testing: Building prototypes and carrying out tests to verify the design assumptions. These tests make it possible to identify and correct any errors before the machine is put into production.
5. Technical documentation: Preparing complete technical documentation, including detailed descriptions, operating instructions, electrical and pneumatic diagrams, as well as test results.
6. Certification and CE marking: Ensuring that the machine meets all requirements of the Machinery Directive 2006/42/EC and other applicable standards. At this stage, the integrator may also carry out the CE certification process.

With a detailed approach to machine design, the industrial automation integrator can deliver solutions that are not only efficient, but also safe and compliant with applicable regulations.

Industrial automation integrator: Project management in industrial automation

Project management is a key factor for success in industrial automation. This process requires a coordinated approach to planning, execution, and monitoring to ensure the timely and efficient implementation of automation systems. The industrial automation integrator acts here as the coordinator overseeing every stage of the project.

Key aspects of project management:

1. Planning: Defining the project objectives, scope of work, schedule, and budget. Planning also includes identifying the human and technical resources required to complete the project.
2. Risk management: Identifying potential hazards and developing strategies to minimize risk. In industrial automation, it is particularly important to anticipate risks related to system safety and reliability.
3. Team coordination: Managing the teams of engineers, technicians, and specialists working on the project. This requires effective communication and cooperation between different company departments and external partners.
4. Progress monitoring: Regularly tracking progress, controlling quality, and assessing compliance with the schedule and budget. Monitoring makes it possible to quickly identify and resolve any issues.
5. Documentation and reporting: Maintaining project documentation and regularly reporting progress to management and the customer. The documentation covers all aspects of the project, from technical plans to test and certification results.
6. Implementation and acceptance: Carrying out final tests, installing the systems on the customer’s site, and training personnel. Customer acceptance of the project is the final stage confirming that all requirements and expectations have been met.

Effective project management in industrial automation requires the integrator to have broad technical knowledge as well as strong organizational skills. This makes it possible to implement advanced automation systems on time and within budget.

Machinery Directive 2006/42/EC: What should you know?

Machinery Directive 2006/42/EC is one of the key legal acts governing machine safety in the European Union. It sets out the minimum requirements for the design and construction of machinery to ensure the protection of users’ health and safety.

Key aspects of Machinery Directive 2006/42/EC:

1. Scope: The Directive covers all machinery placed on the market or put into service in the European Union. It also covers interchangeable equipment, safety components, lifting accessories, and chains, ropes, and webbing.
2. Essential requirements: Machinery must meet the applicable essential health and safety requirements. These requirements include, among other things, mechanical, electrical, and thermal hazards, as well as noise.
3. Conformity assessment: Before placing machinery on the market, the manufacturer must carry out a conformity assessment to ensure that the machine meets all Directive requirements. For certain machines, testing by a notified body is required.
4. Technical documentation: The manufacturer must prepare and retain technical documentation, including, among other things, a design description, technical drawings, risk analysis results, and the EC Declaration of Conformity.
5. CE marking: Machinery that meets the Directive requirements must bear the CE mark. This marking confirms that the product complies with European safety requirements and may be legally sold within the EU.
6. EC Declaration of Conformity: The manufacturer must issue an EC Declaration of Conformity confirming that the machine meets all Directive requirements. This declaration must accompany the machine and include, among other things, the manufacturer’s details, a description of the machine, and references to the standards applied.

Industrial automation integrators play a key role in ensuring that machinery complies with the requirements of the Machinery Directive 2006/42/EC. With broad technical knowledge and practical experience, integrators can effectively manage conformity assessment processes, prepare the required documentation, and carry out the necessary testing and certification activities.

Partly completed machinery: What are the risks?

Partly completed machinery is equipment supplied in an incomplete state and requiring further work before it can be put into service. This type of machinery presents specific challenges in terms of regulatory compliance and safe use.

Key risks associated with partly completed machinery:

1. Non-compliance with requirements: Partly completed machinery may not meet all safety requirements set out in the Machinery Directive 2006/42/EC. This means additional integration work is required to ensure compliance.
2. Incomplete documentation: Supplied machinery may not include complete technical documentation, which makes conformity assessment and CE certification more difficult.
3. Operational risk: Using partly completed machinery without appropriate safety measures can lead to serious accidents and damage. A detailed risk analysis in accordance with EN ISO 12100 and the implementation of the necessary risk reduction measures are essential.
4. Need for integration: Partly completed machinery must be integrated with other systems and equipment. This process can be complex and time-consuming, and if carried out incorrectly, it may result in technical and operational problems.
5. Legal responsibility: When partly completed machinery is put into service, responsibility for compliance rests with the company that carries out the integration and completes the machine.

Industrial automation integrators play a key role in managing the risks associated with partly completed machinery. With their experience and technical expertise, integrators can carry out the integration process effectively, ensuring that all machinery meets safety requirements and complies with the applicable regulations.

The CE mark and CE marking: Process and significance

The CE mark is a symbol confirming that a product meets all EU requirements relating to safety, health, and environmental protection. CE marking is mandatory for all machinery placed on the market in the European Union.

CE marking process:

1. Identifying requirements: The first step is to identify the relevant directives and harmonized standards that apply to the product in question. For machinery, the key directive is the Machinery Directive 2006/42/EC.
2. Conformity assessment: Carry out a conformity assessment, which may include risk analysis, technical testing, and verification against harmonized standards. An industrial automation integrator often performs these assessments as part of the implementation process for new systems.
3. Technical documentation: Prepare complete technical documentation, including, among other things, a design description, technical drawings, the results of analyses and tests, and the EC declaration of conformity.
4. EC declaration of conformity: Issue an EC declaration of conformity confirming that the product meets all requirements of the relevant EU directives. This document must be supplied with the product.
5. CE marking: Affix the CE mark to the product as the final confirmation of its compliance with EU requirements. The CE mark must be placed in a visible, legible, and durable location.

The importance of CE marking:

• Safety: CE marking confirms that the product is safe for users and meets all requirements relating to health and environmental protection.
• Legal compliance: Products bearing the CE mark may be legally sold throughout the European Union without additional technical barriers.
• Customer confidence: The CE mark increases customer confidence in the product by confirming its quality and compliance with European standards.

An industrial automation integrator plays a key role in the CE marking process by ensuring that all integrated systems and machines meet the requirements and are properly marked.

Harmonized standards in industrial automation

Harmonized standards are a key part of the certification and CE marking process for machinery. They were developed to align technical and safety requirements across the European Union, making trade and the integration of different industrial automation systems easier. An industrial automation integrator must be thoroughly familiar with these standards to ensure the compliance of the systems they design and implement.

Key aspects of harmonized standards:

1. Definition and purpose: Harmonized standards are standards developed by European standardization organizations such as CEN (European Committee for Standardization) and CENELEC (European Committee for Electrotechnical Standardization). They are recognized by the European Commission as suitable for meeting the requirements set out in EU directives.
2. Use in industrial automation: Harmonized standards cover a wide range of technical and safety aspects related to industrial automation, such as machine design, control systems, electrical and mechanical safety, and explosion protection (ATEX).
3. Essential requirements: Harmonized standards define the essential requirements for the design and operation of machinery that must be met to obtain CE marking. Examples include EN ISO 12100:2012 on risk assessment and machinery safety, and EN 60204-1 on electrical safety.
4. Implementation process: An industrial automation integrator must implement the relevant harmonized standards at every stage of the project, from design through installation and testing. This requires close cooperation with the design office and regular monitoring of changes in regulations and standards.
5. Benefits of applying standards: The use of harmonized standards simplifies the CE certification process, improves the safety of machines and systems, and increases customer confidence in products. Thanks to aligned standards, the integrator can also adapt solutions more easily to different European markets.

Compliance with harmonized standards is an essential part of an industrial automation integrator’s work, ensuring that all implemented systems meet European safety and quality standards.

Risk analysis according to EN ISO 12100: Practical guidance

Risk analysis is a key element in ensuring the safety of machinery and industrial automation systems. The EN ISO 12100 standard provides the basis for risk assessment and sets out the methodology for identifying, evaluating, and eliminating or reducing hazards. An industrial automation integrator must carry out this analysis at every stage of the project.

Practical guidance on risk analysis:

1. Hazard identification: The first step is to identify all potential hazards associated with the machine or system. These may include mechanical, electrical, thermal, chemical, and ergonomic hazards.
2. Risk assessment: Once the hazards have been identified, the risk associated with each one must be assessed, taking into account the likelihood of occurrence and the potential consequences. Risk assessment makes it possible to classify hazards by significance.
3. Risk elimination or reduction: Based on the risk assessment, the integrator must develop strategies to eliminate or reduce hazards. This may include design modifications, the use of guards and safety systems, as well as the implementation of appropriate operating procedures.
4. Documentation of results: All results of the risk analysis must be documented in detail. The documentation should include a description of the hazards, the results of the risk assessment, and the measures applied to mitigate them. This is essential for CE certification purposes and to ensure regulatory compliance.
5. Monitoring and updates: Risk analysis does not end at the design stage. It should be updated regularly as changes are made to the machine or system and in response to new hazards. Regular monitoring makes it possible to detect and resolve issues quickly.
6. Training and awareness: A key element of risk management is staff education and training. Employees must be aware of the hazards and know the procedures to follow if they occur.

Following the guidelines of EN ISO 12100:2012 by an industrial automation integrator ensures that all implemented systems are safe and compliant with applicable regulations, which minimizes the risk of accidents and improves overall workplace safety.

Production process automation: Latest trends

Production process automation is a rapidly evolving field that continuously introduces new technologies and methods to increase production efficiency, quality, and safety. An industrial automation integrator must stay up to date with the latest trends in order to offer clients the most effective and innovative solutions.

Latest trends in production process automation:

1. Industry 4.0: The integration of the Internet of Things (IoT), artificial intelligence (AI), and data analytics to create smart factories. These systems enable real-time monitoring and optimization of production processes.
2. Robotics: The use of industrial robots to perform tasks that are dangerous, repetitive, or require high precision. Modern robots are becoming increasingly advanced and can work alongside people on the production line.
3. SCADA systems: The development of SCADA (Supervisory Control and Data Acquisition) systems enables advanced monitoring and control of production processes. An industrial automation integrator can implement these systems to provide full control over production.
4. PLC programming: Modern programmable logic controllers (PLCs) are becoming increasingly advanced, enabling more complex and precise control of production processes. PLC programming is a key part of an integrator’s work.
5. Safety and compliance: As automation increases, the importance of machine safety and standards compliance also grows. Integrators must ensure that all systems comply with safety standards such as ATEX and the Machinery Directive 2006/42/EC.
6. Virtual commissioning: The use of computer simulations to test and optimize automation systems before physical implementation. This makes it possible to identify and resolve issues at an earlier stage, shortening commissioning time and reducing costs.
7. Engineering outsourcing: More and more companies are choosing to outsource industrial automation specialists to gain access to the latest expertise and technologies without having to hire full-time employees.

Production process automation is an area that continues to evolve and create new opportunities. An industrial automation integrator must stay current with the latest trends and technologies in order to offer clients the most effective and innovative solutions.