Discover how to professionally plan and deploy robots to gain a competitive advantage
Your Path to Effective Robotics
Deploying industrial robots is a complex process that can radically improve efficiency, quality, and safety in your company. However, in order to fully utilize the potential of automation, a systematic approach is necessary, including precise analysis of needs, selection of appropriate technologies, and efficient management of the entire project. On this subpage, we present the key elements and stages of "Deploying Robots" - from initial concept and process analysis, through integration and programming, to testing and launching the production line.
At NexaRob, we place great emphasis on a partnership approach with the client: together we define goals, priorities, and work schedules so that the final result perfectly matches actual business needs. Regardless of the industry - food, pharmaceutical, automotive, electronics or other - our team has extensive knowledge of the specifics of various sectors, which translates into effective and tailored deployments.
Learn about proven methods for assessing processes and selecting appropriate robotic solutions
Needs Analysis and Technology Selection
Effective deployment of industrial robots begins with a thorough analysis of the needs and expectations of your company. This makes it possible to precisely define the areas in which automation will bring the greatest value. As part of the "Needs Analysis and Technology Selection" stage, NexaRob focuses on several key tasks:
Process Audit and Priority Identification
- Observation of production and logistics lines: Our engineers conduct a detailed review of workstations, machines, material flow, and environmental conditions.
- Determining key requirements: Together with the client, we define criteria such as required speed, motion accuracy, load capacity, or health and safety conditions in order to preliminarily define the scope of the project.
Defining Key Robotics Parameters
- Reach and payload of robots: What weight needs to be moved? What distances do products travel? Are there any space limitations?
- Level of automation: We analyze whether 100% robotization of a given process is cost-effective, or whether it is worth considering mixed systems (human + collaborative robot).
Adapting Solutions to Industry and Applications
- Type of construction: Depending on the specifics of the tasks (welding, assembly, packaging, machining), we can recommend articulated robots, SCARA, Delta, collaborative or mobile robots.
- Environmental conditions: In industries requiring sterility (food, pharmaceutical) or working in high temperatures (metal, chemical), we pay attention to construction materials, protection classes and additional safeguards.
Report and Preliminary Project Assumptions
- Technological recommendations: We present proposals for specific robot models, vision systems, grippers, sensors or controllers that best meet the requirements of the process.
- Estimating the benefits: We discuss what effects robotization can bring (e.g., reduction of errors, faster production rate, improved safety) and a preliminary return on investment (ROI) schedule.
Thanks to careful needs analysis, you will avoid making wrong purchases and downtime resulting from the mismatch of technology with actual conditions. Moreover, precisely defined goals and priorities allow for better planning of subsequent implementation stages, such as workstation design, without the risk of sudden changes in concept.
How to design an ergonomic and safe working environment for robots that is consistent with your production line?
Workstation Design and Integration
After selecting the appropriate technological solutions, it is time to practically implement robots in your plant. A key stage is Workstation Design and Integration - i.e., creating a layout of lines, safety guards, and control systems so that robots can work in optimal conditions, and people have maximum protection and comfort.
Layout and Arrangement Concept
- Space analysis: Based on the dimensions of the hall, the location of machines, and transport routes, we create a preliminary design for the placement of robots, buffer warehouses, or enclosures.
- Ergonomics and material flow: We ensure the smoothness of the process - from feeding raw materials to picking up finished products - so as to reduce unnecessary movements and shorten cycle times.
Selection of Appropriate Workstations and Grippers
- Adaptation to tasks: Depending on the type of process (e.g., welding, assembly, packaging, machining), we design or select ready-made workstations adapted to a specific task, taking into account load capacity and range.
- Grippers and tools: We offer pneumatic, electromagnetic, adaptive, or specialized grippers (e.g., for hot materials or delicate electronics).
Integration with Devices and Control Systems
- Communication with machines: Robots must interact with upstream/downstream devices, such as presses, injection molding machines, or transport systems.
- Compatibility with IT infrastructure: We ensure consistency with PLC, MES, ERP systems, and also offer the possibility of expansion with IoT platforms or data analytics.
Safety and Standards
- Risk Assessment: Before installation, we conduct a risk analysis and propose protective measures, such as enclosures, light curtains, or emergency stop buttons.
- Collaborative robots: If the process requires close human-machine cooperation, we consider cobots with built-in force sensors and collision detection.
Documentation and Implementation Plan
- Final project: We prepare detailed drawings, material lists, and electrical diagrams to ensure a smooth installation.
- Implementation schedule: We establish the sequence of actions to minimize the impact on daily production and ensure a smooth transition to the next stage.
Designed and integrated in this way, robotic workstations create a solid foundation for moving on to programming and testing, which will ultimately verify the performance, safety, and quality parameters of the entire system.
Set and verify all parameters so that robots operate efficiently and according to design assumptions.
Programming and Acceptance Tests
After developing the concept and designing the workstations, it's time for Programming and Acceptance Tests, which give the robots a specific sequence of movements and logic. At NexaRob, we focus on well-thought-out robot configuration and their virtual simulations, which allows us to fully optimize cycle time and confirm that all automation elements are consistent.
Preparing software and environment
- Choosing a programming language: Depending on the selected robots and customer preferences, we use ABB RAPID, Fanuc Karel, KUKA KRL, or other environments. It is crucial to adapt to existing systems and staff skills.
- Creating algorithms: We define the process logic (e.g., the order of picking up parts, conditions for moving to the next stage), taking into account the reaction to signals from sensors, vision systems, or PLC controllers.
Motion simulation and optimization
- Offline programming: Using simulation tools, we prepare robot trajectories in a virtual environment, reducing the time needed for debugging in the production hall.
- Cycle analysis: During the simulation, we check whether the movement paths cause collisions with equipment elements and whether there are areas where the travel time can be shortened without loss of quality or safety.
Installing software on real robots
- Transferring the program: After refining the algorithms, we transfer the ready-made scripts to the controllers of physical robots. At this point, the first "live" launch takes place.
- Final configuration: We calibrate coordinates, adjust tools (e.g., grippers) and operating parameters (speed, pressing force). All this is done taking into account the guidelines in the integration project.
FAT and SAT Acceptance Tests
- FAT (Factory Acceptance Test): At the NexaRob facility or at the supplier's location, under conditions similar to real-world scenarios, we verify whether the robots achieve their intended performance, accuracy, and safety goals.
- SAT (Site Acceptance Test): The next phase of testing is carried out at the customer's target location. It allows us to verify the operation of the robots in cooperation with the other elements of the line (machines, IT systems).
Verification of results and corrections
- Data analysis: During the tests, we measure cycle times, the number of rejects, or communication errors. We make any necessary corrections to the code or modifications to the technical settings.
- Customer acceptance: After confirming that all parameters have been met (performance, quality, safety), we agree on a plan for moving to the full production stage or further improvement.
Prepare your team for independent supervision and efficient daily robot operation.
Operator and Maintenance Training
Even the most advanced technology will not pass the test if employees cannot use it effectively. At NexaRob, we offer Operator and Maintenance Training, enabling your team to acquire the practical skills necessary for daily operation and maintenance of robots. This minimizes the risk of unplanned downtime, and automation becomes an integral part of the work culture in your company.
Scope of training
- Basic operation and safety: Operators learn how to operate the robot interface, manual and automatic control methods, as well as basic safety procedures (emergency stop buttons, shutdown procedures).
- Programming and customization: If necessary, we provide training in advanced programming languages (e.g., RAPID, KRL, Karel) so that personnel can independently modify motion sequences or operating parameters.
Practical exercises at workstations
- Manual and semi-automatic mode: Participants will learn about the different levels of robot control as well as calibration techniques and setting reference points.
- Troubleshooting: Thanks to exercises in simulated failure conditions, the team gains confidence in dealing with stressful situations, which speeds up the return to normal operation.
Maintenance and Servicing
- Diagnostics and inspections: Employees learn about typical wear parts (e.g., drive belts, cables), lubricant and filter replacement rules, as well as methods for detecting early signs of malfunctions.
- Service planning: We teach how to establish maintenance schedules in order to avoid unnecessary downtime and ensure uninterrupted operation of the line.
Safety and Industry Standards
- Collision response procedures: What to do when the robot detects an obstacle in its work area or when an emergency stop occurs?
- Working with robots: In industries where collaborative robots are used, operators must be familiar with the procedures and regulations governing their close interaction with the machine (e.g., speed limits, force limitations).
Certification and skills development
- Document confirming training: Upon completion of the course, participants may receive an internal NexaRob certificate, highlighting their skills in robot operation.
- Possibility of expansion: In case of line development or introduction of new types of robots, we offer supplementary training that helps to keep knowledge up-to-date.
A well-trained team guarantees that the implemented robots will operate reliably and that any incidents or changes will be handled efficiently. By investing in training, you create a culture of innovation and shared responsibility for the success of automation within your company, which translates into long-term benefits and higher employee motivation.
Guarantee of a stable start for the robotic line and continuous process improvement
Startup, Optimization and Monitoring
After the tests and training are completed, the crucial moment arrives: the launch of the target robotic system in real production conditions. At this stage, NexaRob not only ensures smooth implementation but also optimizes parameters and monitors key performance indicators (KPIs). This allows us to quickly respond to any disruptions and further develop automation to bring even greater benefits.
Line Startup in Production Mode
- Final verification: The last check of the correctness of movement sequences, safety settings, and communication with neighboring machines.
- Transition to full load mode: Robots begin regular operation at the target cycle time, handling actual products and cooperating with personnel and other devices on the line.
Performance and Quality Monitoring
- KPI (Key Performance Indicators): We are analyzing. m.in- cycle time, number of rejects, downtime, or energy efficiency - to gain a clear understanding of how robots affect the profitability of the process.
- Data collection: Integrated IT systems (MES, ERP) or IoT modules enable the archiving of information about robot operation, which facilitates subsequent trend analysis.
Parameter Optimization
- Speed and trajectory adjustment: If it turns out that the robot has spare time, you can increase the dynamics of movements, shortening the cycle time. In reverse situations - we reduce the speed to avoid excessive wear of components.
- Adjustment of grippers and tools: Thanks to ongoing observations, we can modify the settings of gripping force, rotation angles or the method of placing elements in order to reduce errors and accelerate the process.
Identification of Development Opportunities
- Expansion Potential: As market demand grows, you can add more robots or modules (e.g., vision systems, force sensors) to expand the scope of automation.
- Planning further implementations: If an implementation in one area proves successful, we analyze the remaining processes in which similar solutions will bring benefits (e.g., packaging, internal transport).
Support and Service After Implementation
- Ongoing consulting: We act as a consulting partner in current needs for improvements and eliminating minor defects.
- Updates and upgrades: Thanks to periodic service inspections, the lifespan of robots can be extended, and hardware or software modernizations can be carried out if necessary.
Commissioning a robotic line is just the beginning of the journey towards full automation. Regular monitoring and optimization of parameters allow you to fully utilize the potential of robots, as well as adapt to changing business requirements. Our team of engineers supports this process at every stage, guaranteeing that your investment will be profitable and provide real competitive advantages.
Develop your automation in line with growing market needs and new technologies.
Further Development and Modernization
In today's world of industry and services, new challenges constantly arise: changes in the product portfolio, increasing customer requirements, new environmental or legal standards. In order for robots to remain profitable and effective in the long term, NexaRob offers support in the area of further development and modernization of existing production lines. This ensures that your automation is always up-to-date and ready to meet changing needs.
Line Expansion and Adding Additional Stations
- Scale Growth: If the production volume increases, we can easily add more robots or integrate a new stage of the process (e.g., quality control at the end of the line).
- Integration with additional machines: When purchasing new equipment or vision systems, we ensure that communication with the existing environment is smooth and the layout remains ergonomic.
Hardware and Software Modernization
- Controller Upgrade: Older robot controllers can be replaced with newer models, gaining higher computing speed and additional functions (e.g., adaptive motion control).
- Software updates: Introducing new versions of firmware, vision libraries or AI algorithms that will improve process efficiency.
Changing Functions and Flexibility
- Rebuilding stations: When the product range changes or new product variants appear, we can modify grippers, movement sequences or the entire station so that the robot takes on a different role.
- Adapting to new industries: Often, the same devices can be configured for completely different tasks (e.g., packaging, manipulation, surface treatment), which saves investment costs.
Implementing Innovative Functions
- Integration with IoT and Big Data: If your robots have not been connected to an IoT system so far, we can enrich them with sensors and software that analyzes data in real time.
- AI Solutions: Advanced machine learning algorithms enable the robot to independently improve trajectories or adjust operating parameters to changing conditions.
Assessment of Profitability and Financing of Modernization
- ROI Analysis: Together with the client, we check whether the modernization will bring satisfactory benefits for a given amount of costs.
- Forms of support: We propose various financing options (e.g., leasing, investment loan, grants from funds) and service agreements that ensure smooth operations and minimize risk.
Further development and modernizations are a natural step in the life cycle of robotic systems. With the support of NexaRob, you can flexibly respond to new market needs and technological advancements while ensuring the profitability of invested funds. Utilize the potential of innovation so that your automation continuously exceeds customer expectations and guarantees success in the changing business environment.
Do you have any doubts regarding the implementation of robots? Check the answers below or contact us.
Frequently Asked Questions
No. In many cases, a robot can be integrated with existing machines and processes through minor adjustments to the workstation. We always strive to minimize costs and installation work so that the implementation is as smooth as possible.
It depends on the scale of the project, the number of robots, and the level of integration with other systems. In simpler cases, it may take a few weeks, while more complex implementations (with additional vision or transport modules, etc.) can take several months.
Of course. Many solutions are universal, allowing for a quick transition from one process to another (e.g., from assembly to packaging). This provides flexibility in case of changes in product range or production requirements.
Costs depend on many factors: robot model, additional accessories (gripper, vision system), integration with other machines, or level of automation. As part of the project, we always try to accurately estimate expenses and also offer various financing options (loans, leasing, subsidies).
Do you have more questions?
If you need further clarification or would like to discuss the robot implementation process in your facility in detail, please contact us. NexaRob provides comprehensive support - from the conceptual phase to long-term service and development of automated solutions.
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