What Should an SME Consider Before Automating Processes with PLCs and Industrial Robots?

Dec 13, 2024

Industrial automation can be a transformative change for small and medium-sized enterprises (SMEs). Implementing technologies like PLCs (Programmable Logic Controllers) and industrial robots not only enhances operational efficiency but also improves product quality and reduces costs over time. However, this step requires careful evaluation to ensure the benefits outweigh the costs and that implementation is successful. Here are the key factors every SME should consider before automating their processes.

1. Define Automation Objectives

Before implementing any technological solution, it is crucial to clarify the goals you aim to achieve. Common objectives include:

  • Increasing productivity.

  • Reducing human errors.

  • Improving product quality.

  • Optimizing production times.

Clear objectives will help select the right technologies and measure results effectively.

2. Assess Current Processes

A detailed analysis of current processes will help identify specific areas where automation can be most beneficial. Key questions to consider:

  • Which processes are repetitive and prone to human error?

  • Which tasks require consistent precision?

  • Are there production bottlenecks that technology could eliminate?

This evaluation avoids unnecessary or ineffective solutions.

3. Consider the Return on Investment (ROI)

Automation involves a significant upfront investment. Calculating ROI helps determine whether the expenditure is justified. Factors to include:

  • Equipment and software costs (PLCs, robots, sensors, etc.).

  • Installation and integration with existing systems.

  • Staff training.

  • Expected savings in labor, waste reduction, and increased production.

4. Choose the Right Equipment

The market offers a wide variety of PLCs and industrial robots, each designed for different applications. Selecting the right ones to meet your company’s needs is essential. Key factors to evaluate:

  • PLC capabilities: Speed, memory, and compatibility with existing devices.

  • Robot type: Articulated, SCARA, collaborative (cobots), etc., depending on tasks.

  • Scalability: Systems that can expand as production grows.

5. Train Your Workforce

Automation doesn’t eliminate the need for human intervention; instead, it creates new responsibilities. Staff must be trained to:

  • Operate and program the equipment.

  • Perform basic maintenance.

  • Identify and troubleshoot system failures.

Investing in training is vital for long-term success.

6. Ensure Adequate Infrastructure

Implementing automated systems requires a robust infrastructure. This includes:

  • Physical space for installing robots or machinery.

  • Industrial communication networks like Ethernet/IP or Profibus to connect devices.

  • Stable power supply.

Working with engineers to adapt infrastructure to automation needs is essential.

7. Comply with Standards and Regulations

Automation must comply with safety standards and sector-specific regulations. This ensures not only worker protection but also product acceptance in demanding markets. For industrial robots, for example, consider standards like ISO 10218 (robot safety) or certified equipment.

8. Seek Expert Guidance

Automation is a technical process requiring advanced expertise. Engaging professionals in PLC and industrial robot programming simplifies selection, implementation, and maintenance. Partnering with reliable integration companies can make the difference between success and failure.

9. Plan a Phased Implementation

Instead of automating all processes at once, many SMEs opt for gradual implementation. This allows them to:

  • Mitigate financial risks.

  • Identify and resolve issues in early stages.

  • Help employees and processes adapt to change progressively.

Conclusion

Industrial automation with PLCs and robots is a powerful tool for SMEs aiming to grow in competitive markets. However, its implementation requires strategic analysis, adequate investment, and a mindset of continuous improvement. By considering these aspects, companies can ensure that automation not only meets their goals but also drives long-term growth.