Production process automation: How to get started?

Production process automation is one of the key pillars of modern industry, aimed at increasing efficiency, reducing costs, and improving product quality. In the era of Industry 4.0, automation has become essential for companies that want to remain competitive. The purpose of this article is to provide a comprehensive guide to production process automation, highlighting the key steps, challenges, and best practices in this field.

Introduction to Production Process Automation

Production process automation is the integration of different systems and technologies to achieve more efficient and productive manufacturing. This requires an understanding of both the history of and current trends in industrial automation.

Industrial automation covers a broad range of technologies and processes that enable production activities to be automated. From simple assembly lines to advanced SCADA systems and PLC programming, industrial automation has evolved significantly over recent decades, contributing to the emergence of the Industry 4.0 concept.

What can be automated?

Production process automation is possible in virtually any area, and in short, almost anything can be automated. However, that does not always mean it is cost-effective. Although today’s technological capabilities are extensive, the decision to automate a given process must take both the potential benefits and the costs into account.

Our table presents a range of production processes that can be automated. Assembly operations may include assembling simple components, welding, soldering, or automatic part feeding. In the area of quality control, automation can cover visual surface inspection, dimensional measurement, label verification, and functional product testing.

Transport and logistics also offer many opportunities for automation, such as internal transport using conveyor belts, automatic packaging, labelling, sorting, and warehouse management. Mechanical processing may include sheet cutting and forming, welding, grinding, polishing, as well as more complex operations such as milling and turning.

In chemical processes, automation can be applied to painting, varnishing, coating application, mixing, and dosing of chemical substances. Material handling can be automated through loading and unloading, palletising, depalletising, automatic dosing, and transferring materials between workstations.

Although technology makes it possible to automate almost every aspect of production, assessing the business case for such investments is crucial. Automation delivers benefits such as higher productivity, lower costs, and improved quality, but implementation and maintenance costs, as well as potential technological complications, must be carefully analysed. As a result, every automation decision should be preceded by a thorough feasibility study and cost-benefit analysis.

First Steps in Production Process Automation

To begin production process automation, a company must first clearly understand its needs and objectives. The first step is to identify the processes to be automated. It is important to assess whether any technical solutions already exist that could speed up implementation, and whether the process is currently performed manually.

Many companies face the challenge of automating processes that were previously too expensive to automate because of rising labor costs and staff shortages. It is also worth noting that automating even difficult processes is becoming increasingly cost-effective.

1. Production Process Automation: Feasibility Analysis and Defining Project Assumptions

Once the processes to be automated have been identified, the next step is to define the project assumptions. A feasibility analysis includes assessing the technical possibilities for automation as well as estimating the budget. Working with external companies such as ours is particularly important when a business has limited automation experience.

2. The Automation Process from the Perspective of an Industrial Automation Integrator

An industrial automation integrator plays a key role in the automation process. At the start of cooperation with the client, the integrator analyzes the company’s requirements and helps develop a detailed automation plan. An important part of this process is cooperation with a design office, which handles preliminary design work and prepares technical documentation and operating instructions.

3. The Automation Process from the Client’s Perspective

From the client’s perspective, preparing the company for automation involves several key steps. First, it is necessary to assess which processes can be automated and what benefits this will bring. The next step is to choose the right automation partner. Engineering outsourcing can be an effective solution, especially for companies that do not have sufficient internal resources.

4. Production Process Automation: Building a Test Station and Process Testing

For new processes, once the initial concepts have been developed, it is worth building a test station and carrying out tests. This makes it possible to verify the assumptions and optimize the process before investing in the final machine or solution.

5. Planning and the Pre-Project Phase

Developing detailed automation plans and budgeting are key stages of the pre-project phase. It is important to ensure compliance with harmonized standards and the Machinery Directive 2006/42/EC. A risk assessment according to EN ISO 12100 is an essential part of this process, making it possible to identify and assess potential hazards.

Developing Detailed Automation Plans

The first step in the pre-project phase is to develop detailed automation plans. This process includes several key stages:

1. Defining project assumptions:
   • Identifying automation objectives: improving efficiency, reducing costs, increasing quality.
   • Defining the scope of automation: which processes will be automated and which technologies will be used.
   • Preliminary assessment of technical feasibility: analysis of available technologies and their application in the context of the company’s specific needs, including advanced SCADA systems.
2. Feasibility analysis:
   • Technical assessment: verifying whether the planned solutions are technically feasible.
   • Economic assessment: analyzing costs and the potential savings that automation will deliver.
   • Operational assessment: evaluating the impact of automation on existing processes and organizational structures.
3. Cooperation with external companies:
   • Selecting partners for cooperation: engineering companies, technology suppliers, system integrators.
   • Technical consultations: working with experts to develop optimal solutions.
   • Preparing preliminary project plans: developing project documentation that will serve as the basis for further work.

Budgeting

The next key stage is budgeting, which includes:

1. Cost estimation:
   • Equipment costs: purchase of machines, robots, and control systems.
   • Installation costs: costs related to system assembly and integration.
   • Operating costs: maintenance, energy, and staff training costs.
2. Project budget development:
   • Prepare a detailed budget covering all direct and indirect costs.
   • Include financial contingencies for unforeseen expenses.
   • Review and approve the budget by company management.

Ensuring Compliance with Standards and Regulations

Ensuring compliance with applicable standards and regulations is critical to the success of an automation project. This includes:

1. Harmonized standards:
   • Ensuring that all components and systems meet the requirements of harmonized standards.
   • Following international standards to ensure system compatibility and safety.
2. Machinery Directive 2006/42/EC:
   • Complying with the requirements of the Machinery Directive, which sets out the minimum safety requirements for machinery.
   • Ensuring that all machines and equipment comply with the Directive before being placed on the market.

Risk Analysis According to EN ISO 12100

Risk analysis is an essential part of the pre-project phase, ensuring that potential hazards are identified and assessed. This process includes:

1. Hazard identification:
   • Analyzing each stage of the production process to identify potential hazards.
   • Taking into account all possible sources of hazards, such as mechanical, electrical, thermal, and chemical hazards.
2. Risk assessment:
   • Determining the likelihood of hazards occurring and their potential consequences.
   • Classifying risk according to its significance and the need for action.
3. Development of a risk management strategy:
   • Developing and implementing measures to minimize risk, such as additional safeguards, emergency procedures, and personnel training.
   • Regularly reviewing and updating the risk analysis to reflect changes in production processes and technology.

Through careful planning and analysis, the pre-project phase provides a solid foundation for the later stages of production process automation, minimizing risk while maximizing efficiency and safety.

6. Production Process Automation: Machine Design and System Integration

The machine design process covers many technical aspects that are crucial to creating an efficient and safe production system. As part of this process, various analyses are carried out and advanced technologies are applied to ensure that the machines being designed will operate in line with requirements and specifications.

Strength Calculations (FEA) and Structural Analysis

Strength calculations (FEA) and structural analysis are essential parts of the machine design process. They make it possible to:

1. Load simulations:
   • Perform static and dynamic load simulations to assess how the machine will respond under different operating conditions.
   • Analyze stresses, deformations, and potential failure points in the machine structure.
2. Material optimization:
   • Select suitable structural materials to ensure machine strength and durability.
   • Reduce machine weight without compromising safety or functionality.
3. Verification of compliance with standards:
   • Ensuring that the design meets all applicable standards and regulations relating to structural strength and safety.

PLC Programming and Integration with SCADA Systems

PLC programming (Programmable Logic Controller) and integration with SCADA (Supervisory Control and Data Acquisition) systems are key technical elements that enable efficient management of production processes. This process includes:

1. Control system design:
   • Creating electrical and logic diagrams for control systems.
   • Programming PLC controllers to manage machine operations in real time.
2. SCADA system integration:
   • Implementing SCADA systems to monitor and manage production processes.
   • Integrating SCADA systems with PLCs, enabling the collection, analysis, and visualization of production data.
3. Testing and validation:
   • Testing control and monitoring systems to ensure reliability and accuracy.
   • Validating software and hardware to confirm that they operate in accordance with the design assumptions.

Preparing Technical Documentation

Preparing technical documentation is a key stage in the machine design process. This documentation includes:

1. Technical specifications:
   • Detailed descriptions of all machine components and systems.
   • Assembly, commissioning, and maintenance instructions.
2. Diagrams and technical drawings:
   • Comprehensive electrical, hydraulic, and pneumatic diagrams.
   • CAD drawings showing the machine design.
3. Operating and safety instructions:
   • Guidance for operators and technical personnel.
   • Safety procedures and emergency protocols.

7. Production Process Automation: Advanced Analyses in the Design Process

During machine design, a range of advanced analyses is carried out to ensure system optimization and safety. These analyses make it possible to identify potential issues at an early stage and implement appropriate corrective measures.

Design FMEA: Analysis of Design Failures and Their Effects

Design FMEA (Failure Mode and Effects Analysis) is an analytical method used to identify potential flaws in a machine design and assess their impact on system performance. This process includes:

1. Identification of potential failures:
   • Analysis of components and systems to identify possible failure points.
   • Creating a list of potential failures based on experience and historical data.
2. Risk assessment:
   • Assessing the likelihood of each failure and its potential impact on machine operation.
   • Classifying failures according to their criticality.
3. Planning corrective actions:
   • Developing risk-reduction strategies, such as design changes, additional testing, or the introduction of safeguards.
   • Monitoring and documenting the results of the measures implemented.

Process FMEA: Analysis of Process Failures and Their Effects

Process FMEA is similar to Design FMEA, but it focuses on the analysis of production processes. It includes:

1. Production process analysis:
   • Identifying key stages of the production process that may be exposed to failures.
   • Assessing the impact of potential process failures on production quality and efficiency.
2. Process risk assessment:
   • Analyzing the likelihood and consequences of failures occurring in the production process.
   • Prioritizing risks and planning preventive actions.
3. Implementation and monitoring:
   • Implementing corrective measures in the production process.
   • Regularly monitoring and reviewing the effectiveness of the changes introduced.

Design for Assembly and Design for Manufacturing

Design for Assembly (DfA) and Design for Manufacturing (DfM) are design optimization strategies aimed at improving ease of assembly and manufacturability. This includes:

1. Assembly optimization:
   • Designing components in a way that makes them easier to assemble, reducing production time and costs.
   • Simplifying the design, minimizing the number of parts, and improving access to key elements.
2. Manufacturing optimization:
   • Selecting materials and manufacturing technologies that increase efficiency and reduce costs.
   • Designing for ease of manufacture and minimizing complex production operations.

Risk Assessment in Accordance with EN ISO 12100

Risk assessment in accordance with EN ISO 12100 is a key element of machine design, ensuring that risks are identified and minimized at every stage of the design process. It includes:

1. Hazard identification:
   • Analyzing each stage of the production process to identify potential hazards.
   • Taking into account all possible hazard sources, such as mechanical, electrical, thermal, and chemical hazards.
2. Risk assessment:
   • Determining the likelihood of hazards occurring and their potential consequences.
   • Classifying risk according to its significance and the need for action.
3. Development of a risk management strategy:
   • Developing and implementing risk-reduction measures, such as additional safeguards, emergency procedures, and staff training.
   • Regular reviews and updates of the risk analysis to reflect changes in production processes and technology.

Advanced analysis during the design process is essential to ensure that the machines being developed are not only efficient, but also safe and compliant with applicable standards. These analyses make it possible to identify and eliminate potential issues at an early stage, which contributes to the success of the entire automation project.

8. Prototype Build and Testing

Once the design phase is complete, prototypes are built and tested. This process is critical because it verifies theoretical assumptions in practice and helps detect any issues early. At this stage, a safety audit is carried out, along with tests such as FAT (Factory Acceptance Test) and SAT (Site Acceptance Test).

Safety Audit

The safety audit is the first step in prototype testing. Its purpose is to ensure that all machine components and operating processes meet safety requirements and industry standards. This audit helps identify and eliminate potential hazards before more advanced functional testing is carried out.

FAT (Factory Acceptance Test)

Factory Acceptance Test is conducted at the manufacturer’s facility and is intended to verify whether the prototype meets all technical specification requirements and design assumptions. The FAT includes several key stages:

1. Documentation review: Before testing begins, the project team thoroughly reviews all technical documentation to ensure that all components have been installed in accordance with the design.
2. Functional testing: Functional tests are performed to check whether the prototype operates as required. These tests may include simulation of normal operating conditions as well as load testing.
3. Safety testing: Verification that all safety systems operate correctly, including emergency systems, interlocks, and guards.
4. Results reporting: All test results are documented and compared against the design assumptions. Any deviations are analysed and, if necessary, the prototype is modified.

SAT (Site Acceptance Test)

After FAT is completed, the prototype is transported to its final location, where the Site Acceptance Test is carried out. The SAT is intended to verify whether the system operates correctly under actual production conditions. It includes:

1. On-site installation: The engineering team installs the prototype on site, integrating it with the existing production infrastructure.
2. Functional testing: As with FAT, functional tests are performed, but this time in the actual operating environment. This includes checking all machine functions in the context of the overall production process.
3. Performance testing: Verification of machine performance under real production conditions, including full-load testing and testing over an extended period of use.
4. Compliance testing: Verification that the prototype meets all local regulations and standards, which may differ from those applied at the manufacturer’s facility.
5. Personnel training: Training for operators and technical staff to ensure that all users are properly trained to operate the new system.

Reporting and Acceptance

Once SAT is complete, all results are documented and presented to the customer. If the machine meets all requirements and performs as expected, it is formally accepted. If any issues are identified, the engineering team makes the necessary corrections and repeats the tests until compliance with the design assumptions is achieved.

The prototype build and testing process is crucial to ensuring that the final product is reliable, safe, and efficient. Thanks to thorough FAT and SAT testing, companies can be confident that their automation investment will deliver the expected benefits.

9. Automation Implementation and Maintenance

Implementing automation systems includes installation and commissioning, as well as training employees to operate the new equipment. The operating manual is a key document that ensures correct and safe use of the systems. Maintaining production efficiency requires the implementation of strategies such as TPM and SMED.

10. Production Process Automation: CE Certification and Regulatory Compliance

For machines to be legally used in the European Union, they must undergo the CE certification process. Compliance with the Machinery Directive 2006/42/EC and obtaining the CE marking are key steps in this process. Issuing an EC Declaration of Conformity confirms that the machine meets all legal requirements.

The Future of Production Process Automation

The shift to Industry 4.0 means implementing new technologies and innovative solutions that further improve production efficiency and performance. Continued development and process optimization are essential to maintaining competitiveness in the market.

Production process automation is a complex but essential step toward improving the efficiency and competitiveness of manufacturing companies. From a thorough analysis of needs and capabilities, through defining design assumptions and testing, to implementation and maintenance of automation systems, every phase requires collaboration and advanced technical expertise. With the right approach and partners, automation can deliver significant benefits in both costs and production quality.